This article uses coupled Eulerian–Lagrangian finite element algorithm to conduct a three-dimensional thermomechanical study to capture the shape and characteristics of defect type generated while achieving the dissimilar friction stir welding of aluminium alloys. The volume-of-fluid method is used to model the Eulerian region and predict the localised formation of process defects. Three different tool shapes are utilised to achieve the dissimilar friction stir welding joining between AA 2024-T3 on the advancing side and AA 6061-T6 on the retreating side. Process parameter effects such as rotational tool speed, traverse tool speed and tool tilt angle are also investigated. The finite element model results are validated by comparing with the results of a previous experimental study. The results showed the augmentation of the traverse welding speed from 40 to 80 mm/min is a key factor in causing process imperfections such as void and tunnel defects. The lower tilt angle value of 1° resulted in long tunnel defects when high rotational speeds are applied. Also, the combination of high rotational and low transverse speeds promotes the production of a free-defect friction stir welding joint.
