Tool wear in Friction stir welding (FSW) is a critical factor influencing the quality of the welding process, mainly when dealing with materials such as aluminum (Al) alloy because It has a smaller window of workability than other metals due to its increased thermal conductivity and low melting point, which can rapidly lead to burn-through. Throughout this operation, close attention was paid to the tool's geometry, encompassing factors like shoulder diameter and probe profile, given their direct correlation with welding efficiency. This study investigates the wear mechanism of WC/Co (tungsten carbide-cobalt) and WC/Co DLC (diamond-like carbon-coated tungsten carbide cobalt) tools during FSW of High pressure die casting(HPDC)aluminum alloy. These probes were chosen because of their high strength and toughness compared to other steel probes usually used in FSW. HPDC, on the other hand, was selected due to its high demand across various industries, such as automotive or aerospace. This aluminum alloy type is frequently used in battery and automation industries. The wear mechanisms, including abrasive wear, grooves, and scratches, were analyzed through a Digital microscope, dimensional analysis, and Scanning electron microscopy (SEM). The measured samples undergo a thorough cleaning, and their width is assessed in the pre- and post-welding phases. The observed before and after the examination indicates the reduction in width caused by abrasion. The results show that WC tools exhibit significant wear resistance. DLC has also proved to be a promising method for protecting tools against abrasive and adhesive wear mechanisms; nevertheless, more work needs to be done. Thus Further research is recommended to optimize coating processes and understand the impact of welding parameters on tool wear and performance. Nevertheless, the utilization of WC uncoated and coated tools in FSW represents a groundbreaking advancement that will shape the future of welding processes for future generations.