Abstract—Friction stir welding is an emerging severe plastic deformation technology and has been used to produce a butt-joint on Ti-6Al-4V alloys sheet with a thickness of 2.5mm at rotation speeds of (1500 and 2000 rpm) and a constant travel speed of 200 mm/min. The effect of welding and rotation speeds on microstructure, tensile strength, and corrosion resistance property has been investigated. Micro-structural study of welded joint specimens has been performed by scanning electron microscopy for both stir zone and thermo-mechanically affected zone. Tensile property and micro-hardness studies have been done to identify the joint strength. Micro-structure correlates with the mechanical property. XRD has been investigated to distinguish between α and β phases. Finally, the EBSD has been conducted to identify the recrystallization phenomenon in the stir zone. A corrosion study has been performed for friction stir welded joints in Ringer’s solution which is equivalent to body fluid solution. Finally, the Tafel plot analysis has been employed to determine the corrosion rate for SZ and TMAZ. We found 96% of joint strength achieved for friction stir welded joint than the base metal. This study promises applications not only in the welding industry but also in other fields of engineering technologies and our practical life.