A Review on the Stir-Cast Aluminium Metal Matrix Composites: Properties, Challenges, and Research Opportunities

This review presents a detailed study on the fabrication of aluminium matrix composites (AMCs) using the stir-casting technique and the associated processing challenges. Owing to their low density, high specific strength, good wear resistance, and thermal stability, AMCs have attracted significant interest from both researchers and industrial sectors. Among the various fabrication routes, stir casting is widely preferred due to its simplicity, cost-effectiveness, and suitability for large-scale production. However, the process is constrained by inherent differences in the physical and mechanical properties of the aluminium matrix and the reinforcement materials, such as density mismatch, melting temperature variation, wettability, strength, and plastic deformation behavior. These factors strongly influence particle distribution, interfacial bonding, and overall composite performance. The review critically examines these challenges and highlights key considerations for improving the quality and reliability of stir-cast aluminium matrix composites.