Abstarct: Rotational friction welding, is a solid state welding method, applied to join axial mextallic components. The first stage of welding involves applying a compressive axial load to the components spinning at a relative speed. This produces a contact pressure and thus a frictional dissipation at the interface. As a result of heating, temperature increases near the contact zone and the mextallic materials soften. This is followed by a second stage in which an axial forging load is applied and which leads to considerable flow of mextal, called flash, and the two parts are joined. In this dissertation, friction welding of Inconel 600 rod 4 mm in diameter and Kovar alloy rod 3 mm in diameter, is studied through finite element and experimental studies. The parameters considered include heating time, spin speed and forging load. For finite element analysis, an axially symmetric model including twist effects is employed in a fully implicit coupled temperature-displacement analysis. The bodies were discretized using GGAX4T finite elements. To avoid sever distortion of the elements, the analysis is stopped after the moving rod displacement reaches a specified value. Subsequently, the analysis restarts with the fresh mesh using the “mesh to mesh solution mapping capability of Abaqus/standard. Due to large number of restarts required, a python scxript was developed for convenient. baxsed on a table of experiment design, effect of parameters were analyses and optimum values for a successful weld were obtained. baxsed on these results, a welding setup was designed and employed for experimental studies. Friction welding experiments were carried out on the samples successfully. The recovered samples were subjected to tensile test and the results showed that the joint strength was larger than the weaker baxse mextal.