Influence of Short Carbon Fiber Distribution on Microstructural Evolution and Mechanical Performance of Upward Friction Stir Processed Carbon Fiber/Aluminium Composite

Aluminum matrix composites have gained attention for high‐performance engineering applications, especially in transport industries for bearing liners, cylinder liners and rings, brake and clutch pads due to their wear resistance and excellent strength‐to‐weight ratio. The lightweight feature of the composites makes it ideal for improving fuel economy, reducing emissions, and optimizing structural integrity. In this study, carbon fiber (CF)/aluminium (Al) composites are fabricated through upward friction stir processing (UFSP), which can achieve uniform fiber dispersion and interfacial bonding between fiber and matrix and ensure uniform properties throughout the processed region. The study reveals a 14% increase in tensile strength, 36% in case of hardness, and 44% in case of impact resistance, with respect to the base Al matrix. Scanning electron microscopy (SEM) and electron backscatter diffraction fractography reveal uniformity in the dispersion of the fiber network within the matrix, which is essential for matrix‐to‐fiber load transfer and resistance to crack initiation. This study provides an insight into upscaling the UFSP technique to fabricate industrially deployable products.