Aluminium matrix surface composites are gaining alluring role especially in aerospace, defence, and marine industries. Friction stir processing(FSP) is a promising novel solid state technique for surface composites fabrication. In this study, AA6061/SiC surface composites were fabricated and the effect of tool plunge depth on pattern of reinforcement particles dispersion in metal matrix was investigated. Six varying tool plunge depths were chosen at constant levels of shoulder diameter and tool tilt angle to observe the exclusive effect of plunge variation. Process parameters chosen for the experimentation are speed of rotation, travel speed and tool tilt angle which were taken as 1400 rpm, 40 mm/min, and 2.5 °respectively. Macro and the microstructural study were performed using stereo zoom and optical microscope respectively. Results reflected that lower plunge depth levels lead to insufficient heat generation and cavity formation towards the stir zone center. On the other hand, higher levels of plunge depth result in ejection of reinforcement particles and even sticking of material to tool shoulder. Thus, an optimal plunge depth is needed in developing defect free surface composites. Aluminum matrix surface composites are gaining alluring role especially in aerospace, defense, and marine industries. Friction stir processing (FSP) is a promising novel solid state technique for surface composites fabrication. In this study, AA6061 / SiC surface composites were fabricated and the effect of tool plunge depth on pattern of reinforcement particles dispersion in metal matrix was investigated. Six varying tool plunge depths were chosen at constant levels of shoulder diameter and tool tilt angle to observe the exclusive effect of plunge variation. Process parameters chosen for the experimentation are speed of rotation, travel speed and tool tilt angle which were taken as 1400 rpm, 40 mm / min, and 2.5 ° respectively. Macro and the microstructural study were performed using stereo zoom and optical microscope respectively. Results that lower plunge depth levels lead to insufficient heat generation and cavity formation towards the stir zone center. On the other hand, hig her levels of plunge depth result in ejection of reinforcement particles and even sticking of material to tool shoulder. Thus, an optimal plunge depth is needed in developing defect free surface composites.