In the present research, the effect of micron sized graphite addition on the microstructure and tensile failure of Al6061 alloy has been studied. The Al6061 alloy metal matrix composites reinforced with 6, 9 and 12 varying weight percentages of graphite particles were fabricated by novel two step stir cast route which helps in improving the wettability of Al6061 alloy matrix with graphite particles. The synthesized composites were subjected to microstructural studies, density, hardness and tensile properties testing. Microstructural characterizations of obtained samples were carried out by SEM microscopy, EDS and XRD patterns. The occurrence of graphite particles were confirmed by the XRD patterns. The density and hardness of metal composites have been decreased with adding of graphite reinforcement, while the ultimate tensile strength and yield strengths were improved with the addition of graphite particles. There was increase in the elongation of the Al6061 alloy composite after the incorporation of the reinforcement. Various fracture mechanisms were observed in the Al6061-graphite composites using SEM.

An Al2014–alumina (Al2O3) composite’s characteristics are significantly influenced by the reinforcement particle size variation. Therefore, this study examines the microstructure, mechanical, fractography, and wear performance of an Al2014–Al2O3p composite made using a unique two-stage stir casting method and various alumina weight fractions (9, 12, and 15 wt %). Three categories of alumina particle size are used, i.e., fine particle size (FPS, 8 μm), intermediate particle size (IPS, 53 μm), and coarse particle size (CPS, 88 μm). The shapes of the composites were characterized using scanning electron microscopy. According to scanning electron microscopic analyses of the microstructure, the FPS dispersion was more uniform than IPS and CPS, whereas CPS causes agglomeration. Additionally, the studies show that the FPS composite outperformed CPS and IPS composites in terms of mechanical characteristics and wear performance. The fractography study shows conical and equiaxed dimple failure in the Al2014 matrix and the circular cavities.

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