Aluminum and its alloys are in high demand in the industrial sector because of its wide availability, low cost, high strength-to-weight ratio, excellent thermal conductivity, low electrical resistance, and remarkable formability. In this experiment, authors used few variables to see how they affect joint attributes like ultimate tensile strength (UTS) and yield tensile strength (YTS). Variables include the shoulder diameter (SD), shoulder flatness (SF), pin profile (PP), pin diameter (PP). Multi-objective optimization utilising ANOVA and RSM is performed on the outcomes of a comparable FSW of AA6061. Results from the research show that for AA6061 FSWs, the four investigated parameters-SD, SF, PP, and WS-and their interactions have a major impact on the outcomes. The optimization approach suggests the following parameter values for maximum tensile characteristics in welded connections: 18 mm SD, 2 mm SF, square pin profile, and 30 mm/min welding speed, which is proven to be in well agreement with expected outcomes of tensile properties within ± 15%. © 2024 Elsevier B.V., All rights reserved.