Synergistic Enhancement in Mechanical Integrity, Tribological Response, and Corrosion Resistance of AA2219 Hybrid MMCs Reinforced with SiC and Al ₂ O ₃ : Fabrication, Experimental Characterization, and Wear Optimization

High Resolution Image Download MS PowerPoint Slide The pursuit of lightweight, high-strength and corrosion-resistant materials is the crucial key for next-generation aerospace applications. Current research focuses on the fabrication, characterization, and optimization of aerospace-grade Aluminum Alloy 2219 hybrid metal matrix reinforced with Silicon Carbide (SiC) and Alumina (Al 2 O 3 ) using the stir casting method to tailor its mechanical, wear, and corrosion properties. The SiC content was varied from 3 to 12 wt %, while Al 2 O 3 was maintained at a constant 7 wt %. Microstructural investigation confirmed uniform distribution of reinforcements up to 6 wt % SiC, whereas higher contents resulted in porosity and particle clustering. The optimized composition (AA2219 + 6 wt % SiC + 7 wt % Al 2 O 3 ) displayed a peak hardness of 152.7 HV and tensile strength of 376.3 MPa, more than twice that of the base alloy. Wear analysis revealed a 70% drop in mass loss and coefficient of friction, reinforced by strong load transfer and tribolayer formation. Corrosion resistance enhanced nearly 4-fold due to the formation of a dense protective oxide film. Statistical optimization using Minitab regression and response surface methodology identified the optimum parameters as 6.44 wt % SiC, 33.7 N load, and 509 RPM, yielding the least wear. This research establishes the optimized AA2219–SiC–Al 2 O 3 composite as a high-performance material for aerospace structural applications with a balanced synergy of mechanical, wear, and corrosion properties.