The joining of copper to aluminum is inevitable for certain application in the electrical industry due to good conductivity and response offered by copper, aluminum for weight reduction. Whilst in the majority of cases, aluminum and copper can be joined by adhesive bonding, mechanical fastening, fusion welding and solid-phase welding techniques. Friction welding is well known for its ability to weld aluminum to many metals and consequently is being considered seriously. The present study describes about producing a sound joint between two dissimilar metals of pre-strained aluminum to commercially pure copper. Commercial pure aluminum is strained to reduce the disparity in strength level and the effect of pre-strain on friction welding is envisaged. The stronger metal (copper) in this combination is further weakened by intentionally removing some of the material so that a sound joint is obtained. Friction welding was carried out with pre-determined process parameters and the effect of initial geometry on friction welding is illustrated. Post weld characterization such as mechanical and microstructural studies of these welds was carried out to assess the quality of welds. © 2009 IEEE.