Fabrication of AL6061–SiC Metal Matrix Composites via Stir Casting: A Response Surface Methodology Approach to Microstructure Analysis

Abstract

To This study investigates the fabrication and microstructural characterization of Al6061–SiC composites using a Response Surface Methodology (RSM) approach to optimize stir casting parameters. Aluminum 6061 was used as the matrix material, while silicon carbide (SiC) particles with a size of less than 10 µm served as the reinforcement. The Aluminum Metal Matrix Composites (AMMCs) were produced through the stir casting technique, which is considered a cost-effective and efficient fabrication method. The composite samples were prepared according to the experimental design generated using the RSM Box–Behnken Design (BBD). The main processing parameters examined in this study were the reinforcement weight fraction (3.5 wt%, 7.0 wt%, and 10.5 wt%), melting temperature (625°C, 650°C, and 675°C), and stirring speed (225 rpm, 250 rpm, and 275 rpm). Microstructural examination carried out using a metallurgical microscope and high-resolution scanning electron microscope (SEM) indicated a relatively uniform dispersion of SiC particles within the aluminum matrix; however, minor particle agglomeration and porosity were also detected.