The replacement of copper by aliminium is inevitable for certain application in the electrical industry due to economic reasons. Whilst in the majority of cases, aluminium can be joined only by adhesive bonding, mechanical fastening and solid-phase welding techniques. Friction welding offers an alternative welding process for the joining the aluminium bars. Frinction welding is well known for its ability to weld aluminium to many metals and consequently is being considered seriously. The present study examines the friction welding of aluminium bars. Three welding parameters including welding time, speed of rotation and applied pressure are considered. To carry out a statistical analysis (factorial analysis) determining the affecting parameters on the mechanical properties of the resulting welds, each factor is considered at three levels. Metallurigical investigation is carried out using SEM and optical microscopy.