The Aluminium based metal matrix composites (AMCs) are famous for their superior mechanical properties, lightweight, and enhanced corrosion resistance. A slow rise in the reinforcement fraction enhances the mechanical behaviour of the base alloy but badly disturbs ductility. The stir casting method has been employed for the fabrication of SiC reinforced aluminum metal matrix composite (MMC). Optical micrographs (OM) and scanning electron microscopy (SEM) with energy dispersive x-ray analysis (EDAX) have been used for the portrayal of the composite microstructure, surface topography, and fracture behavior. Also, mechanical (tensile strength, micro-hardness, impact strength) characterization of the fabricated AMC has been explored. Employing a carbide cutter, MMC has been machined with various arrangements of machining parameters. To evaluate the machined surface quality, the Ra parameter has been evaluated. Response surface methodology (RSM) has been applied for optimizing the surface finish. The occurrence of hard reinforcement in base Al-alloy makes the MMC difficult to machine. But machining turns relatively simpler at high cutting speed and low feed rate, causing improved surface finish. The best surface finish (Ra = 1.145 µm) was achieved at 0.066 feed rate (mm/tooth), 157 cutting speed (m/min), and 0.528 depth of cut (mm).

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Aluminium metal matrix composites (AMCs) have become quite popular for light weight, low cost, and good workability. The present work reports the impact of silicon carbide (SiC) reinforcement on the physical, microstructural, and mechanical characteristics of Al-4032/SiC composites with 4, 6, 8% of SiC (particle size 54μm) fabricated through bottom pouring stir casting. Density and porosity measurements of all three AMCs have been performed using the rule of mixture. The microstructure of the AMC samples has been analyzed using an optical microscope (OM), x-ray diffraction analysis (XRD), and scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS). The mechanical properties, in terms of the ultimate tensile strength (UTS), elongation, micro-hardness, and impact toughness of the AMCs have also been obtained according to American society for testing and materials (ASTM) standards. A maximum 1.52% increase in theoretical density, while a maximum 2.92% decrease in experimental density has been recorded for 8% reinforcement. The UTS, microhardness, and impact toughness of the AMC have been found to improve significantly owing to the addition of ceramic particles. The uniform distribution of SiC particles all over base Al-4032 matrix material has been noticed by SEM and OM for AMCs up to 6% reinforcement.

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Aluminum-based composites are known for better mechanical properties, superior corrosion performance, and light weight. Gradual increase in the reinforcement (SiC particles) produces RECEIVED