Background: AA2519-T87 is a new armour grade aluminium alloy employed in the fabrication of light combat military vehicles. Joining of this material using fusion welding processes, results in the formation of solidification defects like porosity, alloy segregation and hot cracking. In order to overcome the solidification related problems, solid state welding processes such as friction stir welding (FSW) can be used. Though the joining takes place below the melting temperature of the material, the thermal cycle experienced by the thermo-mechanical-affected zone (TMAZ) and heat-affected zone (HAZ) is causing grain coarsening and precipitates dissolution in the age-hardenable aluminium alloys, which deteriorate the joint properties. To get rid of this problem, underwater friction stir welding (UWFSW) process can be employed. The water cooling reduces the heat, and thus, the thermal softening required taking place in TMAZ and HAZ. Therefore, the material flow is entirely different in FSW and UWFSW.