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Recently, friction stir welding of dissimilar materials has become one of the biggest issues in lightweightand eco-friendly bonding technology. In this study, a lightweight torsion beam axle, which is an automobilechassis component, was used in the welding to cast aluminum material. The friction stir welding process ofA357 cast aluminum and FB590 high-strength steel as well as the effects of the process parameters wereinvestigated and optimized using a novel definitive screening design (DSD). ANOVA was used to predict theimportance of the process parameters with 13 degradation experiments using the proposed DSD. Also, FSWedexperiments were conducted using an optical microscope analysis to investigate the tensile strength behaviorin the weld area. In addition to determining the interaction between the tool’s rotational speed and the plungespeed, results indicate that the influence of the plunge depth was the most significant.