Friction stir processing (FSP) is one of the plastic deformation processes which can significantly affect the surface properties of materials. The objective of this study is to investigate the effect of doping nano-sized Al₂O₃ particles on the surface of 5083 Al through FSP, on the hardness and wear resistance of 5083 Al. It is observed that the friction stir processed (FSPed) sample possesses higher hardness, especially in the nugget zone, as compared to 5083 Al. Wear resistance of the FSPed sample is observed to be significantly inferior to that observed for 5083 Al, as a result of high coefficient of friction and higher friction force during the course of sliding wear, which lead to detachment of hard Al₂O₃ particles from the surface of FSPed sample. The SEM examination of worn track and wear debris reveals that the primary operative wear mechanism in FSPed is abrasive whereas in 5083 Al, both abrasive and adhesive wear mechanisms operate.

friction stir processing, nano-composite, hardness, wear.