Aluminium alloy 6063 has a wide application in special machine elements, architectural sections, automobiles and frame systems. AA6063 has high strength to weight ratio but low hardness and wear resistance property. Friction Stir Processing (FSP) is a surface modification process through which mechanical properties of the surface can be improved by reinforcing ceramic particles. In this present investigation, surface property of Aluminium alloy 6063 is modified by reinforcing Boron Carbide (B4C) powder particles via FSP. The distribution of B4C particles were examined for different reinforcing techniques, based on Hardness and Impact strength, by keeping volume fraction (22.38%) constant. The tool pin profiles such as threaded cylindrical and square pin were also compared for the best distribution of B4C in the surface of base metal through different reinforcing techniques. The tool rotational speed 1200rpm, travel speed 40mm/min and axial force 10kN are kept constant. ©2006-2015 Asian Research Publishing Network (ARPN).