Friction stir welding (FSW) is an innovative technique to produce a hybrid joint of thermoplastic polymers and metals in the recent past. A review of the friction stir welding processes and fabrication of polymer-based nanocomposites was developed to meet the challenges of the industry’s needs in the twenty-first century. These hybrid structures predominantly will play a vital role in future innovations. In the recent past, it is widely used in the automobile and aerospace sectors. It is due to its lightweight and high strength-to-weight ratio. This article focuses on the recent development that has been made in the joining of thermoplastic polymers and metals through the friction stir welding technique and friction stir processes. This article provides a comprehensive study of the influences of various process parameters on weld performance. The effect of surface pretreatment on the adhesive mechanisms is presented. Finally, mechanical behavior like hardness and tensile strength of joints, and the microstructural features of joints are presented. Based on the detailed survey, this paper consolidated the way to improve the thermoplastic polymers and metals joints through FSW. © 2021, The Brazilian Society of Mechanical Sciences and Engineering.