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In the present research, the friction stir extrusion process as a novel method for wire fabrication from AA6063 aluminum alloy was utilized. For optimization of the process parameters, the L9 standard array of Taguchi design of experiment method was used. The important process parameters include: rotational speed, force, tool face geometry and the die hole size as input variables and grain size and hardness as quality criteria was considered. The tensile test, micro hardness and metallography investigation for studding wire mechanical properties were used. The rotational speed parameter with over 63 percent and after that the force with significant contribution percentage as second parameter was determined. The tool face and the hole size do not have sizeable effect on the mechanical properties and they were introduced as minor process parameters. By investigation of samples, it were determined that with correct setup of process parameters, defect-free wire with grain size over 23 times less than the base metal could be produced. It can increase the ultimate tensile strength of 14 percent against of the base metal

Keywords: Friction extrusion, Optimization, Mechanical properties, Taguchi, AA6063 aluminum alloy

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