Aluminum 7075 alloy (AA 7075) is one of the prime materials used in the aviation and automotive industry because of its high strength to weight ratio, good amount of fatigue strength and high machinability. Friction stir processing (FSP) is one of the emerging solid state process that refines the microstructure and hence improved mechanical properties are obtained. The process temperature during FSP affects the resulting microstructure so the attempt for reducing the process temperature can result into reduction in the grain size. The fine grain size microstructure delivers high percentage of elongation which reduces the number of joints and welds in the critical structural applications. So, by implementing coolants such as water and carbon dioxide (CO2) during this process had hindered the grain growth and very fine grained microstructure was obtained. The fine grain microstructure offers higher elongation and hardness as deformation starts from the grain boundaries. In this experimental investigation we intended to keep the temperature generation during the process as low as possible by keeping the process parameters of 765 rpm, 31.5 mm/min fees rate and 20 tilt of the tool (optimized for tapered threaded cylindrical pin tool) constant. All the samples were examined by metallographic characterization using optical microscope. The grain size measurements for all three FSP samples were carried out. Water and CO2 cooled FSP samples reported much more fine grain as compared to naturally cooled sample because of the less heat input during the process.

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