The aim of this article is to create a new technique for predicting discontinuity formation, its place and magnitude during aluminium alloy (AA6061) friction stir welding (FSW). The effectiveness of the technique was demonstrated using visual inspection, hardness and tensile test of the friction stir welded joints. The measured current was analysed through power calculations. In each of the FSW stages, the energy consumption is significantly varied, clearly distinguishing the penetration of the tool, its revolution, its traverse movement and its metal removal rate. The findings of tracking the energy consumption indicate that using power consumption means the significance of weld quality. FSW has been carried out based on two factors - two levels. Response surface methodology (RSM) is employed to develop a
mathematical model. Analysis of variance (ANOVA) technique checks the adequacy of the developed mathematical model, which is used effectively at 95% confidence level. In contrast, tensile and hardness tests also showed that welds at high power usage failed continuously within the welding area, due to reduced welding temperature and absence of penetration in the welding zone.