Continuous drive rotary friction welding is a solid state welding process which is widely used in joining of circular geometry components such as solid rod or hollow sections. Successful applications of aluminum pipes are used in many structural and non structural domains such as oil, gas and petrochemical equipments, heat exchangers, cycle frames etc., require some type of tubular component joining. By addressing the weldability issues will promote usage of this material in industrial application. This paper presents the joining and mechanical characterization of aluminum AA6061-T6 pipes by continuous drive friction welding. To study the weldability, design of experiments based Taguchi's orthogonal array L25 was used. Five process variables namely burn off length, friction force, upset force; upset time and spindle speed were chosen to conduct the experiments. Experiments were carried out on aluminum pipes having 19.5 mm outer diameter and pipe thickness of 3 mm. Ultimate tensile strength of the joint were evaluated using universal testing machine. Micro structural analysis and micro hardness test were also carried out at base metal, heat affected zone and weld metal to study the impact of variable on quality of weld joint. The importance of each parameter was analyzed using analysis of variance (ANOVA). The results indicate that it is possible to weld aluminum pipe joints equal to the strength of base material using continuous drive friction welding.