Friction welding, eco-friendly welding is widely popular for joining dissimilar joints. This solid-state welding process eliminates the smoke, fumes, fluxes caused by the fusion welding process. In this work, the aluminium 6063 and stainless steel 304 was joined through rotary friction welding process with flat faying surfaces as per Taguchi L9 orthogonal array with friction pressure (FP), upset pressure (UP), and friction time (FT) were the major parameters and then the optimized parameters were identified with grey relational analysis (GRA). The heat-affected zone during friction welding was narrow to 15-20 microns during the friction welding process; it improves the weld interface strength and showed good bonding between the metals. The dissimilar weld joints were tested for axial shortening, tensile and yield strengths, % elongation, peak load, and hardness along the weld zone. A maximum of 97% joint efficiency was obtained for the 9th experiment with 18 MPa FP. The increase in FP also increases in tensile strength of the dissimilar joint. Through this investigation, it is known that the axial shortening can be made within the limit if we main the welding parameters.
