LAUSR

ABSTRACT The fabrication of metal matrix composites (MMCs) presents several challenges, including non-uniform particle distribution, process complexity, and the formation of porosity and voids. While multi-pass friction stir processing (FSP) can mitigate some of these issues, it is labor-intensive and time-consuming. To overcome these challenges, this study introduces a novel approach utilizing counter-rotating twin-tool friction stir processing (CRTTFSP) for surface MMCs fabrication. The incorporation of two counter-rotating FSP tools facilitates higher temperature involvement, resulting in improved particle distribution while significantly reducing processing time. Specifically, Al/SiC and Al/Diamond surface composites were fabricated using CRTTFSP, and the results were compared with those obtained from the dual-pass FSP technique, with potential application in automotive aluminum trim. Improved processing efficiency of up to 90.57%, uniform material homogeneity with enhanced microhardness properties by up to 51.96%, and cost-effectiveness demonstrate the CRTTFSP process as a significant potential for the industrial deployment.