Several developments have been occurring in the field of materials processing, and friction welding is an important metal-joining process that has varied industrial applications. Friction welding of tube-to-tube plate using an external tool (FWTPET) is a vital friction welding process which is capable of producing leakproof high-quality weld joints. In the present study, FWTPET welds have been prepared with five different tube preparations. Liquid penetrant test (LPT) has been conducted in order to detect the occurrence of surface defects. Macro- and microstructural studies have been conducted and they reveal that improper weld configuration is susceptible to defect formation. Besides, hardness and tensile strength of five different tube preparations have been presented and analyzed. The present study leads to the production of defect free weld joints which have numerous industrial applications.