In this study, the tool wear mechanism in the probes used for Stationary Shoulder Friction Stir Welding (SS-FSW) of Al-60XX was explored. Also, two reconditioning methods were tried to test the feasibility of remanufacturing of these probes. Being manufactured in USA, the alloy used as the probes’ material is a technically hard-to-produce and costly aerospace one (MP159), thus, remanufacturing policy regarding these probesseemed reasonable and became an inspiration for this work. The candidate materials having similar mechanical properties to the probes’ alloy were selected to be Stellite-6and Castomag 45351 (hardfacing SS). The former material was provided as powder and deposited on the probes surface by powder-based Laser Metal Deposition (LMD-p),and the later was deposited by Wire Arc Additive Manufacturing (WAAM). It was found that Stellite-6 supper alloy makes a very homogenous and defect-free bonding with the Base Material (BM) i.e., MP159, employing a soft Transition Zone close to the interface of the cladded layer. Due to softness of this region no buffer layer (intermediate layer) was needed in between the materials and led to a crack/pore-free bonding. At the end, a simple cost evaluation is provided to support the idea and implementation of the plan, with the help of a deposition strategy designed (assumed) for the remanufacturing process.