In this study, hybrid aluminum (Al) matrix composites reinforced with copper-coated carbon fibers and SiC particles (SiCp-Cu@CF/Al composites) were manufactured by the powder metallurgy method. With the carbon fiber mass fraction fixed at 1 wt%, the effect of SiC particle mass fraction on the microstructure and properties of the composite was systematically investigated. The results indicated that with the addition of 3 wt% SiC particles, the SiCp-Cu@CF/Al composite exhibited a hardness of 73.47 HB and a tensile strength of 344.38 MPa, which were 30.6% and 22.1% higher than those of the copper-coated carbon fiber reinforced aluminum matrix (Cu@CF/Al) composite, respectively. Meanwhile, the composite demonstrated an average friction coefficient of 0.4526 and a wear rate of 0.93 × 10-2 mm3/N·m, representing reductions of 42.7% and 66.6%, respectively. Carbon fibers enhanced the tensile strength primarily through axial load-bearing, while SiC particles improved the hardness and wear resistance via dispersion strengthening and grain refinement. The synergistic effect of these two reinforcements, aided by a graded stress distribution at the interface that inhibited crack propagation, led to a complementary improvement in the overall mechanical and tribological properties. This work provides a systematic understanding of the synergistic strengthening and wear-resistance mechanisms of SiCp-Cu@CF/Al composites fabricated by powder metallurgy, and identifies an optimized SiC particle content for achieving balanced mechanical and tribological performance.
YadavRSinghMShekhawatD, et al.The role of fillers to enhance the mechanical, thermal, and wear characteristics of polymer composite materials: a review. Compos. Part A2023; 175: 107775. https://doi.org/10.1016/j.compositesa.2023.107775
2.
YadavRSonwalSSharmaYK, et al.A mini review on physical, mechanical, tribology analysis of micro-nano fibers and ceramics reinforced polymer composites for advanced manufacturing processes. Polym Adv Technol2025; 36(5): e70205. https://doi.org/10.1002/pat.70205
3.
LiuZYWangLHWangYN, et al.Enhancing strengthening efficiency of graphene nano-sheets in aluminum matrix composite by improving interface bonding. Compos. Part B2020; 199: 108268.
4.
JuhaszKLBaumlPKaptayG. Fabrication of carbon fibre reinforced aluminum matrix composite by potassium iodide (KI)-potassium hexafluoro-titanate (K2TiF6) flux. Mater Werkst2012; 43: 310–314.
5.
KuttanAAKhansoleABHarshaAS, et al.Assessing additive manufacturing techniques for polymer and metal matrix composites in aerospace applications. Trans Indian Inst Met2025; 78(8): 1–10. https://doi.org/10.1007/s12666-025-03671-2
6.
SinghMYadavRDodlaS, et al.The influence of nanoparticle surface coatings on fiber-reinforced polymer composites: a review of mechanical, tribological, and thermal properties. Compos Interfaces2026: 1–29. https://doi.org/10.1080/09276440.2026.2613181
7.
AnggoroBSHandokoESoegijonoB. The influence of Cu doped on structure and mechanical properties of aluminium material. Matec. Web. Conf2018; 197: 02009.
8.
VoroninSVLobodaPSLediaevME. Effect of porosity and the ordered porous structure type on the mechanical properties of aluminum materials. AIP Conf Proc2016; 1785(1): 040092.
9.
LiuCYeJWeiX, et al.Strength-ductility synergy in 3D-printed (TiB + TiC)/Ti6Al4V composites with unique dual-heterogeneous structure. Compos. Part B2023; 266: 111008. https://doi.org/10.1016/j.compositesb.2023.111008
10.
ZhangXLiSPanD, et al.Microstructure and synergisticstrengthening efficiency of CNTs-SiCp dual-nano reinforcements in aluminum matrix composites. Compos Appl Sci Manuf2018; 105: 87–96. https://doi.org/10.1016/j.compositesa.2017.11.013
11.
YadavRMeenaALeeSY, et al.Experimental tribological and mechanical behavior of aluminium alloy 6061 composites incorporated ceramic particulates using Taguchi analysis. Tribol Int2024; 192: 109243. https://doi.org/10.1016/j.triboint.2023.109243
12.
YadavRLeeHHMeenaA, et al.Effect of alumina particulate and E-glass fiber reinforced epoxy composite on erosion wear behavior using Taguchi orthogonal array. Tribol Int2022; 175: 107860. https://doi.org/10.1016/j.triboint.2022.107860
13.
WangHMSuWXLiuJQ, et al.Microstructure and properties of FeCoNiCrMn and Al2O3 hybrid particle-reinforced aluminum matrix composites fabricated by microwave sintering. J Mater Res Technol2023; 24: 8618–8634. https://doi.org/10.1016/j.jmrt.2023.05.100
14.
SuNLiuKSuY, et al.Fabrication, microstructural characterization and mechanical properties of carbon nanotubes and silicon carbide nanoparticles hybrid reinforced aluminum matrix composites. Mater Sci Eng, A2025; 937: 148444. https://doi.org/10.1016/j.msea.2025.148444
15.
GuoMTTsaoCY. Tribological behavior of aluminum/SiC/nickel-coated graphite hybrid composites. Mater Sci Eng, A2002; 333: 134–145.
LeeGSungMYoukJH, et al.Improved tensile strength of carbon nanotube-grafted carbon fiber reinforced composites. Compos Struct2019; 220: 580–591. https://doi.org/10.1016/j.compstruct.2019.04.037
19.
DuanLYZhaoXWangY. Oxidation and ablation behaviors of carbon fiber/phenolic resin composites modified with borosilicate glass and polycarbosilane Interface. J Alloys Compd2020; 827: 154277.
20.
LvZZWangJGuoYC, et al.Effect of Cu coating thickness on carbon fiber surface on microstructure and mechanical properties of carbon fiber reinforced aluminum matrix composites. Mater Today Commun2023; 34: 105424. https://doi.org/10.1016/j.mtcomm.2023.105424
21.
LiXLiaoYMaK, et al.Tribological behavior of carbon nanotube reinforced aluminum matrix composites with varying matrix alloys. Sci China Technol Sci2025; 68(4): 1420202. https://doi.org/10.1007/s11431-024-2835-9
22.
YeTXuYRenJ. Effects of SiC particle size on mechanical properties of SiC particle reinforced aluminum metal matrix composite. Mater Sci Eng, A2019; 753: 146–155. https://doi.org/10.1016/j.msea.2019.03.037
LvZZShaJJLinGZ, et al.Mechanical and thermal expansion behavior of hybrid aluminum matrix composites reinforced with SiC particles and short carbon fibers. J Alloys Compd2023; 947: 169550. https://doi.org/10.1016/j.jallcom.2023.169550
25.
LvZZLiuXBWangJF, et al.Enhancing damping capacity and mechanical properties of aluminum matrix composites by the synergistic strengthening of SiC particles and carbon fibers. Mater Lett2023; 334: 133728. https://doi.org/10.1016/j.matlet.2022.133728
26.
UreñaARamsJCampoM, et al.Effect of reinforcement coatings on the dry sliding wear behaviour of aluminium/SiC particles/carbon fibres hybrid composites. Wear2009; 266(1-2): 1128–1136. https://doi.org/10.1016/j.wear.2009.03.016
27.
MenacheryNThomasLPThomasS, et al.Development and characterization of carbon fiber reinforcement in Aluminium metal matrix composites. J Phys, Conf Ser2024; 2837(1): 012052. https://doi.org/10.1088/1742-6596/2837/1/012052
28.
MaoDMengXXieY, et al.Strength-ductility balance strategy in SiC reinforced aluminum matrix composites via deformation-driven metallurgy. J Alloys Compd2022; 891: 162078. https://doi.org/10.1016/j.jallcom.2021.162078
29.
ChakVChattopadhyayH. Mechanical and tribological properties of ceramic–aluminium composites developed using stirring-assisted squeeze casting. Int J Cast Met Res2023; 36(1-3): 65–75. https://doi.org/10.1080/13640461.2023.2207894
30.
MohanavelVRajanKKumarSS, et al.Effect of silicon carbide reinforcement on mechanical and physical properties of aluminum matrix composites. Mater Today Proc2018; 5(1): 2938–2944. https://doi.org/10.1016/j.matpr.2018.01.089
DeyDBhowmikABiswasA. Effect of SiC content on mechanical and tribological properties of Al2024-SiC composites. Silicon2022; 14(1): 1–11. https://doi.org/10.1007/s12633-020-00757-y
33.
KumarAKantRSinghH. Microstructural and tribological properties of laser-treated cold-sprayed titanium/baghdadite deposits. J Mater Res2022; 37(16): 2698–2709. https://doi.org/10.1557/s43578-022-00675-2
34.
XuHMaGZHePF, et al.Structural characteristics and tribological properties of an ultrafine-grained Al–40Si–5Fe coating prepared by supersonic plasma spraying. J Mater Res2024; 39(2): 220–230. https://doi.org/10.1557/s43578-023-01213-4
35.
PrasadSSharmaSSatishC, et al.Microstructural, mechanical, room, and high temperature tribological properties of graphene oxide reinforced plasma sprayed alumina nanocomposite coatings. J Mater Res2024; 39(12): 1797–1811. https://doi.org/10.1557/s43578-024-01347-z
36.
XianYBZhangYChenL, et al.Improvement on toughness and tribological properties for phosphate bonded MoS2 coatings by introduction of polytetrafluoroethylene. J Mater Res2022; 37(15): 2446–2457. https://doi.org/10.1557/s43578-022-00660-9
37.
LiuLLiWTangY, et al.Friction and wear properties of short carbon fiber reinforced aluminum matrix composites. Wear2009; 266(7-8): 733–738. https://doi.org/10.1016/j.wear.2008.08.009
YadavRSonwalSSharmaRP, et al.Ranking analysis of tribological, mechanical, and thermal properties of Nano hydroxyapatite filled dental restorative composite materials using the R-Method. Polym Adv Technol2024; 35(12): e70010. https://doi.org/10.1002/pat.70010
40.
YadavRSainiSSonwalS, et al.Optimization and ranking of dental restorative composites by ENTROPY-VIKOR and VIKOR-MATLAB. Polym Adv Technol2024; 35(7): e6526. https://doi.org/10.1002/pat.6526
41.
YadavRSinghMMeenaA, et al.Selection and ranking of dental restorative composite materials using hybrid Entropy-VIKOR method: an application of MCDM technique. J Mech Behav Biomed Mater2023; 147: 106103. https://doi.org/10.1016/j.jmbbm.2023.106103
42.
YadavRLeeHH. Fabrication, characterization, and selection using FAHP-TOPSIS technique of zirconia, titanium oxide, and marble dust powder filled dental restorative composite materials. Polym Adv Technol2022; 33(10): 3286–3295. https://doi.org/10.1002/pat.5780
43.
YadavRLeeHH. Ranking and selection of dental restorative composite materials using FAHP-FTOPSIS technique: an application of multi criteria decision making technique. J Mech Behav Biomed Mater2022; 132: 105298. https://doi.org/10.1016/j.jmbbm.2022.105298
44.
YadavR. Fabrication, characterization, and optimization selection of ceramic particulate reinforced dental restorative composite materials. Polym Polym Compos2022; 30: 09673911211062755. https://doi.org/10.1177/09673911211062755
45.
YadavR. Analytic hierarchy process-technique for order preference by similarity to ideal solution: a multi criteria decision‐making technique to select the best dental restorative composite materials. Polym Compos2021; 42(12): 6867–6877. https://doi.org/10.1002/pc.26346
