Article’s

Pure Aluminum and its alloys are highly preferred in weight-critical structural engineering, yet they suffer from low surface hardness and high wear rates when subjected to severe dynamic friction environments. To address these operational limitations, this study presents a systematic investigation into the mechanical, tribological, and electrochemical corrosion responses of Aluminum-Silicon Carbide (Al-SiC) metal matrix composites designed with 5 wt.% and 15 wt.% fractions of alpha-phase SiC micro-particulates (60 μm size) uniformly dispersed within a 1xxx series continuous pure aluminum matrix. The composite configurations were synthesized using a computerized bottom-pouring liquid stir casting technique. Microstructural evaluation via Field Emission Scanning Electron Microscopy (FESEM) and quantitative Energy Dispersive X-ray Spectroscopy (EDS) confirmed a highly homogeneous distribution of the ceramic phase within the continuous metal matrix with defect-free interfacial bonding zones. Mechanical testing demonstrated that the inclusion of 15 wt.% SiC significantly enhanced the Rockwell hardness of the matrix from 48 RHB to 53 RHB and markedly elevated its ultimate compressive load tolerance. Tribological assessments via pin-on-disk sliding tests revealed that increasing the reinforcement volume fraction reduces the average volumetric wear track depth from 122 μm to 100 μm, correlating with a reduction in the steady-state coefficient of friction (CoF) from 0.11 to 0.07. Furthermore, potentiodynamic polarization curves generated in an aggressive 3.5 wt.% NaCl electrolyte demonstrated enhanced structural passivation and a significant reduction in corrosion current density (I_corr). This liquid metallurgical methodology offers an efficient, scalable, and reproducible fabrication route for producing high-durability, lightweight elements tailored for advanced aerospace, structural defense, and automotive engineering industries.