The objective of present study was to determine optimal conditions to achieve satisfactory friction welds between two dissimilar metals namely copper and carbon steel bars of same diameter. Three process parameters namely speed of rotation, axial pressure, and forge pressure were considered for the present study. Two multiple performance characteristics, considered were breaking load strength and upset. The optimization of the process parameters was done using ANOVA. The obtained results indicated that the most significant process parameters are axial pressure and rotational speed that affect the optimization of multiple performance characteristics.

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