<![CDATA[This study aims to investigate the influence of tool rotational speed and joint configuration on the physical and mechanical properties of extruded AA6061-T6 aluminum panels joined by One-Step Double-Acting Friction Stir Welding (ODFSW), a technique that joins both panel faces simultaneously in a single pass. While previous ODFSW studies have focused exclusively on the effect of tool rotational speed in plate or hollow panel geometries using a single joint type, the comparative influence of joint configuration on ODFSW joint quality and mechanical performance has not been systematically addressed in the existing literature. Panels were welded in butt and lap configurations at tool rotational speeds of 1200, 1500, and 1800 rpm, and evaluated through macrostructural observation, microstructural analysis, Vickers microhardness testing, tensile load testing (ASTM A370), and bending testing (ISO 5173). Results showed that increasing rotational speed improved material flow, reduced surface defects, and promoted dynamic recrystallization in the stir zone, yielding a characteristic W-shaped hardness profile with minimum values in the heat-affected zone. Butt joints consistently outperformed lap joints, achieving maximum tensile load capacity of 25.3 kN and bending strength of 10.8 MPa at 1800 rpm, compared to 18.5 kN and 6.3 MPa for lap joints. Fracture occurred in open mode for butt joints and shear mode for lap joints. This work provides the first systematic comparison of butt and lap configurations under identical ODFSW parameters for extruded panels, offering new guidance for optimizing joint design in lightweight civil and structural engineering applications.]]>
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