Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21st century

• Published in: Journal of magnesium and alloys 2024-06, Vol.12 (6), p.2091-2146
• Main Authors: Marode, Roshan Vijay, Lemma, Tamiru Alemu, Sallih, Nabihah, Pedapati, Srinivasa Rao, Awang, Mokhtar, Hassan, Adeel
• Format: Article
• Language: English
• Subjects: Friction stir processing; Lightweight; Magnesium alloys; Metal matrix composites; Surface modification
• ISSN: 2213-9567; 2213-9567
• DOI: 10.1016/j.jma.2024.06.007

•The review emphasizes the potential of Mg alloys in lightweight structures and the evolution of FSP for Mg alloys and MMCs in the 21st century.•It covers novel fabrication methods, reinforcement strategies, machine and tool design parameters, material characterization, and integration with other methods for enhanced properties.•FSP offers simultaneous refinement, homogenization, and densification of microstructures, resulting in high strength and improved surface characteristics.•Challenges include the need for further study on pin profiles, process parameters, and mono and hybrid composites. It is recommended that future research should focus on material flow and reinforcement impact on temperature distribution, among many more.•Despite challenges, FSP has the potential to enhance Mg alloys and MMCs in engineering applications, presenting ongoing progress and potential advancements. Rising concerns about climate change drive the demand for lightweight components. Magnesium (Mg) alloys are highly valued for their low weight, making them increasingly important in various industries. Researchers focusing on enhancing the characteristics of Mg alloys and developing their Metal Matrix Composites (MMCs) have gained significant attention worldwide over the past decade, driven by the global shift towards lightweight materials. Friction Stir Processing (FSP) has emerged as a promising technique to enhance the properties of Mg alloys and produce Mg-MMCs. Initially, FSP adapted to refine grain size from the micro to the nano level and accelerated the development of MMCs due to its solid-state nature and the synergistic effects of microstructure refinement and reinforcement, improving strength, hardness, ductility, wear resistance, corrosion resistance, and fatigue strength. However, producing defect-free and sound FSPed Mg and Mg-MMCs requires addressing several variables and their interdependencies, which opens up a broad range of practical applications. Despite existing reviews on individual FSP of Mg, its alloys, and MMCs, an attempt has been made to analyze the latest research on these three aspects collectively to enhance the understanding, application, and effectiveness of FSP for Mg and its derivatives. This review article discusses the literature, classifies the importance of Mg alloys, provides a historical background, and explores developments and potential applications of FSPed Mg alloys. It focuses on novel fabrication methods, reinforcement strategies,