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Processes
Volume 14
Issue 2
10.3390/pr14020306
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Review

Friction Stir Processing: An Eco-Efficient Route to High-Performance Surface Architectures in MMCs

by
Sachin Kumar Sharma
1,*,
Saša Milojević
2,*,
Lokesh Kumar Sharma
3,
Sandra Gajević
2,*,
Yogesh Sharma
4,
Mohit Sharma
5,
Stefan Čukić
2 and
Blaža Stojanović
2
1
Surface Science and Tribology Lab, Department of Mechanical Engineering, Shiv Nadar Institution of Eminence, Gautam Buddha Nagar, Greater Noida 201314, India
2
Faculty of Engineering, University of Kragujevac, Sestre Janjić 6, 34000 Kragujevac, Serbia
3
Department of Physics, GLA University, Mathura 281406, India
4
Department of Physics & Environmental Sciences, Sharda School of Engineering & Science, Sharda University, Greater Noida 201310, India
5
Department of Physics and Material Science, Jaypee University, Anoopshahr 203390, India
*
Authors to whom correspondence should be addressed.
Processes 2026, 14(2), 306; https://doi.org/10.3390/pr14020306
Submission received: 28 November 2025 / Revised: 9 January 2026 / Accepted: 13 January 2026 / Published: 15 January 2026
(This article belongs to the Section Materials Processes)
Versions Notes

Abstract

Friction Stir Processing (FSP) has emerged as an advanced solid-state surface engineering technique for tailoring high-performance surface architectures in metal matrix composites (MMCs). By combining localized thermo-mechanical deformation with controlled material flow, FSP enables grain refinement, homogeneous dispersion of reinforcement, and strong interfacial bonding without melting or altering bulk properties. This review critically examines the role of FSP in enhancing the mechanical, tribological, and corrosion performance of composites, with emphasis on process–structure–property relationships. Key strengthening mechanisms, including grain boundary strengthening, load transfer, particle pinning, and defect elimination, are systematically discussed, along with their implications for wear resistance, fatigue life, and durability. Special attention is given to corrosion and tribo-corrosion behavior, highlighting electrochemical mechanisms such as micro-galvanic interactions, passive film stability, and interfacial chemistry. Furthermore, the eco-efficiency, industrial viability, and sustainability advantages of FSP are evaluated in comparison with conventional surface modification techniques. The review concludes by identifying critical challenges and outlining future research directions for the scalable, multifunctional, and sustainable design of composite surfaces.
Keywords: surface engineering; reinforcement dispersion; friction stir processing (FSP); solid-state processing; hybrid composites; sustainable manufacturing surface engineering; reinforcement dispersion; friction stir processing (FSP); solid-state processing; hybrid composites; sustainable manufacturing

Share and Cite

MDPI and ACS Style

Sharma, S.K.; Milojević, S.; Sharma, L.K.; Gajević, S.; Sharma, Y.; Sharma, M.; Čukić, S.; Stojanović, B. Friction Stir Processing: An Eco-Efficient Route to High-Performance Surface Architectures in MMCs. Processes 2026, 14, 306. https://doi.org/10.3390/pr14020306

AMA Style

Sharma SK, Milojević S, Sharma LK, Gajević S, Sharma Y, Sharma M, Čukić S, Stojanović B. Friction Stir Processing: An Eco-Efficient Route to High-Performance Surface Architectures in MMCs. Processes. 2026; 14(2):306. https://doi.org/10.3390/pr14020306

Chicago/Turabian Style

Sharma, Sachin Kumar, Saša Milojević, Lokesh Kumar Sharma, Sandra Gajević, Yogesh Sharma, Mohit Sharma, Stefan Čukić, and Blaža Stojanović. 2026. "Friction Stir Processing: An Eco-Efficient Route to High-Performance Surface Architectures in MMCs" Processes 14, no. 2: 306. https://doi.org/10.3390/pr14020306

APA Style

Sharma, S. K., Milojević, S., Sharma, L. K., Gajević, S., Sharma, Y., Sharma, M., Čukić, S., & Stojanović, B. (2026). Friction Stir Processing: An Eco-Efficient Route to High-Performance Surface Architectures in MMCs. Processes, 14(2), 306. https://doi.org/10.3390/pr14020306

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