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IS:6063-T4 aluminum alloy has gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to-weight ratio and good corrosion resistance. This work clarifies the essential terms of varying the tool geometry of shoulder having a bigger diameter up to 18mm, for avoiding welding failure. All the specialized parts of FSW instrument geometry and material of tool is secured on the weld quality of that material. Three different tools pin profile (cylindrical, threaded cylindrical and triangular) have been used to fabricate the joints at three different rotational speeds, i.e. 600, 800 and 1000 rpm and three different welding speeds i.e., 40, 60 and 80mm/min. The results have been evaluated and compared with that original specimen of Al6063-T4. The maximum joint efficiency is 86.65% is observed at a rotational speed of 1000rpm and welding speed of 80mm/min in the case of threaded cylindrical tool pin profile. Again, the maximum joint efficiency is 86.65% is observed at a rotational speed of 600rpm and welding speed of 40mm/min in the case of straight cylindrical tool pin profile. The weld joints quality in cylindrical pin tool and threaded cylindrical pin tool are excellent in the all cases.
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