Friction stir processing applied to AA7075 using a pentagonal pin produced a defect free cross-section with a superior material consolidation. The processed specimens were allowed to cool under in air and water separately. Compared to the air-cooled specimen, the water-cooled specimen exhibited better grain refinement. Rapid cooling using water suppressed the growth of grains and reduced the average grain size to 3.07 μm with increased dislocation density in the microstructure. Water cooled specimen exhibited a better texture index of 1.2600 in the stir zone with S {123}<634>, Copper{112}<111>, and brass {011}<211> as the major types. Average hardness in case of the air-cooled sample was 82.77 HV, while the water-cooled sample exhibited an improved hardness of 103.86 HV due to enhanced dislocation density, grain refinement, and uniformly dispersed strengthening precipitates.
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