Powder-based additive manufacturing (PAM) is a potential fabrication approach in advancing state-of-the-art research to produce intricate components with high precision and accuracy in near-net form. In PAM, the raw materials are used in powder form, deposited on the surface layer by layer, and fused to produce the final product. PAM composite fabrication for biomedical implants, aircraft structure panels, and automotive brake rotary components is gaining popularity. In PAM composite fabrication, the aluminium cast alloy is widely preferred as a metal matrix for its unique properties, and different reinforcements are employed in the form of oxides, carbides, and nitrides. However, for enhancing the mechanical properties, the carbide form is predominantly considered. This comprehensive study focuses on contemporary research and reveals the effect of metal carbide’s (MCs) addition to the aluminium matrix processed through various PAM processes, challenges involved, and potential scopes to advance the research.

The aim of the present paper is to examine the outcome of Al₂O₃-SiC reinforcements on structural and mechanical behavior of Al matrix based hybrid composites. Al-Al₂O₃-SiC hybrid composite has been developed through stir casting with addition of ceramics i.e. Al₂O₃-SiC (2.5 wt.%, 5.0 wt.%, 7.5 wt.% and 10.0 wt.%) in relative and symmetrical proportion. The structural characteristics, i.e. phase, microstructure, EDS; physical property i.e. density and the mechanical properties, i.e. hardness, impact strength and tensile strength of fabricated specimens have been investigated. XRD represents the transitional phase formation among Al base material and Al₂O₃-SiC ceramic phases with inter-atomic bonding between them. SEM reveals that the Al₂O₃-SiC fragments has distributed symmetrically in Al matrix. EDS spectrum of various samples are in confirmation with the XRD results. Density of hybrid composite reduces with increase in weight percentage of ceramic reinforcements i.e. Al₂O₃-SiC because ceramic particle gains low density after preheating. Hardness of hybrid composites increases upto 5 wt.% variation of ceramic reinforcements i.e. Al₂O₃-SiC after that it decreases. Impact strength of hybrid composite has been increased with an increase in weight percentage of ceramic. Al-2.5 wt.% Al₂O₃-2.5 wt.% SiC shows maximum ultimate tensile strength. It is expected that the prepared hybrid composites will be useful for fastener studs.