Aluminum and its alloys possessing desired properties including good strength-to-weight ratio, high thermal and electrical conductivity as well as good corrosion resistance are very popular in aerospace, marine and military industries. Among aluminum alloys, 6XXX group, comparing with other aluminum alloys, owns better weldability, good formability and high corrosion resistance. However, some deficiencies such as poor wear behavior, limits applications of 6XXX alloys. To solve the problem, several methods have been applied. Friction stir processing (FSP) is a method which provides in-situ development of composites, besides alloying of it, over the surface layer of the material. In this regard, Fe particles via groove friction stir processing method were fabricated on the surface of 6061 Aluminum and its properties were studied. Also Al-Cu surface composites using copper particles through similar FSP parameters were made on some similar specimens. Then, the properties of Al-Fe composites were compared with Al-Cu composites. For production of specimens, particles added over a groove that was created on surface of specimens. Then FSP were carried out with 1000 mm/min rotation speed and 25 mm/min linear travelling speed of tool in four passes. X Ray Diffraction (XRD) and Energy Dispersive Spectroscopy (EDS) were used to identify type and chemical composition of phases and intermetallic compounds which formed during FSP. Optical microscopy as well as Scanning Electron Microscopy (SEM) were utilized to study the microstructure of samples. XRD peaks revealed the formation of Al 13 Fe 4 intermetallic on the matrix. Hardness of specimens which were heat treated through T6 process showed a significant increase. Investigation of tribological behavior of specimens represented better wear resistance and high temperature wear resistance of composit samples. Keywords : Friction Stir Processing (FSP), Al-Fe surface composite, 6061 aluminum alloy, intermetallic compounds, tribological behavio
