Summary This paper describes detailed FEM modelling performed to clarify the characteristics of residual stress and plastic strain generated during dissimilar metal friction welding operations. The results obtained may be summarised as follows: When bonding problems of dissimilar materials are being numerically analysed by an FEM thermal elastic‐plastic analysis, comparisons undertaken in the radial direction of both the distribution and magnitude of the z axis stress σz generated in both base metals adjacent to the bondline, as determined from the uniform cooling model from 800 °C to room temperature, provide a sound basis for a decision as to the suitability of the FEM mesh used. A comparison of the yield stress σY and temperature relationships in both base metals shows that the Ti base metal has the lower zero‐σY temperature (mechanical fusion temperature). Thermal diffusion in Ti/AISI304L stainless steel friction welds mainly occurs within a narrow region of around 20 mm from the bondline, and this st...