In this paper, the performance evaluation of Al-graphene nanoplatelets (GNP) composites surface engineered by a modified friction stir processing (FSP) is reported. Here, multiple micro channels (MCRF) are used to incorporate GNPs in the aluminium matrix instead of a single large groove (SCRF) that is usually used in conventional FSP. With the MCRF approach, ~ 18% higher peak temperature (compared to SCRF) was observed owing to the presence of aluminium sandwiched between consecutive microgrooves and higher heat accumulation in the stir zone. The MCRF approach have significantly reduced the coefficient of friction and wear rates of the processed composites by ~ 14% and ~ 57%, respectively as compared to the SCRF approach. The proposed reinforcement filling method significantly improves the particle dispersion in the matrix, which in turn changes the adhesion mode of wear in SCRF to abrasive mode in MCRF fabricated composites. The uniformly squeezed out GNP tribolayer prevented the direct metal to metal contact between composite and its counterpart which have effectively reduced the deterioration rates.

Aluminium metal matrix composites (AMMCs) are the fastest developing materials for structural applications due to their high specific weight, modulus, resistance to corrosion and wear, and high temperature strength. Carbon nanotubes (CNTs) is known as the material of the twenty-first century for its various applications in structural components for their high specific strength as well as functional materials for their exciting thermal and electrical characteristics. The present study comprise a systematic literature review of Al/CNT nanocomposites fabricated through a solid state friction stir processing. The present review is primarily focussed on the dispersion and survivability of CNTs in the Al matrix because these are the key factors in deciding the mechanical properties of the fabricated composite. Additionally, the formability, weldability and machinability of the FSPed fabricated composites reinforced with CNTs are also summarised here. Based on the detailed literature review, following research gaps are identified which require a critical and more focussed attention of the scientific community working in this research area: (i) the presence of agglomeration or clustering of CNTs in the composite, (ii) survivability and shortening of CNTs during FSP, (iii) interfacial reactions or the formation of reaction products (such as Al4C3) between Al matrix and CNTs, and (iv) the unidirectional alignment of CNTs in the fabricated composite. Important suggestions for further research in effective dispersion of CNTs with its preserved structure by FSP are also provided.