In situ Al6061 - titanium aluminides composites were obtained by using friction stir processing (FSP) on a Al6061 sheet and Ti pwder system. The FSP tool used in this study was fabricated using a H13 steel shoulder and a HSS TiN coated end mill tool. Due to other researches, FSP parameters were choose 20 mm/min (linear velocity), 8 rpm (rotational velocity) and 3 degree (tool angle). By 4 reinforcement contents (5%, 10%, 15% and 20%) and 1pass, 3pass and 5pass FSP, 12 sample fabricated and characterized. XRD results showed the titanium aluminides that produced during FSP was TiAl 3 . XRD patterns although showed some not reactioned primary Ti powder particles was remained in composites. Using Williamson-Hall equation mentioned that reinforcement particles were sized about 87 nanometers. Drawing micro-hardness curves and metallographic studies determined the best properties was achieved in 20% reinforcement content and 3pass FSP. Wear test results showed about 60% reduction in weightloss between composite and Al6061-T6 samples. Composite specimen achieved less strength and elongation due to Mg 2 Si solution and brittleness of reinforcement particles, respectively. Keywords : Aluminum matrix composite, Al6061, Friction stir processing, titanium aluminides, mechanical properties, wear behavior.
