Aluminum can't successfully be arc welded in an air environment, due to the affinity for oxygen. If fusion welded in normal atmosphere oxidization readily happens and this outcome in both slag inclusion and porosity in the weld, greatly reducing its mechanical properties. This work presents a systematic approach to develop the suggestion model by three (ANN), response surface methodology (RSM) and regression analysis (RA) for predicting the ultimate tensile strength, percentage of elongation and hardness of 6061 aluminum alloy which is widely used in automotive, aircraft and defense industries by incorporating (FSW) friction stir welding process parameter such as tool rotation speed, welding speed and material thickness. The results obtained through regression analysis and response surface methodology were compared with those through artificial neural networks.

In this paper, a comprehensive practical study in mechanical properties and cost welding of welded Aluminum 6061 pipe using three different types of welds, Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Friction Stir Welding (FSW) with rotation speed (1800 RPM) and travel speed 4mm/min. The mechanical properties of the weld have been also investigated using the hardness, elongation and tensile tests. The microstructure of the welds, including the nugget zone and heat affected zone, has been compared with these three methods using optical microscopy and the basis of heat input in weld joint. The results show that FSW improves the mechanical properties of welded joints compare Tungsten Inert Gas (TIG) and Metal Inert Gas (MIG), respectively.

Six-Sigma is the one of the most sturdy management tool used to realize process privilege. Six-Sigma is a problem-solving methodology that decreases cost and refinement customer goodwill and very decreases waste in all the process implicated creation and delivery of the product and service. Six-Sigma process embraces collection of datum, measurement, and statistics to find out the different types of factors and parameter. This work focuses experimental surveillance on providing a clear connotation of an aluminum pipe welding by using (define, measure, analysis, improve, control) technology under Six-Sigma in order to increase tensile strength and hardness (decrease leakage)problem in aluminum pipe welding. By taking various pipe welding parameter in a machining process the pipe welding strength and hardness increased.

In the present work an attempt has been made to optimize the process parameters of metal inert gas welding for aluminum pipes 6061 to evaluate the output quality characteristics using factorial design. An interaction effect of input parameters is also studied to predict their influence on the output response. The performance of MIG for aluminum pipe is evaluated in terms of joint’s tensile strength and corrosion rate , factorial design technique has been employed using orthogonal array, ANOVA (analysis of variance) to study contribution of each parameter and interaction of them on output and confirmation tests at 95 % confidence level to compare with experimental results. Optimal combination of parameters is presented with a good agreement found between the estimated and experimental results within the preferred significant level after verifying experimentally. It was confirmed that factorial design with ANOVA and confirmation tests successfully improved the quality characteristics of tensile strength and corrosion rate of MIG process.

Friction stir welding was a promising welding technology from the same moment of its existence because of its easy use, being ecologically friendly processed and with no need for filler metal. The present paper discusses the cost analysis of pipe friction stir welding spicily aluminum 6061.cost estimation were performed on pipe with different thickness 2 to 4 mm. rotational speeds 485 to 1800 RPM and a travel speed 4 to 10 mm/min. The each cost component of joining Al 6061 aluminum pipe welding was each component cost (Labor cost, Power cost, Machine cost and Tooling cost) has been closely analyzed and major cost components have been included in the cost model. We used these cost models to predict the cost of friction stir welded pipe joints. Initial results show that the rotational speed, material thickness and travel speed increased due to increase the total cost. Keywords: Friction stir welding, Aluminum pipe, cost analysis