Materials Today: Proceedings 63 (2022) 494–503

Contents lists available at ScienceDirect

Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

A review of recent progress in the fabrication of surface composites

through friction stir processing
Amit Kumar ⇑, Vineet Kumar
Department of Mechanical Engineering, University Institute of Engineering & Technology, Maharishi Dayanand University, Rohtak, Haryana 124001, India

a r t i c l e i n f o a b s t r a c t

Article history: The development of surface composites is an effective tool to encounter surface-related issues, and dur-
Available online 12 April 2022 ing the recent past, friction stir processing has been developed as an energy-efficient process to fabricate
surface composites effectively. FSP is an evolving thermo-mechanical surface modification technology
Keywords: that removes casting defects locally, refines micro-structures, improves various mechanical properties
FSP like hardness, wear resistance, strength, etc., without affecting the bulk properties. Nowadays, besides
Mechanical properties low strength metal systems, i.e., aluminum and magnesium-based alloys, FSP has been reported for mak-
Surface composites
ing surface composites of high strength alloys like steel and titanium-based alloys. The effect of process
Reinforcement particle
variables and tool geometry on surface composites of different alloys have been reviewed largely, but
presently we are away from obtaining desired composites. For the whole understanding of FSPed surface
composites, this review consolidates different aspects of fabricated surface composites, effects of process
parameters, different reinforced particles, number of passes during fabrication of surface composites, tool
wear and tool materials, strengthening mechanisms for of FSPed surface composite including gaps in
recent works and possible suggestions for obtaining cost-effective and defect-free FSPed composites.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 4th International Con-
ference on Advances in Mechanical Engineering and Nanotechnology.

Introduction face composites through friction stir processing. Conventionally

The developments of composite materials and their associated
design and production processes are among the main innovations
in material history. Multifunctional composites may be customized
to satisfy the needs of a specific application due to their unique
combination of mechanical and physical qualities. Metal matrix
composite (MMC) is a solid solution that contains at least two
constituents- one of them must be metal and behaves like a matrix,
and the other one is reinforcement phase in the form of particu-
lates, whiskers, or continuous fibers, etc. [1]. In case, when more
than one reinforcement particle (RP) is used for composite fabrica-
tion, hybrid composite is obtained [2]. Reinforcement of particles
into the surface of metal instead of bulk to improve its surface con-
ditions is termed as metal matrix surface composite. Surface com-
posite (SC) is mostly fabricated using soft metals like Al and Mg as
a matrix to enhance its hardness and wear resistance [3,4]. In their
study, Rathee et al. [5] have revealed that the use of aluminum as
the base metal is especially considerable in the fabrication of sur-
⇑ Corresponding author.
E-mail address: amithoodaymca@gmail.com (A. Kumar).
composites were fabricated using the powder metallurgy tech-
nique or molten metals where RPs or secondary phase particles
were added to molten metal or powdered metal. The composite
fabrication method where RPs are mixed physically with the
matrix, is termed ex-situ composite. Stir casting, squeeze casting,
powder metallurgy, spray forming, liquid metal infiltration, and
mechanical alloying are some techniques for ex-situ composites’
fabrication. Ex-situ composites have some disadvantages like,
these composites show poor wettability between matrix and RPs,
and there are chances of interfacial reactions between these
phases. However, ex-situ composites show isotropic properties
and their low cost and easy preparation make them preferable.
For the fabrication of ex-situ composites, the particle size of rein-
forcement ranges to nanoscales, and the volume fraction of RPs is
the main deciding factor for the properties of these composites.
Many researchers have studied ex-situ composites fabricated
through friction stir processing (FSP) [6–9].
In-situ composites are fabricated through chemical reactions
within matrix and RPs, and such composites show various advan-
tages, like stable composites with good compatibility among the
constituting phases. In-situ composites have a more uniform

https://doi.org/10.1016/j.matpr.2022.03.648
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 4th International Conference on Advances in Mechanical Engineering and Nanotechnology.
A. Kumar and V. Kumar
microstructure, high wear and corrosion resistance, and low sensi-
tivity to thermal shocks. Due to these attributes, in-situ composites
exhibit better mechanical properties. Parameters like weight per-
centages of RPs, reaction time, sintering temperature, and heat-
ing–cooling rate are deciding factors for properties of in- situ
composites. Exothermic dispersion, mechanical alloying, and reac-
tive hot pressing are a few in-situ composite fabrication tech-
niques. Beyond these techniques, FSP is also a useful technique
for in-situ composite fabrication [10–15].
FSP is a composite fabrication technique through a solid-state
processing route in which temperature remains below the melting
point of the matrix [1]. FSP is a modified version of friction stir
welding (FSW) [16,17]. Starting from working with aluminum
alloys, FSP has been developed for successful working with alloys
of high-strength metal systems like copper, titanium, and steel.
This technique offers severe plastic deformation (SPD), resulting
in very fine grains and high misorientation of grain boundaries,
ultimately resulting in proper fusion and mixing of RPs in the
matrix [18]. FSP produces grain refinement, and SPD eliminates
the particles at the interface [19]. In the case of FSP, there is
dynamic recrystallization of microstructure, which makes it
unique among all SPD techniques, and there are high angle grain
boundaries in bulk [20]. Also, FSP modifies only surface properties,
and other SPD techniques modify the material’s bulk properties.
1. Description of FSP mechanism
The process description is shown in Fig. 1. The FSP tool which is
non-consumable, has two types of motion, i.e., rotational speed
(RS) and traverse speed (TS). First, the profiled pin or probe of
the rotating tool is plunged into the workpiece by applying force
on it so that the broad diameter shoulder of the tool just touches
the workpiece. Then the tool is given TS, and it crosses the work-
piece. FSP tool performs two functions, i.e., heating and deforma-
tion of the workpiece. The heating effect, mainly due to friction,
causes extreme deformation that ultimately plasticizes the mate-
rial, and this plastic material is restricted by the tool shoulder to
circulate around the tool, and finally, it is reinforced in the wake
of the tool. As a result, there is SPD of the material flowing around
the tool. In addition, the thermal exposure of the material leads to
the refinement of microstructure significantly. The processed part
of the workpiece, under the tool shoulder, includes stirred zone
(S.Z.), thermo-mechanically- affected zone (TMAZ), and heat-
affected zone (HAZ) [4]. After completing the process, the friction
stir processed (FSPed) zone cools, creating a recrystallized,
defect-free, and fine-grained microstructure. Fine and equiaxed
Fig. 1. Schematic of FSP.
495
Materials Today: Proceedings 63 (2022) 494–503
grains are obtained in the S.Z. due to dynamic recrystallization
(DRX) [13].
2. SC fabrication through FSP
In earlier experiments, SC were fabricated by applying a rein-
forcement powder layer on the metal surface and then performing
FSP subsequently on it. In this procedure, RP distribution remains
in a wider area. Other than this method, reinforcement material
can be added on the metal surface within a specified region, and
in this case, the processed area is within SZ; because the distribu-
tion of the RPs is controlled by the tool probe instead of the tool
shoulder [3,4]. However, the comprehensive coverage of compos-
ites fabricated through FSP is not so wide and inclusive. Different
variants of composites can be fabricated through FSP. Nowadays,
the RPs are filled in the machined cavity on the metal plate [6–
9]. A few very common patterns for cavity making are shown in
Fig. 2(i). Next to machining a cavity on the matrix surface, the rein-
forcing material is filled in it, and FSP is done over it. A schematic of
this process is depicted in Fig. 2(ii). A light binder may also be used
for applying RPs on matrix so that particles don’t displace during
the process. In addition, single-pass or multi-pass FSP may be per-
formed to obtain the proper dispersion of the RPs.
ZrO2, WC, SiC, TiB2, Al2O3, TiC, B4C, graphite particles, carbon
nanotubes (CNT), etc., are commonly RPs for the fabrication of
SCs [23]. The particle size of these materials plays an important
role in the properties of the composites. Also, these particles may
be used as single or as a mixture of two or more. Due to their
capacity to improve typical fiber-reinforced composites’ mechani-
cal and physical characteristics, nanoparticles have recently gained
much interest in the composites field [24]. These unique nanofil-
lers have a nanoscale size that leads to greater surface area (up
to 1000 m2/g) and remarkable thermal, mechanical, and electrical
characteristics [25]. Single-walled carbon nanotubes (SWCNT),
multiwalled carbon nanotubes (MWCNT), montmorillonite, nano
clays, and carbon nanofibers are nanoparticles that are frequently
used in nanocomposites. Stable and fine reinforcements with
excellent interfacial bonding disseminated evenly in the matrix
improve properties [6]. FSP can be used for fabrication of both,
in situ and ex-situ, surface composites, and the research work on
these is summarised as follow:
2.1. Developments in various features of the SC fabrication through
FSP
Firstly, Mishra et al. [26] explored the utility of the FSP in the
fabrication of SCs and they prepared successfully a composite of
AA5083/SiC and reported improvement in microhardness of the
metal surface. They applied a thin layer of SiC powder mixed with
methanol on the surface of the Al5083 plates, dried it in air, and
then FSP was executed over this layer. With time, different meth-
ods of the addition of particles in the matrix have been developed.
Ratna et al. [27] used another matrix plate over the layer of RPs
to prevent the spreading of these particles. This method may be
termed as a sandwich method whose schematic is shown in Fig. 3.
Instead of the application of a thin layer of particles on the
metal surface, the filling of particles in a grooved cavity on the
metal matrix resulted in a more efficient process [28]. To prevent
the scattering of particles during FSP, a cover plate can be used
over the groove [29]. Next to it, hole methods are also being used
to add RPs and it is found that this method generally resulted in
homogeneous particle dispersion [10,11]. Komarasamy et al. [21]
used a zigzag hole pattern on Al5025 metal matrix to fill RP and
then executed FSP and observed better efficiency in respect to
incorporation of particles in the processed zone. D. K. Sharma
A. Kumar and V. Kumar
Fig. 2. (i) Different patterns for filling of reinforcement material (ii) Schematic of surface composite fabrication through FSP.
Fig. 3. Schematic of the sandwich method of adding reinforcement in surface composites. [27].
et al. [22] also adopted a zigzag hole pattern to fabricate the hybrid
SC of AA6061/B4C + MoS2 and reported uniform particle distribu-
tion that resulted in enhanced mechanical properties. This homo-
geneity in the dispersion of RPs in the metal matrix can further
be improved by the use of multi-pass FSP [30,31] and with a
change in direction of the process in between consecutive passes
FSP [32-34].
Further investigations have been made to find the effects of tool
geometry [35] and tool speeds [6,36,37]. The ratio of shoulder
diameter to pin diameter (D/d) was introduced as an influential
parameter for the fabrication of good quality SCs. V. Mahesh
et al. [38] worked for a SC of A1050/Mo and they used shoulder
diameters of 22, 20, and 18 mm and a pin diameter of 6 mm. They
reported that grain refinement and hardness increased with reduc-
tion in shoulder diameter as it resulted in a small nugget zone and
best properties were obtained with 18 mm shoulder diameter (D/d
ratio- 3).
Hybrid composites are fabricated using more than one rein-
forcement particle. The volume fraction of these reinforcement
particles controls the properties of the SCs and process parameters
[28,39–42]. Karpasand et al. [43] fabricated various defect-free SCs
of Al7075/B4C/TiB2 and reported that the particles’ dispersion in
the hybrid composites depended on quantities of RPs and the opti-
mized dispersion was obtained when both the secondary phases
were used in equal amount. B. Yaqoob et al [44] reported that
the method adopted for the mixing of particles also affects the
mechanical properties of hybrid SCs. They fabricated FSPed hybrid
surface composites of AA6061/ graphene + CeO2 and observed that
composite fabricated using solvent-based mixing gave better
mechanical properties than the one fabricated using dry mixing
and this was due to non-clustering of particles in case of solvent-
based mixing.
Zahmatkesh et al. [45] used the plasma spraying method for
dispersion of reinforcement particles to fabricate nanocomposites
496
Materials Today: Proceedings 63 (2022) 494–503
of AA2024/Al2O3. They deposited a 200-lm thick coating of Al2O3
on the specimen and there was uniform dispersion of particles
by plasma spraying. After this deposition, FSP was executed. They
observed that microhardness increased from 90HV to 230 HV. Gan-
dra et al. [46] deposited RPs on the specimen with oxy-fuel spray
technique, a high-velocity spraying, and fabricated composite of
A356/ Al2O3.
Sharma et al. [47] fabricated a composite of Al6061/graphene
nanoplatelets using a single groove reinforcement technique and
multiple microchannel reinforcement filling and then performing
multi-pass FSP. They reported an improvement in the particle dis-
tribution, 18% higher peak temperature (Fig. 4(a)), lower axial force
(Fig. 4(b)), and 28% higher ultimate tensile strength (UTS) in the
case when the later technique of reinforcement filling was used.
In their work, Rathee et al. [48] fabricated AA6063/SiC compos-
ite and concluded that more homogeneity of the SiC particles could
be obtained using groove technique along with tool offset i.e., to
shift the FSP tool from the centerline of the groove towards the
retreating side. They reported that the optimum value of tool offset
was 1.5 mm which was half of the radius of the tool pin.
In another experiment, Rathee et al. [49] fabricated AA6063/SiC
surface composites to investigate the effect of the ratio of groove
width (w) to tool pin diameter (d) on the distribution of secondary
phase particles and reported that ratio (w/d) of 0.5 was optimum
to fabricate good quality SC and a volume fraction of up to 40%
of SiC particles could be achieved with this ratio of w/d.
Khan et al. [50] prepared SC through FSP using CNT/B4C as par-
ticles and Al5083 as the matrix. They used the one-pass approach,
and hole approach to fill RPs and investigated the effect of inter-
hole spacing. They used the spacing of 8 mm and 10 mm and
reported that 10 mm spacing resulted in proper mixing of RPs
and hence best mechanical properties were obtained.
Liu et al. [51] developed hybridization of laser cladding (LC) and
FSP and fabricated Al-Cu/AZ31 composites by this hybridization.
A. Kumar and V. Kumar
Fig. 4. (a) Variation of peak temperature and (b) variation of axial force [47].
On samples of AZ31, a paste of Al and Cu powder in ethylene glycol
was applied in form of a 1 mm layer and the sample was allowed to
cool in the air for 24 h to fix the paste. Then LC was performed in
presence of argon gas to avoid oxidation during this process. After
it, FSP was executed. A defect-free composite with improved corro-
sion properties was obtained.
3. FSP process variables and their effects
By reviewing vast literature, FSP process variables are classified
as shown in Fig. 5. In this categorization of parameters, properties
and effects of RPs are not considered. During the fabrication of
composites, these variables are fixed according to the materials
being used for composites.
3.1. Major variables
Heat input during the process is one of the most important
attributes. Appropriate heat is desired for good composites as
low heat input results in defective composites forming a cluster
of RPs [17]. There will be a non-uniform distribution of the parti-
cles, and low heat input causes hindrance for proper reaction
among the constituents in the case of in-situ composites. More
than required heat input affects grain refinement. For working
with high melting point (M.P.) metal like steel, copper alloys,
Fig. 5. Different FSP process variables.
497
Materials Today: Proceedings 63 (2022) 494–503
etc., high heat input is required, and softer material like Al alloys,
whose yield strength and hardness are low, can be processed with
low heat input. Frigaard et al. [52] proposed a model for average
heat input per unit length during friction stir welding, which is
represented by Eq. (1):
4 2 uPNR3
Q¼ P ð1Þ
3 v
Here, u is friction coefficient, P is pressure (Pa), N is RPM, R is tool
shoulder radius (m), and v is traverse speed (mm/min).
In the case of FSP, heat input is mainly controlled by machine
variables like tool speeds, no. of passes, etc., and tool design vari-
ables [37,53]. Therefore, in the present review, these variables
are considered major variables.
3.1.1. Machine variables
From the analysis of findings of various researchers, it can be
concluded that RS and TS of tool are major factors for determining
heat input during FSP. The amount of heat input affects the devel-
opment of microstructure in the processed and affected regions,
which ultimately decide other properties of the composites. Soley-
mani et al. [54] in two different experiments prepared FSPed sam-
ple of AA5083 and fabricated hybrid SC of AA5083/SiC + MoS2.
They observed that in both cases, with an increase in RPM, finer
grains were obtained (Fig. 6).
A. Kumar and V. Kumar
Fig. 6. Effects of rotational speed on the grain size of (a) FSPed AA5083 samples and (b) MMC of AA5083/SiC + MoS2 obtained through FSP [54].
Bharti et al. [55] processed the samples of Al5052 with FSP and
investigated the effects of tool speed on the mechanical properties.
They reported that there is an increase in the hardness with a
decrease in the TS and an increase in the RS and this happens
due to the increased friction force and ultimately increase in the
heat input which refines the grain.
Aggregation of RPs during fabrication through FSP, despite tak-
ing maximum possible tool speeds, is a major problem as it causes
the deterioration of composites’ strength. Aggregation is more
probable while the size of RP is in nanoscales [36]. This issue can
be resolved with multi-pass FSP. Some other defects, like porosity,
can also be addressed by performing more no. of passes [56]. There
are chances of microstructural inhomogeneity in the fabrication of
FSPed composites as RPs tend to be fixed towards the advancing
side. Some researchers have found that this issue can be resolved
by performing consecutive passes in the opposite direction [7,56-
58]. Jain et al. [33] studied the effect of CNTs and SiC reinforce-
ments in AA5083 using FSP. Three passes were performed with
change in direction and they obtained refined grain structure with
improved mechanical properties of base metal. The role of multi
passes in grain refinement and fragmentation of secondary parti-
cles is shown in Fig. 7.
The proper combination of various machine variables reported
by various researchers to obtain good quality SCs, their findings
regarding different mechanical properties of the fabricated com-
posites, and effects of the machine variables on these mechanical
properties are summarised in Table 2.
3.1.2. Tool material and geometry
During composite fabrication through FSP, the tool bears high
temperature and load, facing deterioration. Commonly used mate-
rials for FSP are H13 steel (for low strength alloys), cermets, poly
cubic boron nitride (CBN), cobalt alloy, and tungsten carbide (for
harder materials) [69]. Tool design plays an influential role in FSP
as it governs the process’s material flow and traverse rate. It is
the tool that stirs and moves the material. The main parts of the
tool are the pin and shoulder. The heat produced during the pro-
cess depends on tool design. The pin is plugged into the workpiece
during the process, and the shoulder touches the workpiece. The
heat produced in the process is mainly due to friction between
the shoulder and the workpiece. So, the relative size of the pin
and shoulder are deciding factors of the heating aspect. The shape
of the tool pin controls the heat generation and the flow of the
material during the process [70].
Also, the shoulder provides confinement to the heated metal
and surface finish of the processed part. Therefore, the shoulder
498
Materials Today: Proceedings 63 (2022) 494–503
is an integral part of the tool, and the pin can be integral to the
shoulder, or it may be inserted separately, and the material of such
pin may be different from the material of the tool. Tool shoulder
may be flat or concave shaped, as shown in Fig. 8(i). The concave
profile acts as a reservoir for the stirred material and the angle of
concavity is mostly kept less than 5° [71]. Tool pins of different
geometrical cross-sections (shown in Fig. 8(ii)) like triangular, con-
ical, cylindrical, hexagonal, square, etc., can be used to fabricate
surface composite. Also, the outer surface of the probe can have
threads or flutes on it.
Patel et al. [72] executed FSP on Al7075 using three different pin
shapes of square, pentagon, and hexagon and reported that in all
three cases there was sticking of workpiece material around the
tool pin and FSP with square pin tool resulted in the best grain
refinement and improved microhardness. Faraji et al. [73] fabri-
cated a composite of Mg/Al2O3 and concluded that finer grain size
was obtained using the triangular tool when compared to the same
obtained with the square alternative.
Yu et al. [74] worked to investigate the heat transfer in magne-
sium alloy during FSP with the help of a 3-D transient computa-
tional fluid dynamics model. They used tool pins with and
without the threads and observed that the thread on the pin show
a great impact on the temperature distribution. Similar results
were given by the reports of Prado et al. [75].
3.2. Minor variables
Thermal properties of the materials of the workpiece and tool
and cooling mechanism during and after completion are catego-
rized as minor variables for fabricating FSPed composites. High
thermal conductivity results in high heat loss, so high heat input
is desired during processing with such materials. A backing plate
under the workpiece can be used to alter the thermal properties
of the workpiece [76,77]. Desired microstructure in nanoscales
and reduction in tool wear can be achieved by using a proper cool-
ing mechanism during the process [78]. Water, air, dry ice, oil, and
alcohol are a few coolants used in the cooling mechanism with FSP.
Najafi et al. [79] used methanol and dry ice mixed as a coolant for
the AZ31/SiC composite fabrication and obtained the grain size of 1
lm. Arora et al. [23] used undersurface cooling and obtained an
average grain size of 2.4 lm.
4. Strengthening mechanisms
The mechanism contributing to the increase in strength of a
metal is known as the strengthening mechanism. Metal strength
A. Kumar and V. Kumar Materials Today: Proceedings 63 (2022) 494–503

Fig. 7. (a) Optical microstructure showing uniformly distributed SiC, (b) fragmented SiC particles obtained through SEM, (c) SEM micrograph showing agglomerated CNT
after single one pass of FSP, and (d) SEM analysis showing uniformly distributed CNT after three passes of FSP [33].

Fig. 8. (i). Different types of tool shoulder (ii) Tool probes of various shapes.

is closely related to its dislocations. For increasing the strength of a
metallic material, dislocations must be hindered for movement.
There are similar strengthening mechanisms in SCs as to bulk
MMCs. Lloyd [80] came out with four main strengthening mecha-
nisms in MMCs: work hardening, Hall-Petch relationship, Orowan
strengthening, and coefficient of thermal expansion strengthening.
Kim et al. [81] worked with metal matrix nanocomposites and pro-
posed grain refinement and coefficient of thermal expansion
strengthening as responsible mechanisms. Sanity-Zadeh et al.
[82] experimented for model validation for nanocomposites of
Al2O3 and Y2O3 particles reinforced in magnesium. They found
Hall-Petch strengthening as the main mechanism for strength
enhancement. They also observed that contribution of coefficient
of thermal expansion and Orowan strengthening for strength
increases when we increase the volume fraction of reinforced cera-
mic particles.
Lee et al. [83] provided a model to estimate the Yield Strength
ðrcy ) of Al/Si FSPed composites prepared by powder metallurgy.
They considered three strengthening mechanisms and found that
Orowan, Hall Petch, and coefficient of thermal expansion were
responsible for the strengthening of the composites. As per their
model, Yield Strength (with 10–15% discrepancies in the model
values and the experimental results) are given by Eqs. (2) and (3).
rcy ¼ rmy ð1 þ 0:5SV Þ ð2Þ
rmy ¼ r0 þ rOR þ rg þ rCTE ð3Þ

499
A. Kumar and V. Kumar Materials Today: Proceedings 63 (2022) 494–503

Here, rmy = matrix yield strength, V = reinforcement particles’ vol-
ume fractions, S = reinforcement particles’ aspect ratio, r0 = initial
matrix strength, rOR = Orowan strengthening, rg = grain size
strengthening, rCTE = coefficient of thermal expansion
strengthening.
Improvement in mechanical properties, i.e., microhardness,
UTS, wear resistance, % elongation, ductility, of surface composites
is shown in Table 1. An increment in microhardness is attributed to
grain refinement and the presence of reinforcement particles. On
the other hand, in some cases, UTS for composites decreases, and
Barmouz et al. [84] suggested that it happens due to non-
uniform distribution and clustering of reinforcement particles.
5. Common defects in FSPed composites
Defects of FSP and FSW are mostly the same because the basic
working mechanism for FSP is similar to that of FSW. Insufficient
heat generation and improper material flow cause various defects
in these processes. FSPed composites are also susceptible to defects
if there is an improper selection of process variables. Some com-
mon types of FSW/FSP defects are wormhole, cavity, tunneling
defect, large voids, surface galling, oxide entrapment, lack of pen-
etration, scalloping, etc. [85](see Table 3).
6. Conclusions and further research scopes
Conclusive remarks of this review about the fabrication of
FSPed surface composites are as:
 Fabrication of surface composites through FSP is easy and
energy-saving. FSP has proven very effective for both, i.e.,
in situ and ex-situ surface composites, as a composite manufac-
turing technique. If there is FSPed in situ surface composite, the
reaction products removal from the site is fast, and it results in
enhancement of reaction rate, so fabrication of in-situ surface
composites through FSP is favorable. Hybrid composites with
promising properties have been fabricated using a mixture of
hard and soft reinforcements in FSPed composites.
 Mechanical properties of soft metals like Al and Mg, which have
high strength to weight ratio, can be improved very effectively
through the FSP technique to make them capable of using in
automotive and aerospace industries. On the other hand, the
use of FSP for the processing of hard metals such as steel, tita-
nium, etc., is limited due to high tool wear. Tungsten-based
and pcBN tools, capable of FSP of hard materials, have limita-
tions due to high cost and low fracture toughness.
 Extremely small reinforcing particles’ aggregation is the funda-
mental issue in producing ex-situ composites. Attainment of the
reaction temperature is the point of concern for in-situ compos-

Table 1
Survey of different types of surface composites.

S. No. Metal system Reinforcement material Type of composite Reference

1. Al Ti In situ (Al- Al3Ti) [10]
2. Al Cu In situ (Al- Al2Cu) [11]
3. Al TiO2 In situ (Al3Ti- Al2O3) [12]
4. Al TiC In situ [13]
5. Al Al2O3 In situ [14]
6. AZ91 Al2O3 + SiC In situ [15]
7. AZ31 MWCNT Ex-situ [6]
8. AZ61 SiO2 Ex-situ [7]
9. AA6061 Al2O3 Ex-situ [8]
10. A356 Al2O3 Ex-situ [9]

Table 2
Analysis of process variables’ effects.

S. Matrix/ Process variables Major observations Ref.

No Reinforcement R.S. (rpm) TS No. of
(mm/ passes
min)
1. AA1050/SiC 1000 15 1  With the increase in R.S. and T.S., there is a uniform distribution of SiC. [59]
At very high speeds, there is weak bonding among SiC and Al alloy
2. AZ91/SiO2 1250 63 1  With the increase in T.S., more refined grains were obtained in S.Z., and it resulted in higher [37]
hardness
3. AZ31/MWCNT 1500 100 1  T.S. was varied from 100 to 25, and it was observed that at T.S. of 100, MWCNTs were not dis- [6]
persed properly, and at T.S. of 25, MWCNTs dispersed without aggregation
4. Al356/ SiC/ 1600 50 4  The maximum hardness value (80H.B.) and wear resistance were obtained at higher R.S. [60]
MoS2
5. Al/TiC 1000 60 1  UTS and hardness improved by 25% and 34%, respectively [61]
6. Al1050/ 1500 100 2  There was an improvement in hardness and tensile strength of 37% and 46%, respectively [62]
SiC + Al2O3
7. Al1016/ 950 30 3  Both hardness and strength declined [63]
MWCNT
8. Al6061/SiC 1600 40 3  In comparison to tensile strength and ductility of base metal, the same for composite improved to [64]
4 times and 7 times, respectively
9. Al2024/ Al2O3 800 25 2  With the increase in T.S., hardness improved [65]
10. Al5083/ Cu 750 25 2  Tensile strength improved by 30%, and ductility improved by 300% [66]
11. Al7075/ 1480 30 1  Only SiC, not B.N., enhanced hardness and wear resistance due to the soft nature of B.N., but BN [3]
SiC + BN BN helped to improve machinability
12. Al7075/ B4C 545 120 1  The hardness of composite enhanced 30–60 % as compared to the base metal [67]
13. Al5052/ Al2O3 RS/ TS – 1–4  UTS improved by 18%, and elongation improved by 65% [68]
range- 8–
100

500
A. Kumar and V. Kumar Materials Today: Proceedings 63 (2022) 494–503

Table 3 Declaration of Competing Interest

Some common defects that may be obtained in FSW/FSP.

S. Defect name and description Possible reasons Ref. The authors declare that they have no known competing finan-
No. cial interests or personal relationships that could have appeared
1. Warm holes or voids formed  Lack of heat input [85,86] to influence the work reported in this paper.
in advancing side High T.S. for a given R.S.
2. Oxide entrapment in the  Lack of surface prepara- [87]
processed zone tion before execution of References
process results in a reac-
tion between Al and O2 [1] D.K. Sharma, D. Mahant, G. Upadhyay, Manufacturing of metal matrix
3. Lack of penetration  Due to improper tool [87] composites: a state of review, Mater. Today: Proc. 26 (Part 2) (2020) 506–
design or tool placement 519, https://doi.org/10.1016/j.matpr.2019.12.128.
4. Surface Galling as metal  Workpiece material [87] [2] M. Akbarpour, H.M. Mirabad, S. Alipour, Microstructural and mechanical
characteristics of hybrid SiC/Cu composites with nano-and micro-sized SiC
shredded from the welded stuck with tool pin
particles, Ceram. Int. 45 (3) (2019) 3276–3283, https://doi.org/10.1016/j.
top
ceramint.2018.10.235.
5. Root flow defect as material  Over penetration of pin [88,89]
[3] E.B. Moustafa, A. Melaibari, M. Basha, Melaibari, Muhammad Basha, Wear and
softened and stuck with Large pin length microhardness behaviors of AA7075/SiC-BN hybrid nanocomposite surfaces
backing plate Excess heat fabricated by friction stir processing, Ceram. Int. 46 (10) (2020) 16938–16943,
6. Scalloping is a series of small  Due to improper tool [90,91] https://doi.org/10.1016/j.ceramint.2020.03.274.
voids that occur in the design (inadequate [4] D.K. Sharma, V. Patel, V. Badheka, K. Mehta, G. Upadhyay, Fabrication of hybrid
advancing side of the shoulder diameter and surface composites AA6061/ (B4C+ MoS2) via friction stir processing, J. Tribol.
processed area. pin length) 141 (5) (2019), https://doi.org/10.1115/1.4043067.
[5] S. Rathee, S. Maheshwari, A.N. Siddiquee, M. Srivastava, A review of recent
progress in solid state fabrication of composites and functionally graded
systems via friction stir processing, Crit. Rev. Solid State Mater. Sci. 43 (4)
(2018) 334–366, https://doi.org/10.1080/10408436.2017.1358146.
[6] Y. Morisada, H. Fujii, T. Nagaoka, M. Fukusumi, MWCNTs/AZ31 surface
ites. These issues can be resolved by using a higher ratio of rota- composites fabricated by friction stir processing, Mater. Sci. Eng. A 419 (1–2)
tion speed to traverse speed and multiple passes because these (2006) 344–348.
steps generate more heat. Pretreatment of the reinforcement [7] C. Lee, J. Huang, P. Hsieh, Mg based nano-composites fabricated by friction stir
processing, Scr. Mater. 54 (7) (2006) 1415–1420.
particles to improve their wettability is another way to ensure
[8] M. Yang, C. Xu, C. Wu, K.-C. Lin, Y.J. Chao, L. An, Fabrication of AA6061/Al2O3
uniform dispersion of the ultra-fine reinforcing particles in the nano ceramic particle reinforced composite coating by using friction stir
FSP nugget zone. processing, J. Mater. Sci. 45 (16) (2010) 4431–4438.
 Fabrication of reasonable composites using FSP relies heavily on [9] Y. Mazaheri, F. Karimzadeh, M.H. Enayati, A novel technique for development
of A356/Al2O3 surface nanocomposite by friction stir processing, J. Mater.
choosing the best FSP variables. The amount of heat generated Process. Technol. 211 (10) (2011) 1614–1619.
during FSP is crucial for developing good quality composites, [10] C.J. Hsu, C.Y. Chang, P.W. Kao, N.J. Ho, C.P. Chang, Al–Al3Ti nanocomposites
and it depends on the friction coefficient between the work- produced in situ by friction stir processing, Acta Mater. 54 (19) (2006) 5241–
5249.
piece surface and tool shoulder. Consequently, the brittle frac- [11] C.J. Hsu, P.W. Kao, N.J. Ho, Ultrafine-grained Al–Al2Cu composite produced
ture might exist due to lesser heat generation than the in situ by friction stir processing, Scr. Mater. 53 (3) (2005) 341–345.
required amount because insufficient heat could not render [12] Q. Zhang, B.L. Xiao, Q.Z. Wang, Z.Y. Ma, In situ Al3Ti and Al2O3 nanoparticles
reinforced Al composites produced by friction stir processing in an Al–TiO2
the material soft enough. Increasing the friction coefficient sig- system, Mater. Lett. 65 (13) (2011) 2070–2072.
nificantly, on the other side, might enable the workpiece to [13] R. Bauri, D. Yadav, G. Suhas, Effect of friction stir processing (FSP) on
adhere to the tool and cause faults. Therefore, tool geometry microstructure and properties of Al–TiC in situ composite, Mater. Sci. Eng., A
528 (13–14) (2011) 4732–4739.
and its speeds are the most influencing variables in FSP. [14] A. Shafiei-Zarghani, S.F. Kashani-Bozorg, A. Zarei-Hanzaki, Microstructures and
mechanical properties of Al/Al2O3 surface nano-composite layer produced by
This review work suggests some future research scopes: friction stir processing, Mater. Sci. Eng., A 500 (1-2) (2009) 84–91.
[15] P. Asadi, G. Faraji, A. Masoumi, M.K. Besharati Givi, Experimental investigation
of magnesium-base nanocomposite produced by friction stir processing:
 The tool wear mechanism needs more investigation as there is effects of particle types and number of friction stir processing passes, Metall
very limited literature available. Proper understanding of tool Mater Trans A. 42 (9) (2011) 2820–2832.
wear is a must because there is a very high tool wear rate for [16] Z.Y. Ma, Friction Stir Processing Technology: A Review, Metall. Mater. Trans. A
39 (2008) 642–665.
the processing of hard metals. [17] R.S. Mishra, Z.Y. Ma, Friction stir welding and processing, Mater. Sci. Eng. R 50
 For FSPed composites, fatigue and creep are the mechanical (2005) 1–78.
properties investigated very limitedly. However, these proper- [18] A. Fattah-alhosseini, M. Vakili-Azghandi, M. Sheikhi, M.K. Keshavarz, Passive
and electrochemical response of friction stir processed pure titanium, J. Alloys
ties have high importance for automobile and space industries, Compd. 704 (2017) 499–508.
so careful and further examination is a must for understanding [19] Q. Zhang, B.L. Xiao, Q.Z. Wang, Z.Y. Ma, Effects of processing parameters on the
them. microstructures and mechanical properties of in situ (Al3Ti+Al2O3)/Al
composites fabricated by hot pressing and subsequent friction-stir
 Processing, through FSP, of hard metals is very limited due to processing, Metall. Mater. Trans. A 45 (2014) 2776–2791.
the cost factor. Hence, there is a need for research for cheaper [20] H.S. Arora, H. Singh, B.K. Dhindaw, Composite fabrication using friction stir
and more durable tools to fabric surface composites of such processing—a review, Int. J. Adv. Manuf. Technol. 61 (9–12) (2012) 1043–1055.
[21] M. Komarasamy, R.S. Mishra, J.A. Baumann, in: Microstructure and Mechanical
metals. Property Correlation in Al-B4C Surface Composite Produced via Friction Stir
 Post-process heat treatment of FSPed composites needs more Processing, Springer, Cham, 2013, pp. 39–46.
investigation as heat treatment changes the mechanical and tri- [22] D.K. Sharma, V. Patel, V. Badheka, K. Mehta, G. Upadhyay, Fabrication of hybrid
surface composites AA6061/(B4C + MoS2) via friction stir processing, ASME J.
bological properties.
Tribol. 141 (5) (2019) 052201, https://doi.org/10.1115/1.4043067.
[23] H.S. Arora, H. Singh, B.K. Dhindaw, Composite fabrication using friction stir
Along with time and continuous research, FSP has evolved as a processing-A review, Int. J. Adv. Manuf. Technol. 61 (2011) 1043–1055.
useful approach for successfully developing MMCs, and it is now a [24] O. Breuer, U. Sundararaj, Big returns from small fibers: a review of
polymer/carbon nanotube composites, Polym. Compos. 25 (6) (2004) 630–645.
well-established technology in this field. However, the industrial [25] J. Gou, S. O’Braint, H. Gu, G. Song, Damping augmentation of nanocomposites
use of this technology will be aided by further study in related using carbon nanofiber paper, J. Nanomater. 2006 (2006) 1–7.
areas and more knowledge about the process and its features. [26] R.S. Mishra, Z.Y. Ma, I. Charit, Friction stir processing: a novel technique for
fabrication of surface composite, Mater. Sci. Eng. A 341 (2003) 307–310.

501
A. Kumar and V. Kumar
[27] B. Ratna Sunil, Different strategies of secondary phase incorporation into
metallic sheets by friction stir processing in developing surface composites,
Int. J. Mech. Mater. Eng. 11 (1) (2016) 1–8.
[28] T. Thankachan, K.S. Prakash, V. Kavimani, Investigating the effects of hybrid
reinforcement particles on the microstructural, mechanical and tribological
properties of friction stir processed copper surface composites, Compos. Part
B: Eng. 174 (2019) 107057.
[29] E.R.I. Mahmoud, M. Takahashi, T. Shibayanagi, K. Ikeuchi, Fabrication of
surface-hybrid-MMCS layer on aluminum plate by friction stir processing and
its wear characteristics, Mater. Trans. 50 (7) (2009) 1824–1831.
[30] N. Gangil, S. Maheshwari, A.N. Siddiquee, Multipass FSP on AA6063-T6 Al:
strategy to fabricate surface composites, Mater. Manuf. Process. 33 (7) (2018)
805–811, https://doi.org/10.1080/10426914.2017.1415448.
[31] P. Sahandi Zangabad, F. Khodabakhshi, A. Simchi, A.H. Kokabi, Fatigue Fracture
of Friction-Stir Processed Al–Al3Ti–MgO Hybrid Nanocomposites, Int. J.
Fatigue 87 (2016) 266–278.
[32] D.K. Sharma, V. Patel, V. Badheka, K. Mehta, G. Upadhyay, Fabrication of Hybrid
Surface Composites AA6061/(B4C + MoS2) via Friction Stir Processing, ASME J.
Tribol. 141 (5) (2019), https://doi.org/10.1115/1.4043067 052201.
[33] V.K.S. Jain, K. Yazar, S. Muthukumaran, Development and Characterization of
Al5083-CNTs/SiC Composites via Friction Stir Processing, J. Alloys Compd. 798
(2019) 82–92, https://doi.org/10.1016/j.jallcom.2019.05.232.
[34] H. Fotoohi, B. Lotfi, Z. Sadeghian, J.-W. Byeon, Microstructural Characterization
and Properties of In Situ Al-Al3Ni/TiC Hybrid Composite Fabricated by Friction
Stir Processing Using Reactive Powder, Mater. Charact. 149 (2019) 124–132,
https://doi.org/10.1016/j.matchar.2019.01.024.
[35] Rajeev Rana, D.B. Karunakar, Anish Karmakar, Influence of Different Tool
Profiles and Process Parameters on Mechanical Properties of Dissimilar
AA6061 and AA7075 Aluminium Alloys by Friction Stir Welding, 2021, pp.
201–207. doi: 10.1007/978-981-33-4018-3_19.
[36] M. Sharifitabar, A. Sarani, S. Khorshahian, M. Shafiee Afarani, Fabrication of
5052Al/Al2O3 nanoceramic particle reinforced composite via friction stir
processing route, Mater. Design 32 (2011) 4164–4172.
[37] D. Khayyamin, A. Mostafapour, R. Keshmiri, The effect of process parameters
on microstructural characteristics of AZ91/SiO2 composite fabricated by FSP,
Mater. Sci. Eng. A 559 (2013) 217–221.
[38] V. Mahesh, A. Arora, Effect of tool shoulder diameter on the surface hardness of
aluminum-molybdenum surface composites developed by single and double
groove friction stir processing, Metall. Mater. Trans. A 50 (11) (2019) 5373–
5383, https://doi.org/10.1007/s11661-019-05410.
[39] S. Ahmadifard, S. Kazemi, A. Heidarpour, Production and characterization of
A5083–Al2O3–TiO2 hybrid surface nanocomposite by friction stir processing,
Proc. Inst. Mech. Eng. L 232 (4) (2018) 287–293, https://doi.org/10.1177/
1464420715623977.
[40] T. Prakash, S. Sivasankaran, P. Sasikumar, Mechanical and tribological
behaviour of friction-stir-processed Al 6061 aluminium sheet metal
reinforced with Al2O3/0.5Gr hybrid surface nanocomposite, Arabian J. Sci.
Eng. 40 (2) (2015) 559–569.
[41] T. Thankachan, K. Soorya Prakash, M. Kamarthin, Optimizing the tribological
behavior of hybrid copper surface composites using statistical and machine
learning techniques, ASME J. Tribol. 140 (3) (2018) 031610, https://doi.org/
10.1115/1.4038688.
[42] T. Thankachan, K.S. Prakash, V. Kavimani, Effect of friction stir processing and
hybrid reinforcements on copper, Mater. Manuf. Processes 33 (15) (2018)
1681–1692, https://doi.org/10.1080/10426914.2018.1453149.
[43] F. Karpasand, A. Abbasi, M. Ardestani, Effect of amount of TiB2 and B4C
particles on tribological behavior of Al7075/B4C/TiB2 mono and hybrid surface
composites produced by friction stir processing, Surf. Coat. Technol. 390
(2020) 125680, https://doi.org/10.1016/j.surfcoat.2020.125680.
[44] B. Yaqoob, R.A. Pasha, M. Awang, M.A. Nasir, A. Hussain, K. Nazir, Comparison
of mixing strategies and hybrid ratio optimization for mechanical properties
enhancement of Al-CeO2-GNP’s metal matrix composite fabricated by friction
stir processing, Metall. Microstruct. Anal. 8 (4) (2019) 534–544, https://doi.
org/10.1007/s13632-019-00553-0.
[45] B. Zahmatkesh, M.H. Enayati, A novel approach for development of surface
nanocomposite by friction stir processing, Mater. Sci. Eng. A. 527 (24-25)
(2010) 6734–6740.
[46] J. Gandra, R. Miranda, P. Vilaca, et al., Producing functionally graded materials
by friction stir processing, J. Mater. Process. Technol. 211 (11) (2011) 1659–
1668.
[47] A. Sharma, V.M. Sharma, B. Sahoo, S.K. Pal, J. Paul, Effect of multiple micro
channel reinforcement filling strategy on Al6061-graphene nanocomposite
fabricated through friction stir processing, J. Manuf. Process. 37 (2019) 53–70,
https://doi.org/10.1016/j.jmapro.2018.11.009.
[48] S. Rathee, S. Maheshwari, A.N. Siddiquee, M. Srivastava, Distribution of
reinforcement particles in surface composite fabrication via friction stir
processing: suitable strategy, Mater Manuf Process. 33 (3) (2018) 262–269,
https://doi.org/10.1080/10426914.2017.1303147.
[49] S. Rathee, S. Maheshwari, A.N. Siddiquee, M. Srivastava, Investigating effects of
groove dimensions on microstructure and mechanical properties of AA6063/
SiC surface composites produced by friction stir processing, Trans. Indian Inst.
Met. 70 (3) (2017) 809–816, https://doi.org/10.1007/s12666-017-1060-7.
[50] M. Khan, A. Rehman, T. Aziz, M. Shahzad, K. Naveed, T. Subhani, Effect of inter-
cavity spacing in friction stir processed Al 5083 composites containing carbon
nanotubes and boron carbide particles, J. Mater. Process. Technol. 253 (2018)
72–85, https://doi.org/10.1016/j.jmatprotec.2017.11.002.
502
Materials Today: Proceedings 63 (2022) 494–503
[51] F. Liu, Y. Ji, Z. Sun, G. Wang, Y. Bai, Enhancing corrosion resistance of Al-Cu/
AZ31 composites synthesized by a laser cladding and FSP hybrid method,
Mater. Manuf. Process. 34 (13) (2019) 1458–1466.
[52] Ø. Frigaard, Ø. Grong, O.T. Midling, A process model for friction stir welding of
age hardening aluminum alloys, Metall. Mater. Trans. A 32 (5) (2001) 1189–
1200.
[53] A. Dolatkhah, P. Golbabaei, M.K.B. Givi, F. Molaiekiya, Investigating effects of
process parameters on microstructural and mechanical properties of Al5052/
SiC metal matrix composite fabricated via friction stir processing, Mater.
Design 37 (2012) 458–464.
[54] S. Soleymani, A. Abdollah-Zadeh, S. Alidokht, Microstructural and tribological
properties of ultra fine grained hybrid composite produced by friction stir
processing, Mater. Phys. Mech. 17 (1) (2013) 6–10.
[55] S. Bharti, V. Dutta, S. Sharma, N.D. Ghetiya, Investigating the effect of tool
speed on the mechanical properties of Al5052 processed by friction stir
processing, Mater. Today Proc. 33 (2020) 1605–1609, https://doi.org/10.1016/
j.matpr.2020.05.547.
[56] M. Barmouz, M.K.B. Givi, Fabrication of in situ Cu/SiC composites using multi-
pass friction stir processing: evaluation of microstructural, porosity,
mechanical and electrical behavior, Compos. Part A: Appl. S. 42 (2011)
1445–1453.
[57] R. Bauri, D. Yadav, G. Suhas, Effect of friction stir processing (FSP) on
microstructure and properties of Al-TiC in situ composite, Mater. Sci. Eng. A
528 (2011) 4732–4739.
[58] M. Zohoor, M.K. Besharati Givi, P. Salami, Effect of processing parameters on
fabrication of Al-Mg/Cu composites via friction stir processing, Mater. Design
39 (2012) 358–365.
[59] A. Kurt, I. Uygur, E. Cete, Surface modification of aluminium by friction stir
processing, J. Mater. Process. Tech. 211 (2011) 313–317.
[60] S. Selvakumar, I. Dinaharan, R. Palanivel, B. Ganesh Babu, Characterization of
molybdenum particles reinforced Al6082 aluminum matrix composites with
improved ductility produced using friction stir processing, Mater. Charac. 125
(2017) 13–22.
[61] M. Hajian, A. Abdollah-zadeh, S.S. Rezaei-Nejad, H. Assadi, S.M.M. Hadavi, K.
Chung, M. Shokouhimehr, Microstructure and mechanical properties of
friction stir processed AISI 316L stainless steel, Mater. Des. 67 (2015) 82–94.
[62] G. Azimi-Roeen, S.F. Kashani-Bozorg, M. Nosko, P. Švec, Reactive mechanism
and mechanical properties of in situ hybrid nano composites fabricated from
an AlFe2O3 system by friction stir processing, Mater. Charact. 127 (2017) 279–
287.
[63] J.R. Paules, M.F. Dilmore, K.J. Handerhan, Development of eglin steel-a new,
ultrahigh-strength steel for armament and aerospace applications, Mater. Sci.
Technol.-Lond. 2 (2005) 13–23.
[64] N. Netto, M. Tiryakioğlu, P. Eason, Characterization of microstructural
refinement and hardness profile resulting from friction stir processing of
6061–T6 aluminum alloy extrusions, Metals 8 (2018) 552.
[65] Z.Y. Ma, A.H. Feng, D.L. Chen, J. Shen, Recent advances in friction stir welding/
processing of aluminium alloys: microstructural evolution and mechanical
properties, Crit. Rev. Solid State. Mater. Sci. 43 (8) (2017) 269–333.
[66] Y. Lv, Y. Ding, Y. Han, L.-C. Zhang, L. Wang, W. Lu, strengthening mechanism of
friction stir processed and post heat treated NiAl bronze alloy: effect of
rotation rates, Mater. Sci. Eng. A 685 (2017) 439–446.
[67] H.G. Rana, V.J. Badheka, A. Kumar, Fabrication of Al7075 / B4C surface
composite by novel Friction Stir Processing (FSP) and investigation on wear
properties, Proc. Technol. 23 (2016) 519–528.
[68] M. Sharifitabar, A. Sarani, S. Khorshahian, M. Shafiee Afarani, Shafiee Afarani,
Fabrication of 5052Al/Al2O3 nanoceramic particle reinforced composite via
friction stir processing route, Mater. Des. 32 (8–9) (2011) 4164–4172.
[69] R. Rai, A. De, H.K.D.H. Bhadeshia, T. DebRoy, Review: friction stir welding tools,
Sci. Technol. Weld. JOI 16 (2011) 325–342.
[70] M.K. Gupta, Effects of tool profile on mechanical properties of aluminium alloy
Al 1120 friction stir welds, J. Adhes. Sci. Technol. 34 (18) (2020) 2000–2010,
https://doi.org/10.1080/01694243.2020.1749448.
[71] V. Sharma, U. Prakash, B.V.M. Kumar, Surface composites by friction stir
processing: a review, J. Mater. Process. Technol. 224 (2015) 117–134.
[72] V.V. Patel, V. Badheka, A. Kumar, Effect of polygonal pin profiles on friction stir
processed superplasticity of AA7075 alloy, J. Mater. Process. Technol. 240
(2017) 68–76, https://doi.org/10.1016/j.jmatprotec.2016.09.009.
[73] G. Faraji, O. Dastani, S.A.A.A. Mousavi, Effect of process parameters on
microstructure and micro-hardness of AZ91/Al2O3 surface composite
produced by FSP, J. Mater. Eng. Perform. 20 (9) (2011) 1583–1590.
[74] Z. Yu, W. Zhang, H. Choo, Z. Feng, Transient heat and material flow modeling of
friction stir processing of Magnesium alloy using threaded tool, Metall. Mat.
Trans. A 43 (2) (2012) 724–737.
[75] R. Prado, Tool wear in the friction-stir welding of aluminum alloy
6061þ20Al2O3: a preliminary study, Scr. Mater. 1 (45) (2001) 75–80.
[76] M.J.C. Rosales, N.G. Alcantara, J. Santos, R. Zettler, The backing bar role in heat
transfer on aluminium alloys friction stir welding, Mater. Sci. Forum 636-637
(2010) 459–464.
[77] P. Upadhyay, A.P. Reynolds, Effects of forge axis force and backing plate
thermal diffusivity on FSW of AA6056, Mater. Sci. Eng. A 558 (2012) 394–402.
[78] N. Xu, R. Ueji, H. Fujii, Enhanced mechanical properties of 70/30 brass joint by
rapid cooling friction stir welding, Mater. Sci. Eng. A 610 (2014) 132–138.
[79] M. Najafi, A.M. Nasiri, A.H. Kokabi, Microstructure and hardness of friction stir
processed AZ31 with SiCP, Int. J. Mod. Phys. B 22 (2008) 2879–2885.
A. Kumar and V. Kumar
[80] D.J. Lloyd, Particle reinforced aluminium and magnesium matrix composites,
Int. Mater. Rev. 39 (1994) 1–23.
[81] Y.G. Kim, H. Fujii, T. Tsumura, T. Komazaki, K. Nakata, Three defect types in
friction stir welding of aluminum die casting alloy, Mater. Sci. Eng. A 415
(2006) 250–254.
[82] A. Sanaty-Zadeh, P.K. Rohatgi, Comparison between current models for the
strength of particulate-reinforced metal matrix nanocomposites with
emphasis on consideration of Hall-Petch effect, Mater. Sci. Eng. A 531 (2012)
112–118.
[83] I.S. Lee, C.J. Hsu, C.F. Chen, N.J. Ho, P.W. Kao, Particle-reinforced aluminum
matrix composites produced from powder mixtures via friction stir
processing, Compos. Sci. Technol. 71 (2011) 693–698.
[84] M. Barmouz, M.K. Besharati Givi, J. Seyfi, Onthe role ofprocessingparameters
inproducing Cu/SiC metal matrix composites via friction stir processing:
Investigating microstructure, microhardness, wear and tensile behavior,
Mater. Charact. 62 (1) (2011) 108–117.
[85] W.J. Arbegast, A flow-partitioned deformation zone model for defect formation
during friction stir welding, Scripta Mater. 58 (5) (2008) 372–376.
[86] M.A. Fakih, S. Mustapha, J. Tarraf, G. Ayoub, H.R. Detection, Assessment of
flaws in friction stir welded joints using ultrasonic guided waves:
503
Materials Today: Proceedings 63 (2022) 494–503
experimental and finite element analysis, Mech. Syst. Signal Process. 101
(2018) 516–534.
[87] R. Zettler, T. Vugrin, M. Schmücker, Effects and defects of friction stir welds, in:
D. Lohwasser, Z. Chen (Eds.), Friction Stir Welding; From Basics to Applications
Woodhead Publishing Series in Welding and Other Joining Technologies, 2010,
pp. 245–276.
[88] F. Khodabakhshi, A. Simchi, A. Kokabi, M. Nosko, P. Švec, Strain rate sensitivity,
work hardening, and fracture behavior of an Al-Mg TiO2 nanocomposite
prepared by friction stir processing, Metall. Mater. Trans. A Phys. Metall.
Mater. Sci. 45 (9) (2014) 4073–4088.
[89] R.S. Mishra, Z.Y. Ma, Friction stir welding and processing, ASM Int. 50 (1–2)
(2005) 1–78, https://doi.org/10.1016/j.mser.2005.07.001.
[90] Y.J. Kwon, I. Shigematsu, N. Saito, Mechanical properties of fine-grained
aluminum alloy produced by friction stir process, Scr. Mater. 49 (8) (2003)
785–789, https://doi.org/10.1016/S1359-6462(03)00407-X.
[91] M. Barmouz, M.K. Besharati Givi, J. Seyfi, On the role of processing parameters
in producing Cu/SiC metal matrix composites via friction stir processing:
investigating microstructure, microhardness, wear and tensile behavior,
Mater. Charact. 62 (1) (2011) 108–117, https://doi.org/10.1016/
j.matchar.2010.11.005.