An Investigation on Friction Stir Processing of Aluminium Alloy Reinforced with High-Entropy Alloys

Abstract:

Friction Stir Processing (FSP) is an advanced solid-state surface modification technique used to enhance the microstructural and mechanical behavior of metallic materials, particularly aluminum alloys. Recently, High-Entropy Alloys (HEAs) have emerged as promising reinforcement materials due to their high strength, thermal stability, and corrosion resistance. Although multiple studies have explored FSP with conventional reinforcements, the integration of HEAs into the stir zone remains limited. This study examines the influence of tool geometry, processing parameters, and reinforcement strategies in FSP while evaluating the feasibility of incorporating HEAs into aluminum matrices. The role of finite element analysis (FEA) in predicting temperature distribution, material flow, and stress evolution is also discussed. The study identifies research gaps and emphasizes the need for experimental validation of HEA-reinforced FSP systems to develop high-performance aluminum-based surface composites.

• Periodical: Materials Science Forum (Volume 1194)
• Pages: 3-17
• DOI: https://doi.org/10.4028/p-xhSU08
• Online since: June 2026
• Authors: Adithya Bhagavatham*, K. Prasanth Kumar Reddy, G.S Vinod Kumar, Sheela Singh
• Keywords: Aluminium Alloy, Friction Stir Processing, Green Manufacturing, High Entropy Alloy

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