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AA6063 is an aluminium alloy with moderate strength. This type of alloy is widely used in the construction and automotive industries. In this article, the role of axial thrust in the formation of microstructure and fracture surface of the weld zone in friction stir welded AA6063 aluminium alloy is discussed. Butt joints were fabricated at five axial thrusts of 4 kN, 5 kN, 6 kN, 7 kN and 8 kN using an unthreaded tool pin. The rotational speed and translational velocity of the tool were maintained constant at 1500 revolutions per minute and 25 mm min−1 respectively. Specimens were prepared from the joints, and tensile testing was carried out. The ultimate tensile strength and percentage of elongation were calculated. Vickers hardness was measured in the weld zone at mid-thickness on the advancing and retreating sides. The microstructure and fracture surface of the joints were also examined. It was found that the joint produced at the axial thrust of 6 kN exhibited superior ultimate tensile strength, higher percentage of elongation and higher micro-hardness. This joint exhibited a superior quality weld zone without kissing bond and tunnel defects.