The proposed work deals with the examination on tool wear in FSW process during the joining of dissimilar copper and aluminum material. Experiments were conducted on FSW machine with the welding parameters viz. tool stirring speed, feed rate, and axial force. The tool is designed with and without pin offset for joining AA6061-T6 alloy and pure copper. Tribological characteristics suggest that minimum values in coefficient of friction and wear rate were observed for an optimum tool stirring speed of 1300 rpm, feed rate of 70 mm/min and axial force of 12 kN. Micro structural characteristics reveal that the formation of ploughing, adhesives and abrasive wears with the formation of IMC’s on the tool pin. Material flow ability characteristics suggest the intermixing of grain boundaries at the weld interface due to severe plastic deformation in enriching the weld strength.