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The selection of welding process parameters is a tedious operation that demands the process evaluation. Multi criteria decision-making strategies for assessing friction stir welding (FSW) process parameters are scanty. Therefore, a comparative study between five different multi-criteria decision-making methods was applied within friction stir welding process to show the deviations in the ranking of the alternatives. The goal is to find the welding parameters (including rotation speed, shoulder diameter, and travel speed) that result in the highest performance scores or rankings for the considered responses, such as ultimate tensile strength, hardness, and surface roughness. In the following, different decision-making strategies (including TOPSIS, GRA, hybrid GRA-TOPSIS, CoCoSo, and MACROS) are applied to calculate the weight of all different decision-making using entropy. The proposed methods in this study are validated by representing the accurate decision maker’s preferences and consideration of uncertainty. The decision-makers choose GRA-TOPSIS and TOPSIS as the best approach with higher efficiency. GRA was determined to be more time-consuming and to have the most variety of outcomes, whereas CoCoSo and MACROS were unable to produce a definite best result. The study is highly promising for researchers and machining specialists to produce quality friction stir welds.

A comparative study of multiple-criteria decision-making methods for selecting the best process parameters for friction stir welded Al 6061 alloy