Dissimilar metals joining has shown precise interest in recent decades due to the stringent fabrication requirements in various industries like a nuclear, power plant and chemical industries. The weld joining process and filler metal choices show the impact on the final weld joint properties. Due to the associated weld process, residual stresses play a significant role like weld distortions and mechanical properties of the joints. Dissimilar materials like SS316L and Inconel 625 plates are joined by using multipass gas tungsten arc welding process with using filler material ERNiCrMo-3 grade. The final weld joints are evaluated for residual stress measurements using X-ray diffraction technique. Thermal distributions during the welding process are mapped with Thermal imaging process in weld joints and base plate interface. Simulations of the thermal and residual stress have been carried by sequence coupled thermo-mechanical analysis using the ANSYS Parametric Design Language with double ellipsoidal heat source model with relevant material properties for both SS316L and Inconel 625 grade materials. Residual stress measurements and simulation results have shown good agreement. The details of the experiments conducted and evaluated residual stresses, modelling and comparison are described in the paper. © 2019 School of Engineering, Taylor's University.