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Aluminium alloy 6063 is medium strength alloy commonly referred to as architectural alloy. It is normally used in intricate extrusions. It has good surface finish; high corrosion resistance is readily suited to welding and can be easily anodized. The structural application of aluminium alloy involves welding and joining, which are difficult using conventional welding processes. In 1991 solid state joining process named friction stir welding was developed. the technique has attracted considerable interest from the aerospace and automotive industries, since it is able to produce defect free joints particularly for light metals i.e. magnesium and aluminium. For the intense requirement and usability of aluminium 6063 alloy was selected as material for study.