ABSTRACT
This chapter provides an overview of the potential applications of friction stir processing (FSP) and challenges involved in developing structures using FSP. FSP is a new method which does not melt the substrate and can become a promising tool in several applications in the manufacturing industry. Along with developing bulk superplastic structures, FSP can be used in applications where selective area modification to introduce site-specific superplasticity. By modifying the microstructure through FSP; increased strength, lower level of distortion and residual stresses, increased fatigue life, wear resistance, increased surface energy and superplasticity can be achieved in the metal without modifying the chemical composition. Casting is one of the basic manufacturing processes through which cost-effective components and structures with complex geometries can be successfully produced. Due to FSP, the cast structure in the fusion zone is completely changed into fine grain structure and eliminates defects or pores present in the weld zone.
