The microstructure and fatigue properties of friction stir welded joints of 7075-T6 Al alloy were discussed. It was shown that the zigzag-curve defect at the root of welds is the key factor to reduce the fatigue performance of single-sided friction stir welded joints of 7075-T6 high strength aluminum alloy. On the other hand, the FSW joints of 7075-T6 Al alloy achieved higher fatigue strength compared to the traditional fusion design curves IIW FAT40 and Draft Eurocode 9 design category 55-6 for structural aluminum alloy components. (c) 2007 Elsevier B.V. All rights reserved.