This study investigated the use of the linear regression algorithm (LRA) for estimating the cost of tungsten inert gas (TIG) welding of dissimilar metals, specifically, stainless steel 304 and aluminum 2024. Various cost analysis parameters, including weld time, power cost rate, labor cost, filler rod cost, and shielding gas cost, were considered. LRA was employed to develop a predictive model for welding costs based on these parameters. The model was then used to optimize welding parameters by identifying the combination that minimized overall welding costs. The results demonstrate that LRA effectively identified a more cost-effective parameter set compared to traditional methods. This highlights the potential of LRA in enhancing the cost-effectiveness of TIG welding processes. The findings have practical implications for field engineers and researchers, enabling the identification of optimal parameters for cost estimation and significant cost savings.