The aim of the present work is to optimize the Friction welding of tube to tube plate using an external tool (FWTPET) with clearance fit of commercial aluminum tube to Al 2025 tube plate using an external tool. Conventional frictional welding is suitable to weld only symmetrical joints either tube to tube or rod to rod but in this research with the help of external tool, the welding has been done by unsymmetrical shape of tube to tube plate also. In this investigation, the various welding parameters such as tool rotating speed (rpm), projection of tube (mm) and depth of cut (mm) are determined according to the Taguchi L9 orthogonal array. The two conditions were considered in this process to examine this experiment; where condition 1 is flat plate with plain tube Without holes [WOH] on the circumference of the surface and condition 2 is flat plate with plane tube has holes on its circumference of the surface With holes [WH]. Taguchi L9 orthogonal array was utilized to find the most significant control factors which will yield better joint strength. Besides, the most influential process parameter has been determined using statistical Analysis of variance (ANOVA). Finally, the comparison of each result has been done for conditions by means percentage of contribution and regression analysis. The general regression equation is formulated and better strength is obtained and it is validated by means of confirmation test. It was observed that value of optimal welded joint strength for both tube without holes and tube with holes are to be 319.485 MPa and 264.825 MPa, respectively. © 2016, The Korean Society of Mechanical Engineers and Springer-Verlag Berlin Heidelberg.