Dear Sathishkumar Sankar.

Friction stir processing (FSP), developed based on the principle of FSW and is known as the surface modification technique. It's an effective way to refine the microstructure of a material and thereby improve its mechanical properties. Also, it can be used to produce surface composite layers by the addition of ceramic powders during the process. For further information please read the attached file.Article Friction stir based welding and processing technologies - pr...

Thank you so much for sharing your knowledge, it is really amazing sir and it will be helpful for my research ....

Thanks a lot ....

There are many advantages:

-No solidification problems such as (solidification & liquation cracking)

-Solid state weld process

-Can be used to weld dissimilar metals

-Green technology and environmental friendly

-Produces very fine grain size and hard surfaces with good quality

-No need for filler material

-No need for shielding gas

-Less thermal stress in comparison with fusion weld processes

-Can weld materials cant be welded in fusion weld processes

Also, here are some following good links towards the subject:

http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.160.7596&rep=rep1&type=pdf

https://ujcontent.uj.ac.za/vital/access/services/Download/uj:5335/CONTENT1?view=true

Thank you so much @ Abdulaziz Albannai. it is very useful for my research ... Thanks a lot sir

Friction stir processing is an excellent choice to make metal matrix composites.

Advantageous are:

(1) Uniform distribution of reinforcement particles.

(2) Porosity is almost nil.

(3) Avoids unnecessary interfacial reaction between the matrix and the reinforcement particles.

(4) Physical properties of the reinforcement have least or no influence on the process.

(5) Exceptional grain refinement.

(6) Consumes less energy.

(7) Multiple type and kinds of reinforcements can be mixed with ease to produce hybrid composites.

Disadvantageous are:

(1) Tool wear is more especially if abrasive ceramic particles are used as reinforcements.

(2) Optimizing numerous process parameters is tedious to obtain defect free stir zone. A defect free stir zone does not guarantee uniform distribution. Second stage of tuning the parameters is mandatory.

(3) High volume fraction (>25 vol.%) is not possible to produce. Nano particles will further limit the volume fraction to less than 5%.

(4) Multiple passes are required to obtain uniform distribution which is bit tricky to avoid thinning due to accumulated plunging.

(5) FSP removes the heat treated condition of processed materials and it is necessary to apply post heat treatment to recover the property loss.

Friction stir processing (FSP), developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys, is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ.

Attached a good review can help you to understand the FSP well

I m really Excited your Response sir

Thank you so much Raheem Al-Sabur

Advantages: Uniform distribution and less porosity

Disadvantages: Not suitable for mass production and restricted depth of penetration of tool.

Thank you Manickam Ravichandran sir

Uniform distribution of reinforcement is one of the advantage

Disadvantage is related not suitable for higher volume fraction

FSP represents less to no interfatial reactions between reinforcing particles and the matrix, no segregation, no gravity agglomeration when nano size powder is used, controlled distribution after multi pass process or through parameters optimisation, grain refinement in SZ, higher insertion rate of powder, voids and particles agglomeration like in casting are avoided, and residual stress induced CTE mismatch is less due to the low temperature of the process