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This work is focused on the influence of different friction stir welding (FSW) parameters on AA6082 T-6 and AA5083-O alloys welding quality, by using Taguchi, Grey Relational and Weight Method. Four welding parameters were investigated, namely tool rotation speed (TRS), welding speed (WS), tool pin profile (TPP) and shoulder diameter (SD). The optimized setting of these input parameters was investigated so that weld parts quality could be optimized. Analysis of variance (ANOVA) was used to investigate the effects of these welding process parameters on response variables, viz. elongation (EL) and ultimate tensile strength (UTS). Single response optimization was carried using Taguchi Technique while grey relational analysis (GRA) was used for simultaneous optimization of two responses. Once the optimal settings of control factors were identified, confirmation experiments were performed for the validation of results. In the multi-response optimization, TRS was found to have the maximum effect (57.9%), followed by WS, SD and TPP. Weight method was applied for providing the priority to the response (i.e. EL and UTS). The response with higher priority presented a weight equal to 0.7, while the lower priority given corresponds to a weight of 0.3.

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