Friction stir spot welding is a solid-state welding process where the joints are formed due to plastic deformation. This technique is economically sound when compared to that of Resistance spot welding. In this research work, the process parameters of friction stir spot welded Al 5754-Al 6061 joined were identified with Response Surface Methodology. The results showed that the tool rotational speed was the most significant parameter that impacted the tensile shear force of the weld joint. The maximum load-bearing capacity of 6.060 kN was obtained at 1000 RPM and 0.04 mm/s. Additionally, the influence of plate position and tool profile on the tensile shear force of the weld joint is also studied. The test result obtained at the optimal welding conditions with respect to the plate position and tool profile showed that both the plate position and tool profile had a significant influence on the load-bearing capacity of the weld joint. © 2019 Elsevier Ltd. All rights reserved.