High-bypass-ratio gas turbine engine, fan exit guide vanes (FEGV) decrease drag and enhances efficiency. It utilizes a noteworthy amount of aluminum vanes, between 84 and 108 parts per gas turbine engine. Still significant weight lessening of about 40-50 lb. per engine is conceivable by supplanting aluminum with AA6063-Ni Particulate Composite vanes. In the present work, Friction Stir Processing (FSP) technique is employed for development of AA6063-Ni Particulate Composite. The matrix material is aluminium alloy (AA6063) which has good properties such as light weight with high strength and extrudability applications and the reinforcement metal Nickel has some peculiar properties such as high resistance to corrosion, good toughness and good impedance. The specimens are made with a groove of depth 4.5mm and width of three variable dimensions such as 0.4mm, 0.8mm and 1.2mm. It is successfully processed by providing a combination of tool rotational speed in between 1200 and 1500 rpm and lower travel speed 20–40 mm/min.