Review of Parametric Strategies for Enhancing the Mechanical and Wear Properties of Friction Stir Processed Aluminium Alloys Composites

In manufacturing industries, the surface properties of materials are very important because many engineering material’s failures originate from the surface. Friction stir processing (FSP) has been established as an effective surface modification technique for correcting surface defects, improving microstructural homogeneity as well as enhancing the mechanical and wear properties of engineering materials. Being a solid-state technique, FSP is void of solidification cracking and dilution. Also, the composite surface can be produced using FSP. However, achieving a well-refined microstructure and optimal mechanical and wear properties requires a proper set of processing parameters for every material system. Non-ferrous metals, especially aluminium alloys, have been well processed using FSP. The increasingly wide applications of aluminium alloys by manufacturers are largely due to its favourable combination of properties including high strength-to-weight ratio, excellent corrosion resistance, high ductility, and low cost. Therefore, FSP of aluminium alloys and aluminium alloys-made components for optimal performance usually requires parameters optimization as well as reinforcement additions. This work presents a comprehensive review of parametric effects on the microstructure, mechanical, and wear properties of friction stir processed aluminium metal matrix composites. It also documents the existing parametric strategies (e.g., tool geometries) and areas that could be harnessed in the future.