Rotary friction Welding (RFW) has wide application in the aerospace industry for manufacturing large volume fuel tanks due to its exceptional advantages, including low distortion, less defects, and high mechanical joint properties. The weld interface quality is limited to poor temperature distribution, improper frictional pressure, and time to weld. The present study is to optimize the friction welding parameters of the Monel-Copper joint by rotary friction welding such as frictional pressure (20bar, 25bar, 30bar, and 35bar), upset pressure (15bar, 20bar, 25bar, and 30bar), and frictional time (5 sec, 7sec, 9sec, and 11sec). The friction temperatures of the weld joints are noted during the welding process. The input process parameters have been optimized by design of experiment and analysed by the ANOVA method. The temperature and pressure distribution of the weld joints are evaluated by finite element analysis software.