Abstract: The present study focuses on the influence of a 5-pass overlapped friction stir lap welding of AA6061-T6 on the mitigation of defects and its simultaneous effect on microstructure and mechanical properties. Tool pin overlapping percentage of 0%, 25%, 50% and 75% was employed, from which it was observed that defects significantly reduced at higher overlapping. Fine equiaxed grains were observed across all the nugget zones in both top, and bottom regions were developed due to simultaneous overlapped passes; the grain size of which varied from 8.5 µm to 3.5 µm. The grains became finer, which increased of overlapping percentage. The microhardness of the processed zone was significantly reduced during overlapping that varied from a range of 43 HV0.1 to 49 HV0.1 as compared to base metal which was interpreted due to changes in grain size and secondary precipitate distribution during overlapping. A maximum ultimate tensile strength of 230 MPa was achieved at 50% overlapping, whereas minimum ultimate tensile strength of 160 MPa was achieved at 0% overlapping. Fractography of fracture surface showed a ductile failure at 50% that showed a number of dimples of varying shapes and sizes.