<p>The high strength-to-weight ratio of AA7075 T-6 makes it a primary choice for aerospace industry applications. However, establishing the joint integrity of its weldments remains a challenge. This study investigates the combined impact of heat input and stirring action during friction stir welding on the microstructure and mechanical properties of AA7075-T6 aluminum alloy. The Taguchi L9 orthogonal array is utilized to optimize both the process and tool parameters. The considered process parameters are tool rotational speed and feed rate, while different tool pin profiles are examined to underscore their role in material stirring. Among all the experiments, the best results in terms of the finer grain size and highest mechanical properties were achieved with an optimal combination of heat input at 560&#xa0;rpm and a feed rate of 63&#xa0;mm/min. Additionally, the stirring action provided by the threaded cylindrical pin profile contributed significantly to these outcomes. Increasing the tool rotational speed leads to increased dissolution of strengthening Zn and Mg precipitates from the base metal into the metallic matrix. The result of analysis of variance concludes that tool rotational speed has the most significant effect on material’s mechanical behavior among all factors. Process parameters are optimized by the signal-to-noise ratio, and results of confirmatory tests show experimental values in good agreement (within 4-7.5%) with model-predicted values for all mechanical properties. Moreover, fractography investigation revealed that at high heat input, the mixture of cleavage and dimple structure resulted in a decrement of mechanical properties. This experimental investigation establishes and underscores the relationship between heat generation and material stirring process parameters for the joint integrity of aerospace-grade AA7075.</p>