The invention is the process of fabrication and the chemical makeup of a tool used for Friction Stir Welding and Processing. The novel aspects in the fabrication method allow for the tool to be made in fewer steps than current practice, allow the use of lower cost methods in fabrication, reduces the need for rare and expensive elements, and result in better distribution and homogeneity of the chemical constituents in the alloy product itself. The net result is expected to produce a tool blank that will be significantly lower cost, higher performance, and more durable than existing products. The invention allows for a significant reduction in densification process temperature when compared to commercial tooling.