The effect of various tungsten carbide (WC) pin tools and operating parameters on the material structure and properties of an AA1100 friction stir welding (FSW) weld were evaluated. Three different pin shapes were employed (conical, square and threaded). For each tool shape, welds were generated for a set of tool (revolutions per minute, RPM) (710, 1120 and 1400) and advancing speeds (150, 250 and 400 mm/min). Weld samples were tested for mechanical strength by tensile testing. Morphology was examined using optical microscopy, and weld composition with scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD). No weld contamination from the tools was observed. However, a number of structural defects, inherent to the FSW process, were observed (including tunnel voids, kissing bonds and swirling lines). These defects, associated with the stirring action, could not be eliminated. The results show how the operating parameters may be optimized to produce stronger welds.

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