The present research work demonstrates the effect of friction stir process (FSP) and its process parameters (rotation speed and travel speed) on the microstructure evaluation, microhardness and wear behaviour of FSPed AA6082. The microstructure characterization of the processed samples was examined using the Optical Microscope (OM). Dry sliding wear test was carried out by varying the sliding velocity (0.5, 0.75 and 1.0 m s−1) and applied load (5, 10 and 15N) using the pin on disc apparatus. Wear mechanisms experienced by the FSPed AA6082 were mapped, and the optimal FSP and wear parameters have been determined using Taguchi analysis. The results showed that there is a significant improvement in the microhardness (92 HV0.3) and wear resistance for RS 1250 rpm & TS 40 mm min−1 due to the grain strengthening mechanism and microstructure modification. Formation of oxide layer played a crucial role on the wear resistance of the FSPed AA6082 and its significance has been discussed elaborately using the Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS). © 2021 IOP Publishing Ltd