Abstract In this research paper, an endeavour was made to devise empirical relations amidst the process parameters of friction stir welding (FSW) and tensile relevant strength of AZ80A Mg alloy joints, based on a 6 parameters—5 levels based central composite design (CCD). Mathematical equations illustrating the impact of process parameters of FSW were formulated based on quadratic regression based analysis to optimize the parameters for attaining superior tensile strength and sensitivity related equations were established from these numerical models. A detailed sensitivity characteristic relevant map for the FSW of AZ80A Mg alloys was established forecasting the fine tuning related prerequisites of the employed FSW parameters. Coefficient of determinant (R 2 ) announced that 99.062% of the overall variability was described by the formulated model and only lower than 1% of the overall variations was not justified by the model. Predicted R 2 was also in perfect agreement with the adjusted R 2 and announced the model’s capability to demonstrate 95.43% of the variability in the generated data. Highest value of tensile relevant strength (80.77% of the parent metal) was exhibited by the AZ80A Mg alloy joint fabricated under optimized parameters. Tensile relevant strength of AZ80A Mg joints was observed to be highly sensitive to traverse speed of the employed tool.