Welding is a process where two similar or dissimilar metals are joined to create a complex joint used in various fields. Among the many welding methods, arc welding stands out as one of the best. In arc welding, two metals are brought into contact, and the junction is heated, causing the metal to melt and fill the gap between the parent metals. This study aims to identify the most effective edge joint for arc welding and optimize the process parameters for welding BSRM A 415 square bars. Optimizing welding parameters is crucial because they significantly influence the quality of the weld. Without determining the optimal values, the experiment cannot be accurately completed, and the resulting products may lack long-term sustainability. BSRM A 415 square bars were chosen due to their quality billets, guaranteed strength, safe welding properties, and ISO certification. They are ideal for intricate structural designs and offer both strength and cost efficiency. Four input parameters were selected for the welding process: welding current, voltage, travel speed, and electrode diameter, with hardness and ultimate tensile strength as output responses. The study used the Taguchi orthogonal array and Grey Fuzzy methods to analyze and optimize the parameters. These methodologies, along with various tools and techniques, helped achieve the desired outcomes effectively.