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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Hybrid aluminum matrix composites (HAMCs) are a new class of advanced composite and hybrid materials that can be customized and engineered to achieve specific properties for specific applications in specific environments. HAMCs are popular in the transportation industry due to their reduced cost and fuel consumption as compared to conventional materials. This research article has mainly focused on multi-response optimization through an L16 orthogonal array experimental design employing Taguchi-based Grey Relational Analysis. It was intended to explore the influence of tetra hybrid reinforced HAMCs synthesized using 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% of Gr and (0.5, 2.5, 4.5, and 6.5) wt% of SCBA on physicomechanical properties of HAMCs when milling time, compaction pressure, and sintering temperature were varied. The Taguchi-Grey's relational analysis gave the optimal combination of the process and reinforcement parameters for both the physical and the mechanical properties such as milling time (5 hrs.), compaction pressure (55 MPa), sintering temperature (450 °C), Gr content (0.5 wt%), and SCBA content (4.5 wt%). At the optimum parameter settings, the average density, porosity, hardness, compressive strength, and ultimate tensile strength were 2.5118 gm/cm3, 0.8653%, 4228.45 MPa, 343.33 MPa, and 1516.41 MPa, respectively. The utilization of Taguchi and GRA methods has significantly confirmed that the influence of compaction pressure was highest among all the other four parameters. The newly synthesized tetra hybrid reinforced HAMCs have shown superior physicomechanical properties compared to pure Al, and single as well as double reinforced HAMCs. Therefore, it is anticipated that the newly developed tetra hybrid reinforced AMC material will be utilized in heavy-duty, aerospace, medical, automotive, marine, and other applications.

Aluminum metal matrix composites are potential materials for aerospace and automobile industrial applications due to their enhanced mechanical and tribological properties. Aluminum reinforced with silicon carbide particles has been developed with enhanced mechanical and tribological behavior, but it lacks wettability between matrix and reinforcement causing weak bonding, which reduces the degree of enhancement. The objectives of this study were to fabricate aluminum-based metal matrix composites with enhanced wettability at varying stirring speeds (350, 450, 550 rpm), stirring time (5, 10, 15 min), weight percentage of SiC (0, 5, 10 wt.%), and weight percentage of MoS2 (0, 2, 4 wt.%). Nine samples were fabricated using stir casting based on Taguchi L9 orthogonal array. Hardness, tensile strength, and wear rate of the developed composite were investigated and analyzed as a single response characteristic using Taguchi’s signal-to-noise ratio and as a multi-response characteristic using hybrid Taguchi–grey relational analysis (HTGRA). The results revealed that the addition of SiC in the composite produced better hardness, tensile strength, and wear rate. The addition of MoS2 in the composite showed better hardness and tensile strength only up to 2 wt.% of MoS2, and in the case of wear rate, the addition of MoS2 in the composite up to 4% showed better wear resistance. Al–SiC–MoS2 hybrid composite shows better enhancement in hardness, tensile strength, and wear resistance than the Al–SiC composite.

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