A friction stir welding axis-lead (x-y instrument motion) method is examined using the identical AA6061-T6 alloy system in our current study. These efforts will increase the weld quality in friction stir welding using axis-lead tool movement of similar alloys. Axis-lead (x-y) tool path method was implemented to achieve high quality of weldments through complete mixing of two parent metal alloys. Three different step sizes (x-y movement) of 1 mm, 1.5 mm, 2 mm and width of 10 mm in tool path were selected for welding process. Process parameters have been set for the tool rotation speed 2000, 2200 rpm and weaving rates 100, 150 mm/min. An axial load of 6KN was applied for all the joining processes. The effectiveness of the axis-lead method over the conventional method was confirmed by mechanical and micro structural interpretations. The mechanical results revealed better results from axis-lead FSW method in all criteria compared to the conventional FSW method. The step sizes (x-y tool movement) of 1 mm, rpm of 2200 and weaving rates of 150 mm/min combination give superior weld quality among others. The study of the micro-structure revealed defect-free grain structures in the welded zone.