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ABSTRACT
Friction stir processing (FSP) was evolved as a potential technique for producing surface composites. Processed surface properties of soft and hard materials such as; hardness, abrasive, erosive and corrosive resistance, tensile strength, fatigue life, ductility, formability and corrosion resistance can be improved through FSP without changing the base material properties. Initially, FSP was limited to fabricating soft materials like aluminum and magnesium and its alloys. But now, it has been slowly introducing for hard materials and high temperature also such as; steel, titanium and nickel, cobalt and iron-based alloys. The leading concerns of this progressive research are to review and highlight the various process parameter effects on resultant microstructure, mechanical properties and related defects. The fundamental strengthening mechanisms during FSP of several surface composites are also discussed with various existing models and simulations. This review article has exhibited few research gaps on surface composites obtained through FSP and provide useful guidelines to academicians and researchers in effective surface composite fabrication.