Friction Stir Processing, commonly known as FSP, is an innovative technique to refine microstructures and produce surface composites without any inherent defects. The heat generated during the FSP is primarily contributed by plastic deformation and edge friction which subsequently impacts the microstructure and the processed sample's properties. In this article, FSP was performed at a tool stirring speed of 1000 rpm and 40 mm/min traveling speed. The temperature profile was obtained at arbitrary locations for AA7075 with and without Silicon Carbide (SiC). Channel and hole techniques were deployed to compare the temperature using type K thermocouples at three locations. It was found that the channel method has higher temperature values (Tp) than the hole method for both AA7075 and AA7075/SiC, whereas the Tp values for AA7075/SiC composites were found to be lowered than processed AA7075. Microstructure, mechanical, and corrosion properties were assessed for the AA7075 and AA7075/SiC. The interlayer difference between the processed and the unprocessed region has adverse effects on tensile strength. In contrast, the hardness and corrosion resistance improvement was accounted due to the uniform dispersion and pinning action of SiC. Thermo-mechanical modelling was carried out to simulate the temperatures at the plunging phase and was found to be in accordance with experimental results. © 2023