Friction stir welding (FSW) is a solid-state welding process, which plays a
significant role in solid-state welding processes for nonferrous alloys. Conventional arc
welding processes for aluminum alloys such as tungsten inert gas (TIG) and metal inert gas
(MIG) are replaced by FSW. The effect of process parameters such as tool rotational and
traverse speeds, tool geometry, plunge depth, tilt angle, etc., on weld quality were considered
in several optimization studies. Multi-criteria decision-making (MDCM) techniques such as
grey relational analysis (GRA) were used to determine the optimal condition among
experimental runs designed using response surface methodology (RSM). The Taguchi method
was widely applied with MCDM techniques. Therefore, the experiments were conducted
according to response surface methodology. Input parameters were (14, 16 and 18) mm for
shoulder diameter (SD), (0.0, 0.2 and 0.4) mm for plunge depth (PD), and (30, 60 and 90) mm
for fixture position (FP), which is the distance between fixture bolts used to fix the welded
plate. The results obtained by GRA were similar to the ANOVA optimizer, and the optimum
process conditions are shoulder diameter of 14 mm, plunge depth of 0.2 mm, and fixture
position of 60 mm.