Friction stir welding (FSW) is a solid-state joining process with a wide range of applications in the E-mobility, automotive, aerospace and energy industries. However, FSW is subjected to specific challenges including comparatively high process forces and high requirements on the clamping technique as well as tool wear resulting from the tool-workpiece interaction and thermo-mechanical stresses. Geometric-related tool wear can cause premature tool failure, process instabilities or weld seam irregularities. Therefore, tool wear in general, wear limits and tool life are essential factors for the efficient and sustainable implementation of friction stir welding. Against this background, this study analysed areas of significant tool wear on the shoulder and probe as a function of process temperature, weld seam length and weld seam quality. This provided functional correlations for determining limiting conditions on maximum tolerable tool wear. Geometrical deviations of the tool, induced by wear, were detected experimentally at different measuring points on the probe and shoulder and varying weld seam length. The investigations were carried out using a force-controlled robotized welding setup in which AA-6060-T66 sheets with a thickness of 5 mm were joined by weld seams up to 500 m in length. To identify the maximum tolerable tool wear, the weld seam properties were determined by visual and metallographic inspections and by tensile tests at 50-m intervals on the weld seam. It was shown that a 50% reduction in rotational speed (lower temperatures) resulted in less wear and thus in an increase of tool life of up to 150%. In addition, it was shown that the shoulder, like the probe, was also subject to significant wear. These results can be incorporated into FSW maintenance schedules to maximize tool life and minimize scrap rates.