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The main objective of this work is to compare the friction stir welding with plasma arc welding processes using dissimilar materials. The materials used AA 8011 and AA 6061.The factors compared in this process are the weld quality, different welding feed and rotation speed. The effects of welding processes on the impact test and micro hardness behaviour were studied. Morphological analysis was carried out using SEM analysis. Taguchi’s, DOE method and ANOVA is done to find the parameters that have highest influence on weld strength. The results show that the FSW joints exhibit superior tensile and fatigue, impact test, and micro hardness properties compared to plasma arc welding. This is mainly due to the presence of mechanical properties are superior to plasma arc welding. Keywords: Friction stir welding, SEM, AA 8011, AA 6061, plasma arc welding, ANOVA, and DOE