This paper presents a new welding quality evaluation approach depending on the analysis

by the fuzzy logic and controlling the process capability of the friction stir welding of

pipes (FSWoP). This technique has been applied in an experimental work developed by

alternating the FSW of pipes process major parameters: rotation speed, pipe wall thickness

and travel speed. variable samples were friction stir welded of pipes using from 485 to 1800

rpm, 4–10 mm/min and 2–4 mm for the rotation speed, the travel speed, and the pipe wall

thickness respectively. DMAIC methodology (Defining, Measuring, Analyzing, Improving,

Control) has been used as an approach to analyze the FSW of pipes, it depends on the

attachment potency and technical commonplace demand of the FSW of pipes process.

The analysis controlled the Al 6061 friction stir welded joints’ tensile strength. To obtain

the best tensile strength, the study determined the optimum values for the parameters from

the corresponding range.

This paper is the first to optimize the friction stir welding (FSW) process considering the Clamp Pitch (mm) and Clamping Torque effect using the Various combinations of parameters were constructed using factorial design and responses, resulting in a comprehensive factorial analysis. Conspicuous changes in the tensile strength, yield strength, hardness, and power profile were observed for all amalgamations of parameters. Significant parameters of the FSW process have been considered in many optimization studies, however, the effect of the Clamp Pitch (mm) and Clamping Torque (Nm) has been never studied. Three levels of three parameters were used in the experiments: Clamp Pitch, tool rotational speed and Clamping Torque. The full factorial analysis was performed, was applied as an approach for selecting the values of the Significant factors of the parameters. For each result the three key parameters were important with p-values of less than 0.05, suggesting their significance in the phase of FSW. Mathematical models built with high R-sq. and least percentage error were adequate for the investigated responses. The findings were gained by important parameter values factors of 30 mm, 1800 rpm and 70 Nm for the take into consideration parameter range for the Clamp Pitch, rotational speed and Clamping Torque respectively.