Metal matrix composite creation

A friction-based fabrication tool comprising:

• a spindle member comprising a hollow interior for housing a coating material disposed therein prior to deposition on a substrate;
• a coating material disposed within the hollow interior;
• wherein the interior of the spindle is shaped to exert a normal force on the coating material disposed therein along an entire length of the coating material disposed within the hollow interior and imparts a rotation to the coating material during rotation of the spindle at a speed sufficient for imposing frictional heating of the coating material against the substrate;
• wherein the spindle is operably connected with a downward force actuator which pushes the coating material through the throat of the non-consumable member resulting in frictional heating and compressive loading of the coating material onto the substrate and a motor for rotating and translating the spindle relative to the substrate;
• and
• wherein the spindle comprises a shoulder surface with a flat surface geometry or a surface geometry with spiral or other surface features, and/or surface nubs for enhancing mechanical stirring of the loaded coating material, which shoulder surface is operably configured for trapping the loaded coating material in a volume between the shoulder and the substrate and for forming and shearing a surface of a coating on the substrate.