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Al-Mg alloy was friction stir processed (FSP) incorporating two different sized SiC particles. Reduction of particle size after FSP was very significant with coarser SiC particles than finer. The density of SiC particles in FSP nugget was found to be uniform from top to bottom with coarser SiC particles, whereas it was more at the bottom than the top with finer. Tool wear after FSP was found to be relatively more with coarser particles than finer.

Two different configurations of photoanodes based on anodic iron oxide were investigated for photoelectrochemical water oxidation. A self-ordered and vertically oriented array of iron oxide nanotubes was obtained by anodization of pure iron substrate in an ethylene glycol based electrolyte containing 0.1M NH4F + 3 vol% water (EGWF solution) at 50 V for 15 min. Annealing of the oxide nanotubes in a hydrogen environment at 500 °C for 1 h resulted in a predominantly hematite phase. The second type of photoanode was obtained by a two-step anodization procedure. This process resulted in a two-layered oxide structure, a top layer of nano-dendrite morphology and a bottom layer of nanoporous morphology. This electrode configuration combined the better photocatalytic properties of the nano-dendritic iron oxide and better electron transportation behaviour of vertically oriented nano-channels. Annealing of these double anodized samples in an acetylene environment at 550 °C for 10 min resulted in a mixture of maghemite and hematite phases. Photocurrent densities of 0.74 mA cm−2 at 0.2 VAg/AgCl and 1.8 mA cm−2 at 0.5 VAg/AgCl were obtained under AM 1.5 illumination in 1M KOH solution. The double anodized samples showed high photoconductivity and more negative flat band potential (−0.8 VAg/AgCl), which are the properties required for promising photoanode materials.