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 cos