Aluminum-reinforced silicon carbide composite (Al/SiC) has gained popularity as a metal matrix composite for various applications in aerospace, automotive, defense, and other fields due to its high specific strength, lightweight, and wear-resistant characteristics. Due to their excellent material properties, drilling precise holes especially in thick Al/SiC composites is a difficult task. The present research aims for laser beam percussion drilling of precise holes with better accuracy by reducing the hole taper, non-circularity, and spatter size. This study may help figure out the best way to use a laser beam to drill holes in a 4.5 mm thick Al/SiC composite. The experimental results suggest that reducing the pulse width and increasing the assist pressure lead to a decrease in hole taper and better hole circularity. Genetic algorithm optimization technique was used to optimize the hole top circularity, resulting in a notable 7.587% improvement and a 2.736% improvement in the bottom circularity of the hole, respectively. The hole taper was significantly minimized by 31.943%, with spatter size also significantly reduced by 37.796%. This research further indicates the positive contributions of process parameters to improve the drilling efficiency and accuracy.
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