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In this research, newly modified solid-state friction-stir welding (FSW) technology was employed to bond the sheets of an aluminum-magnesium alloy (AA5058) and poly-methyl-methacrylate (PMMA) in a lap-joint design. Effects of processing parameters including tool rotational speed (w), traverse velocity (v), tilt angle and plunge depth on the surface morphology, materials flow pattern, microstructural characteristics, and mechanical properties of the dissimilar FSWed joints were studied. The geometry of U-antler macro-mechanical interlocking and interfacial micro- and nano-scale chemical bonding was mainly controlled by the tool tilting angle. A sound dissimilar weld with the highest tensile strength of around 45 MPa was attained at an optimum working window containing w = 1600 rpm, v = 25 mm/min, tool tilt angle of 2°, and plunge depth of 0.2 mm. Fracture of dissimilar lap joints occurred during …