Five-pass friction stir processing (FSP), with 50% overlap, was conducted on cast A356. Overlapping FSP did not exert a significant effect on the size and distribution of the Si particles. In the as-FSP condition, the strength and ductility of the transitional zones between two FSP passes were slightly lower than those of the nugget zones. Further, in the multiple-pass material the strength of the previously processed zones was lower than that of the subsequent processed zones due to overaging from the FSP thermal cycles. (c) 2006 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.
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