Friction stir processing (FSP) is solid state process that has been used recently for microstructural modification and surface composite development. In this study FSP has been used to incorporate Al2O3 nanoparticles on the surface of AA7075 with the aim of manufacturing low density high hardness surface nanocomposites for military vehicles and
transportation applications. The Al2O3 nanoparticles were packed into grooves of 1mm width and 7.5mm depth that were machined in 15mm thick plates of AA7075. The FSP was done using FSP tool of cylindrical probe of 6mm diameter and 20mm diameter shoulder. The tool rotation rate and tool travel speed were selected based on available literature to produce uniform dispersion of Al2O3 nanoparticles. The effect of post processing heat treatment after incorporating Al2O3nanoparticles into different temper conditions of AA7075-T6 and AA7075-O was investigated. The developed nanocomposites were investigated and characterized using optical microscopy, scanning electron microscopy, and hardness testing.