A 5052-H34 aluminum alloy rod having a diameter of 5 mm was friction-welded using a conventional automatic friction welder. The effect of welding conditions on the microstructure and mechanical properties of the welded joints were investigated. The total loss of mechanical strength of welded joints increases when increasing both the rotational speed and friction time. In addition,the total loss was negligibly low when the welding condition was submitted to N = 6000 rpm and t1 = 1 s. The welded joints showed a symmetrical macrostructure with respect to the weld interface and rotational axis. A layer with ne-grained microstructure was formed at the weld interface. The layer grew thicker by increasing both the rotational speed and friction time. The heat-affected zone was formed around the ne-grained layer. It tends to be larger with an increase in both the rotational speed and friction time. The softened area of the joints reached approximately 8 mm from the weld interface. In addition, the weld interface was cured under conditions of N = 6000 rpm and t1 = 1 s. The highest tensile strength of thin diameter joints was 209 MPa, which was obtained under conditions of N = 6000 rpm and t1 = 3 s. Its joint ef ciency reached 80% of that of the base metal.

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