Table 1 Maximum thickness of surface composite layer achieved in different material systems using FSP and the corresponding method used to incorporate the secondary phase into the matrix

Aluminum/its alloys

SiC

Groove filling

2

Wang et al. (2009)

Al₂O₃

Groove filling and closing

4

Shafiei-Zarghani et al. (2009)

MWCNTs

Groove filling

2.2

Lim et al. (2009)

Al₂O₃

Holes filling

3

Yang et al. (2010)

SiC and MoS₂

Groove filling

3.5

Alidokht et al. (2011)

Ni particles

Groove filling

0.15

Devinder and Bauri (2011)

Al₂O₃

Groove filling and closing

3.8

Sharifitabar et al. (2011)

TiC B₄C

Groove filling

6

Maxwell Rejil et al. (2012)

Graphite, Al₂O₃, and SiC

Groove filling

3.5

Anvari et al. (2013)

SiC and Al₂O₃

Surface coating and FSP

0.204

Miranda et al. (2013)

Al₂O₃

Surface coating and FSP

0.1

Mazaheri et al. (2014)

Magnesium/its alloys

SiO₂

Groove filling and closing

3–3.5

Lee et al. (2006)

CNTs

Groove filling

2

Morisada et al. (2006)

SiC

Groove filling and closing

2.5

Asadi et al. (2011)

Al₂O₃

Groove filling

5–6

Azizieh et al. (2011)

Al₂O₃

Groove filling

2–2.5

Faraji et al. (2011)

Carbon fibers

Sandwich method

2.7

Mertens et al. (2012)

SiC and B₄C

Holes filling and closing

3

Madhusudan Reddy et al. (2013)

SiC

Direct friction stir processing tool

0.15

Huang et al. (2014)

Hydroxyapatite

Groove filling

2

Ratna Sunil et al. (2014b)

Copper/its alloys

SiC

Groove filling

2

Barmouz et al. (2011)

Graphite

Groove filling and closing

Not reported

Sarmadi et al. (2013)

B₄C

Groove filling and closing

5

Sathiskumar et al. (2013b)

TiC

Holes filling and closing

Not reported

Sabbaghian et al. (2014)

SiC

Holes filling

Not reported

Akramifard et al. (2014)

Titanium/its alloys

Hydroxyapatite

(i)Groove filling

(ii)Surface coating

0.16

Farnoush et al. (2013)

Hydroxyapatite

Holes filling

0.16

Farnoush et al. (2013)

Steels

TiC

(iii)Groove filling

(iv)Surface coating

1.5–2

Ghasemi-Kahrizsang and Kashani-Bozorg (2012)