Friction Stir Surfacing(FSS)has been developed for fabrication of surface composite. The process involves rotating a solid consumable bar with one of its ends pressed hard against a substrate material such as a plate. Commercial pure aluminium and medium carbon steel is used as tool and substrate. Heat is generated at the tip of the consumable, producing a plasticized layer. Lateral movement of the substrate, relative to the rotating consumable, deposits this plasticized material on to the substrate. There is no melting of the substrate material and therefore no dilution of the substrate. The...