Al2014–Alumina Aerospace Composites: Particle Size Impacts on Microstructure, Mechanical, Fractography, and Wear Characteristics

[Image: see text] An Al2014–alumina (Al(2)O(3)) composite’s characteristics are significantly influenced by the reinforcement particle size variation. Therefore, this study examines the microstructure, mechanical, fractography, and wear performance of an Al2014–Al(2)O(3p) composite made using a unique two-stage stir casting method and various alumina weight fractions (9, 12, and 15 wt %). Three categories of alumina particle size are used, i.e., fine particle size (FPS, 8 μm), intermediate particle size (IPS, 53 μm), and coarse particle size (CPS, 88 μm). The shapes of the composites were characterized using scanning electron microscopy. According to scanning electron microscopic analyses of the microstructure, the FPS dispersion was more uniform than IPS and CPS, whereas CPS causes agglomeration. Additionally, the studies show that the FPS composite outperformed CPS and IPS composites in terms of mechanical characteristics and wear performance. The fractography study shows conical and equiaxed dimple failure in the Al2014 matrix and the circular cavities.