Analysis of Characterization and Drilling Behaviour of Aluminium Based Hybrid Composites

The growing demand for lightweight yet high-strength materials in sectors such as aerospace, automotive, and structural engineering has driven intensive research into metal matrix composites (MMCs). Aluminium, by virtue of its excellent strength-to-weight ratio, corrosion resistance, and workability, serves as a prime matrix candidate for such composites. However, to meet the escalating performance requirements, reinforcement with hard ceramic particles has emerged as an effective strategy. Hybrid composites comprising Al6061 alloy as the matrix, combined with varying proportions of SiC and fly ash, were synthesized using the stir casting technique. The process parameters were carefully optimized: reinforcements were preheated to 600°C to enhance wettability, stirring was carried out at 550 rpm for 10 minutes to ensure homogeneous dispersion, and the molten slurry was cast into preheated steel moulds. Four composite systems were developed—unreinforced Al6061, Al + 7% SiC, Al + 5% SiC + 5% fly ash, and Al + 7% SiC + 3% fly ash—chosen to systematically study the influence of reinforcement content and type. In essence, this study provides a balanced perspective on the dual impacts of hybrid reinforcement. It confirms that aluminium-based hybrid composites with SiC and fly ash are structurally superior and thus attractive for lightweight load-bearing applications.