A Review of Recent Progress in Solid State Fabrication of Composites and Functionally Graded Systems Via Friction Stir Processing

Friction stir processing (FSP) is a rapidly emerging newer solid-state technique for composite fabrication. It involves surface modification which in turn enables successful adaptation of surface properties through plastic deformations in solid state. During initial years of FSP inception, it was primarily employed in development of metal matrix composites of light metal alloys like aluminum. However, recently, it has gained an alluring role in fabrication of composites of various nonferrous and ferrous metal alloys as well as of polymers. In addition to composite fabrication, FSP has evolved as a revolutionary technique in developing functionally graded systems/surfaces (FGS) of metal matrix. This article covers all aspects of FSP in which reinforcement particles are embedded in the base matrix to develop composites and FGS. It presents a critical review on domains of recent developments, effects of different types of reinforcement particles and properties enhancement of composites, and FGS fabrication. In addition to this, various issues, challenges, and future work that demand attention are systematically addressed.