Defect-free sound joints of high-phosphorus (0.094 wt%) weathering steel (SPA-H) were successfully fabricated using friction stir welding (FSW). This study examines the microstructural evolution and mechanical properties of joints produced at different FSW parameters. Tensile tests of the joints revealed that fractures occurred in the base metal (BM) region, indicating almost 100 % welding efficiency. Furthermore, the stir zones (SZ) demonstrated a marked improvement in tensile properties. Particularly, at the rotation rate of 80 rpm and axial load of 45 kN condition (below A1), the microstructure featured ultra-fine ferrite and cementite, resulting in high hardness (270 HV) and tensile strength (704 MPa) in steel with just 0.08 wt% C, while maintaining nearly 80 % of the total elongation of BM. However, the SZ at 80 rpm exhibited an unusual decrease in local elongation despite the fine ferrite grain size and cementite presence. Electron probe microanalysis (EPMA) and nano-hardness revealed pronounced phosphorus segregation in the ferrite region and significant localized hardness disparities induced by the segregation behavior. The strain concentration at the interfaces between these regions during the tensile process leads to crack initiation and rapid propagation. The negative factor caused by the phosphorus segregation accelerates the failure of the specimen during the necking stage and ultimately shows decreased local elongation.