This paper presents a systematic approach to develop the mathematical model for predicting the ultimate tensile strength, yield strength, and percentage of elongation of AA6351 aluminum alloy which is widely used in automotive, aircraft and defense Industries by incorporating (FSW) friction stir welding process parameter such as tool rotational speed, welding speed, and axial force. FSW has been carried out based on three factors five level central composite rotatable design with full

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... ns technique. Response surface methodology (RSM) is employed to develop the mathematical model. Analysis of variance (ANOVA) Technique is used to check the adequacy of the developed mathematical model. The developed mathematical model can be used effectively at 95% confidence level. The effect of FSW process parameter on mechanical properties of AA6351 aluminum alloy has been analyzed in detail.