Recent advances in friction stir processing (FSP) for microstructural refinement and surface property enhancement

  • Ahmed M. Hewidy orcid

    Department of Mechanical Engineering, Benha Faculty of Engineering, Benha University, Benha 13518, Egypt
Article ID: 2509
DOI: https://doi.org/10.59400/mea2509
Keywords: friction stir processing, aluminum alloys, surface modification, hardening with strengthening particles, hybrid in situ surfaces

Abstract

Friction stir processing (FSP) has emerged as an advanced solid-state metalworking technique derived from the principles of friction stir welding (FSW). Originally developed for aluminum alloys, FSP enables controlled modification of the near-surface microstructure of metallic components through localized severe plastic deformation, material stirring, and frictional heating. These combined effects promote significant grain refinement, improved homogeneity, and densification within the processed zone, resulting in enhanced mechanical and surface performance. In recent years, FSP has been widely applied to produce ultrafine-grained structures, fabricate surface metal–matrix composites, and support the in situ formation of reinforcing phases, such as intermetallic compounds. Owing to its effectiveness in tailoring surface characteristics, FSP has strong potential for industrial implementation across the aerospace, automotive, marine, and biomedical sectors, particularly in applications requiring wear-resistant surfaces, lightweight structural elements, and high-performance materials. This review highlights recent progress in FSP research and provides insights into current developments and future directions of the technique.

Published
2025-10-06
How to Cite
Hewidy, A. M. (2025). Recent advances in friction stir processing (FSP) for microstructural refinement and surface property enhancement. Mechanical Engineering Advances, 3(4). https://doi.org/10.59400/mea2509
Issue
Vol. 3 No. 4 (2025)
Section
Review

Copyright (c) 2025 Ahmed M. Hewidy

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

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