Abstract Fabrication and welding remain important parts of the history of the development of humankind. With the advancement in welding techniques, nowadays there are so many welding techniques that are not only easy but also cost-efficient and at the same time environment friendly. Friction stir welding falls in that category. For a better understanding of the friction stir welding technique, one must have all the knowledge about the material’s property and interface nature. There should have been proper knowledge that which kind and nature of joint is feasible for which kind of material. When FSW was a new field, it is only used to weld aluminum as aluminum can’t be weld using conventional techniques of welding. The basic concept in FSW is associated with the rotation of the tool at a certain speed to join the material by applying high temperature. In this paper, simulation and analyzation of FSW model will be discussed along with stability techniques performed in MATLAB and SOLIDWORKS. The finite element analysis, mesh analysis, and mathematical modeling was done using the partial differential equations. All the related equations, mathematical formulas were solved to get the optimized results for friction stir welding technique with the help of which an optimized solution was found which is very stable, efficient, and at the same time economical as compared to conventional welding techniques. In the later part of this thesis, results will be analyzed and compare with the standard and reliable results available online.