| Summary: | Low density of magnesium makes it an ideal choice as it is lighter than steel and aluminium alloys. Combination of cast magnesium alloys component can be used widely in the automobile sector and factories but were restricted. Friction stir processing is an infinite machining operation used to enhance the structural workpiece in solid-state strengthening. By using a straight cylindrical tool pin profile which will be used throughout this study, the effects of FSP parameters on magnesium AZ91A can be investigated. Variation of feed rates, (10–58) mm/min with a fixed rotational speed, 1208 RPM were applied for each single FSP pass. Mg alloy will be plated with Al6061 sheets and reinforced with Al2O3 particles before running FSP. Mechanical properties and metallographic requirements are the characterizations in investigating the effects of machining parameters of FSPed workpiece. Both characterizations can be gained via Rockwell hardness test and optical microscopy. Finally, this study discovered that the average hardness of FSPed Mg–Al-Micro Al2O3 was reduced significantly with the increment of feed rates. Next, improved hardness at HAZ points as well as reduced surface roughness at three distances from FSP starting point were detected.
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