A comprehensive review of the synergistic effects of adhesive nanoparticles and friction stir processing parameters on microstructure and mechanical properties of hybrid metal matrix composites

Friction Stir Processing (FSP) is a solid-state process well known for enhancing the performance of aluminum matrix composites (AMCs). In high engineering practice, materials are widely used for their good strength-to-weight ratio, high wear resistance, and consistent thermal characteristics. Nevertheless, conventional production processes are often hindered by a lack of uniform distribution of reinforcement particles and unfavorable interfacial forces, which may adversely affect overall material performance. FSP can circumvent such challenges by altering the microstructure without melting the base material, resulting in significant improvements in properties. This review will provide an in-depth discussion of recent advances in the application of FSP to AMCs, focusing on microstructural development, mechanical behavior, wear performance, and corrosion resistance. The extensive plastic deformation and dynamic recrystallization during processing help refine the grains and enhance uniform particle distribution, thereby increasing hardness, strength, and fatigue life. Additionally, incorporation of ceramic and hybrid reinforcements has been observed to improve wear performance and functional properties. The influence of major process parameters, including tool geometry, rotational speed, and traverse speed, is also discussed in terms of maximizing material properties. Although remarkable progress has been made, there are still issues to be addressed, such as particle clustering and differences in corrosion behavior. Future studies should focus on interface adjustment, enhanced hybrid reinforcement strategies, and the use of modeling techniques to improve the prediction of processing results. These will aid in the extended application of FSP-treated AMCs in the aerospace, automotive, and marine sectors.