Processing–Structure–Property Correlation in AA2024–SIC Aluminium Matrix Composites Developed Through Stir-Assisted Casting

In the present study, AA2024–SiC aluminium metal matrix composites were successfully fabricated using the stir casting technique with varying silicon carbide (SiC) reinforcement contents of 2 wt.%, 4 wt.%, and 6 wt.%. The fabrication process was carried out at a melting temperature of 850 °C to achieve uniform reinforcement distribution and improved interfacial bonding. The prepared composites were characterized through density measurement, porosity analysis, optical microstructural examination, microhardness testing, and tensile strength evaluation. The results indicated that the incorporation of SiC significantly enhanced the composite properties. Experimental density increased from 2.546 g/cm³ to 2.701 g/cm³, while porosity decreased from 2.245% to 1.768% with increasing SiC content. Microstructural analysis revealed refined grains and improved particle dispersion at higher reinforcement levels. Furthermore, microhardness and tensile strength increased from 67.35 HV to 84.23 HV and 89.63 N/mm² to 124.95 N/mm², respectively. The 6 wt.% SiC composite exhibited the best overall performance.