Enhancing Mechanical Properties of Al-6061-Cu/Mg−Al₂O₃/SiC Composites: A Comparative Study of Stir Casting and Ultrasonic Casting Techniques

Aluminum composites with improved mechanical properties are highly sought after in various industries. Two main methods, stir casting and ultrasonic casting, are used to create these composites. Stir casting involves mechanically stirring reinforcement materials into a molten aluminum matrix, while ultrasonic casting uses vibrations to disperse reinforcements in the molten metal. Understanding the differences between these techniques and their impact on mechanical properties is crucial for optimizing composite fabrication. This article presents a comprehensive comparison of stir and ultrasonic casting procedures and evaluates their impact on the characteristics of aluminum composites. This study involved the fabrication of aluminum metal matrix composites (AMMCs) utilizing both traditional stir casting and ultrasonic-assisted stir casting techniques. The latter method utilized an ultrasonic probe to overcome the limitations of the earlier technique by introducing ultrasonic energy. The AMMCs were produced using CuMg/SiC/Al₂O₃ microparticles with concentrations ranging from 2 to 16%, increasing in increments of 2%, and with a size of 60 µm. The study conducted a thorough evaluation and comparison of the mechanical and physical characteristics of composites produced using both procedures. It specifically examined the impact of filler content on the density of AMMCs. The microstructural examination showed that the CuMg/SiC/Al₂O₃ microparticles were evenly distributed when the ultrasonic probe was utilized. The experimental results clearly demonstrated a significant improvement in the mechanical and physical qualities as a result of using the ultrasonic-assisted stir casting technique. By exploring the methodology, key parameters, and experimental results, this study offers valuable insights into the selection and optimization of casting techniques for the production of high-performance aluminum composites.