Aluminium 6063 has a wide application in the field of Engineering. Aluminium 6063 has high strength but low hardness and wear resistance. Friction Stir Processing (FSP) is a recent development to modify the surface property of Aluminium. Friction stir processed surface enhance good surface properties like high hardness and wear resistance by reinforcing additives like ceramic particles. In this current investigation, Aluminium 6063 surface property is modified by reinforcing Boron Carbide (B4C) powder particles via FSP. The distribution of B4C particles into the surface is important for the good surface property. The tool pin profiles such as threaded cylindrical and square pin were compared for the best distribution of B4C into the surface of base metal through different additive packing methods. Grooves and holes are the different packing methods to reinforce additive particles via FSP. A single pass FSP with tool rotational speed 1200rpm, travel speed 40mm/min and axial force 10kN are kept constant. Microstructural observations and wear test were conducted on Friction stir processed specimen for different additives packing methods and corresponding tool pin profiles. © Research India Publications.