Overview

This book provides a complete pathway from materials engineering to optimized manufacturing for aluminium matrix composites. It details the stir-casting fabrication of an Al6061-Al2O3-SiC composite, verifies property gains through tensile, shear, torsion, hardness, and SEM analyses, and then develops electrochemical machining (ECM) process maps linking voltage, feed, and electrolyte flow to material removal rate (MRR) and surface roughness (Ra). Using response surface models derived from 27 controlled trials, it applies NSGA-II to generate Pareto-optimal machining parameters, including a validated near-optimum around U ≈ 9.35 L/min, F ≈ 0.104 mm/min, and V ≈ 23.38 V that balances throughput and finish (MRR ≈ 0.5486×10⁻3 kg/min, Ra ≈ 3.404 μm). The result is a practical decision toolkit that unites microstructure-aware composite design with data-driven ECM optimization, enabling reproducible, burr-free machining of abrasive AMCs. The text is intended for engineers, researchers, and advanced students seeking rigorous, implementable methods from lab to production.

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