Effect of TiC Reinforcement on the Microstructure and Performance of AA2014 Composites Fabricated via Vortex-Assisted Sand Casting

Abstract Recent advances in manufacturing technologies have significantly increased the demand for materials exhibiting superior mechanical performance and reduced thermal expansion, particularly in the defense, automotive, and aerospace industries. While conventional monolithic alloys struggle to meet these severe requirements, metal matrix composites have emerged as promising structural alternatives. Therefore, the purpose of this study is to investigate the mechanical, structural, and machinability effects of varying Titanium Carbide (TiC) reinforcement ratios on the AA2014 aluminum alloy matrix. Methodologically, three composite variants containing 3, 5, and 7 wt.% TiC were successfully manufactured via a cost-effective vortex-assisted sand casting process. A comprehensive characterization was then performed using XRD, SEM, Vickers microhardness, tensile testing, abrasion wear testing, and cutting force measurements. The experimental results revealed that TiC particles were distributed homogeneously up to 5 wt.%, whereas macroscopic agglomeration occurred at 7 wt.%. Consequently, while hardness and wear resistance increased linearly with the reinforcement ratio, the ultimate tensile strength exhibited a distinct threshold, peaking at 5 wt.% TiC before declining due to particle clustering. Furthermore, machinability tests demonstrated that cutting forces increased proportionally with the hard ceramic phase content. In conclusion, this study establishes a clear structure–property–machinability relationship, demonstrating that the sand-cast AA2014 composite reinforced with 5 wt.% TiC offers the most favorable compromise between mechanical strength, wear resistance, and processability for industrial structural applications.