Friction stir processing (FSP) was developed based on the same principles of friction stir welding (FSW) mainly to enhance the surface properties of various materials and to produce surface composites. In this work surface composites of AA7075 as the metal matrix that reinforced with ultra-fine sized SiO2 particles were developed using FSP. A groove of 3 mm depth and 1.2 mm width was made on the surface of AA7075 to provide the highest reinforcement volume fraction on the produced surface composites. FSP tool with a square profiled tool pin of 3.5 mm pin length and of 5mm pin side was used. The FSP parameters used were 600 rpm and 50 mm/min. The developed surface composites were evaluated using different metallographic techniques to investigate the macro and micro features. Also the hardness profile was measured across the processed zone. The surface composites achieved by three consecutive passes of processing showed uniform particle distribution across the stirring zone of the surface composite. Moreover, the surface composite hardness was improved by 10-30% compared to the unreinforced alloy. The tool with a square profiled tool pin enables obtaining sound surface without any visible defects.