In this study, Al 1080 alloy materials were welded using friction stir welding process. The influence of stirrer design on the welding process was investigated. For this purpose, five different stirrers, one of them square cross-sectioned and the rest were cylindrical with 0.85, 1.10, 1.40 and 2.1 mm screw pitched were used to carry out welding process. Bonding Could be effected with the square, 0.85 and 1.10 mm screw pitched stirrers. Microscopic examination of the weld zone and the tension test results showed that the best bonding was obtained with 0.85 mm screw pitched stirrer. In addition, temperature distribution with in the weld zone was also determined. (C) 2003 Elsevier Ltd. All rights reserved.