Friction stir welding (FSW) is a solid-state process, which is based on friction welding. It is an effective solid-state welding process in which similar and dissimilar materials can be joined. In the FSW, the tool is used to join the faces of two materials, by generating friction with the help of the tool shoulder. Due to this friction, there will be a rise in temperature, which softens the material near the tool surface and feasibility to mechanically intermix and join the material. This study mainly focuses on the FSW of two dissimilar metals of AA1100 and MG-AZ31. During this experiment, many defects may arise such as distortion, crack formation, lack of fusion, undercut, and incomplete penetration. These defects can be eradicated by selecting the appropriate tool profile, tool material, and suitable weld parameters (which were determined by the variations in temperature, stress-strain generated during the process). From various literature surveys, it has been observed that the weld parameters will affect the quality of the weld. In this given context the present work highlights the variations in deformation, stress, temperature distribution, and strain were systematically investigated and analyzed.

Keywords : Welding; Friction; Tool Material