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Journal of Materials & Metallurgical Engineering Review Article

Squeeze Casting of Hybrid Aluminum Matrix Composites: A Critical Review of Process Optimization, Reinforcement Strategies, and Performance Outcomes

  1. Arvinder Singh Channi Department of mechanical Engineering, Guru kashi University, Talwandi Sabo
  2. Manjot Kaur Channi Department of Electronics and Communication, National Institute of Technology

Abstract

Increasing demand for lightweight, performance-oriented components in automotive, aerospace, and defense industries has driven advancements in squeeze casting, a hybrid technique merging forging and die-casting advantages to produce near-net-shape aluminum matrix composites (AMCs) with superior mechanical-tribological properties. This review critically examines the interplay of process parameters (e.g., squeeze pressure: 70–150 MPa, melt temperature: 650–800°C), reinforcement characteristics (volume fraction ≤10%, particle size: 10–71µm), and interfacial engineering strategies (flux-assisted bonding, ultrasonic dispersion) in optimizing AMC performance. Key findings reveal that squeeze pressure (95–105 MPa) and controlled solidification (die temperature: 150–250°C) minimize porosity, refine grain structures (e.g., 90→60µm grain size), and enhance tensile strength (up to 232 MPa) and hardness (up to 58 HRF). Reinforcement strategies, such as hybrid Al₂O₃/SiC systems, improve wear resistance by 78%, while interfacial modifications (e.g., K₂TiF₆ flux, Ti/Mg additions) suppress harmful intermetallics and boost load transfer efficiency. Despite challenges like particle agglomeration and brittle fracture, squeeze-cast AMCs demonstrate forged-grade properties, outperforming conventional stir/sand casting in strength (UTS +80%), corrosion resistance (+72%), and dimensional precision. This synthesis underscores squeeze casting’s viability for industrial applications requiring defect-free, high-integrity components, while identifying optimal parameter windows and future research directions for scalable production.

Keywords

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