Hybrid aluminum matrix composites (HAMCs) are a new class of advanced materials that can be customized and engineered to achieve specific properties for specific applications in specific environments. HAMCs find a wide range of popularity in the transportation sector because of lower noise and lower fuel consumption over other materials. This research aims to synthesize, characterize, and test the physicomechanical characteristics of tetra hybrid (SiC, Al2O3, Gr, and sugarcane bagasse ash (SCBA)) reinforced HAMCs via powder metallurgy (PM) processing. Tetra hybrid reinforced HAMCs were synthesized using a pure Al matrix with fixed wt% of primary reinforcements (5 wt% SiC and 5 wt% Al2O3) and varying wt% of secondary reinforcements such as 0.5, 2.5, 4.5, and 6.5 wt% Gr and 0.5, 2.5, 4.5, and 6.5 wt% SCBA. It mainly focused on phase purity investigation using XRD, thermal analysis using TGA-DTA, and surface area and micropore size analysis using BET and physicomechanical tests to explore the materials’ behavior of the newly synthesized HAMCs. The increase in wt% of secondary reinforcements decreases both the density and porosity while increasing the hardness and compressive strength up to a certain level above which it begins to reverse because of the increase in wt% of hard particles of SiC, Al2O3, and SCBA. The Vickers hardness and compressive strength of the AS4 HAMC with 10 wt% (SiC+Al2O3) and 9 wt% (Gr+SCBA) were improved by 446.40% and 209.75%, respectively. The newly synthesized tetra hybrid reinforced HAMCs showed superior physicomechanical properties compared to pure Al and single and double reinforced HAMCs. As a result, the new tetra hybrid reinforced HAMC material is predicted to have potential applications in automotive, aerospace, defense, and various other structural applications.

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Hybrid reinforced particulate aluminum matrix composite materials (HAMCs) are a breakthrough kind of material made by combining two or more distinct reinforcing components in the aluminum (Al) matrix. Composites with many reinforcing phases offer a superior overall mix of characteristics than composites with only one. This article’s wide literature review of metal matrix composite (MMC) especially for aluminum matrix composites (AMC) was carried out. Discussions of various widely adopted synthesis methods such as stir casting and powder metallurgy have been presented. The effect of various reinforcement ceramic particles such as silicon carbide (SiC), aluminum oxide (Al2O3), graphite (Gr) on the mechanical and metallurgical properties of MMC has been reviewed. The summary of various characterizations such as X-ray diffraction (X-RD), and optical microscopy (OM) including testing such as hardness, tensile, compressive, and tribological behavior has been discussed in detail to demonstrate a full grasp of the many features of HAMCs, such as manufacturing, physicomechanical properties, wear, and corrosion characteristics. Future developments and potentially useful materials as alternative reinforcements are discussed at the end of the review.

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