Friction Stir Processing of aluminum alloys: A Review

Abstract Friction stir processing is solid state process known for its ability to modify microstructures and changes the properties of a metal to its improved one with the help of intense and localized plastic deformation [1]. If in tests, with actively cooled magnesium-alloy workpieces the microhardness gets tripled in the area of the friction stir processed seam i.e. 120-130 Vickers hardness [2]. This processing also helps to convert a heterogeneous microstructure to a more homogeneous and refined microstructure. Re-processed areas are superior in strength and also have superior formability compared to parent material, e.g. aluminum castings can be processed to bind voids, or extrusions can also be improved in highly stressed areas. FSP in combination with superplastic forming provides the potential to form complex-shaped parts at higher strain rates and in section thicknesses which is not possible using conventional superplastic processing [3]. In this article of review, current stage of FSP and development occurred to understand it is addressed.