High strength-to-weight ratio of non-ferrous alloys, such as aluminium, magnesium and titanium alloys, are considered to be possible replacement of widely accepted steels in transportation and automobile sectors. Among these alloys, magnesium is self explosive and titanium is costlier, and aluminium is most likely to replace steels. Application of aluminium or its alloys is also thought of as an appropriate replacement in defence field, especially to enhance the easiness in mobility of combat vehicles while maintaining the same standard as that of conventional armour grade steels. Hence most of the investigations have been confined to aluminium or its alloys as base material and open an era of developing the newer composite materials to address the major limitation, i.e. tribological properties. The surface composites can be fabricated by incorporating the ceramic carbides like silicon carbide, carbides of transition metals and oxides of aluminium using surface modification techniques, such as high energy laser melt treatment, high energy electron beam irradiation and thermal spray process which are based on fusion route. These techniques yield the fusion related problems, such as interfacial reaction, pin holes, shrinkage cavities or voids and other casting related defects, and pave the way to need of an efficient technique which must be based on solid state. Recently developed friction stir processing technique was used in the present investigation for surface modification of AA7075 aluminum alloy, which is an alternative to steels. In the present investigation, 160 μm sized boron carbide powder was procured and was reduced to 60 μm and 30 μm using high energy ball mill. Subsequently these powders were used to fabricate the surface composites using friction stir processing.Ballistic performance testing as per the military standard(JIS.0108.01) was carried out. In the present work, an analytical method of predicting the ballistic behavior of surface composites was developed. This method was based on energy balance, i.e., the initial energy of impact is same as that of energy absorbed by multi layers. An attempt also has been made to validate the analytical results with the experimental findings. Variation between the analytical and experimental results may be accounted due to the assumptions considering such as isotropic behavior of target and shearing area of contact as cylindrical instead of conical interface As the analytical model yields the ballistic performance in the closer proximity of experimentally obtained, it can be considered to be an approximation to evaluate the ballistic performance of targets. Among these alloys, magnesium is self-explosive and titanium is costlier , and aluminum is most likely to replace steels. Application of aluminum or its alloys is also thought of as an appropriate replacement in defense field, especially to enhance the easiness in mobility of combat vehicles while maintaining the same standard as that of conventional armor grade steels . Most of the investigations have been confined to aluminum or its alloys as base material and open an era of developing the newer composite materials to address the major limitation, ie tribological properties. The surface composites can be fabricated by incorporating the ceramic carbides like silicon carbide, carbides of transition metals and oxides of aluminum using surface modification techniques, such as high energy laser melt treatment, high energy electron beam irradiation and thermal spray process which are based on fusion route. Such techniques yield the fusion related problems, such as interfacial reaction, pin holes, shrinkage cavities or voids and other casting related defects, and pave the way to need of an efficient technique which must be based on solid state. 160 μm sized boron carbide powder was procured and was reduced to 60 μm and 30 μm using high energy ball mill. Ballistic performance testing as per the military standard (JIS.0108.01 ) was carried out. In the present work, an analytical method of predicting the ballistic behavior of surface composites w asdeveloped. This method was based on energy balance, ie, the initial energy of impact is same as that of energy absorbed by multi layers. An attempt also has been made to validate the analytical results with the experimental findings. Variation between the analytical and experimental results may be accounted due to as isotropic behavior of target and shearing area of ​​contact as cylindrical instead of conical interface As the analytical model yields the ballistic performance in the closer proximity of experimentally obtained, it can be considered to be an approximation to evaluate the ballistic performance of targets.