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The development of lightweight and high-strength materials is critical for many industries, including aerospace, automotive, and electronics. Metal matrix composites (MMCs) have shown great promise in meeting these requirements. The structural and physical properties of Al6061 alloy reinforced with hybrid MMCs, including TiB2, SiC, and fly ash (FA), were investigated in this research review. The MMCs investigated were made using the stir-casting process. Their microstructure, structural characteristics, and mechanical features were examined. The inclusion of TiB₂ and SiC enhanced the composite’s hardness, tensile strength, and wear resistance, while the addition of FA lowered its density and improved its thermal and corrosion resistance. However, the volume percentage, particle dimension, and arrangement of the reinforcing components all had an effect on the physical characteristics of the composite. Therefore, the optimum combination of the reinforcing materials must be carefully selected to achieve the desired properties. The result of this review provides valuable insights into the development of high-performance MMCs for various industrial applications.

Wire Electrical Discharge Machining (WEDM) is an electrothermal machining process used to produce complex profiles electrically conductive materials. In this investigation, multiobjective optimization using hybrid approach of Taguchi method (TM) and Principal Component Analysis (PCA) has been performed to find the optimal input process parameters like pulse-on time ($T_{\mathrm{\text{on}}}$), pulse-off time ($T_{\mathrm{\text{off}}}$), peak current (I), wire speed (WS) for output parameters, namely, cutting velocity (CV), power consumption (PC), and surface roughness (SR). Three different Aluminum based Metal Matrix Composites (AMMC) were fabricated using three different reinforcements i.e. 10wt.% Aluminum Oxide (Al₂O₃), 10wt.% Silicon Carbide (SiC), and combining 5wt.% Al₂O₃ with 5wt.% SiC through the stir casting process. The experiments were conducted based on the L₉ orthogonal array approach of Taguchi methodology and regression equations were developed based on the experimental data for the prediction of output parameters. The results of analysis of variance (ANOVA) shows that WS and I are the two most significant factors for CV of all three developed composites whereas for SR, $T_{\mathrm{\text{on}}}$ and I play critical role. The optimal results show that for machining of Al6061/Al₂O₃ and Al6061/SiC optimal input parameters are $T_{\mathrm{\text{on}}}=5$$\mu$s, $T_{\mathrm{\text{off}}}=4$$\mu$s, $I=1$A, and $\mathrm{\text{WS}}=3.12$m/s. For hybrid MMC (Al6061/Al₂O₃/SiC), optimized input parameters are $T_{\mathrm{\text{on}}}=5$$\mu$s, $T_{\mathrm{\text{off}}}=7$$\mu$s, $I=1$A, and $\mathrm{\text{WS}}=3.12$m/s. At optimal input parameters though the CV decreases by 1.53% the PC and SR decreases by 8.95% and 15.47%, respectively, in case of hybrid composite. The machined surface at optimal input parameters were examined by the Scanning Electron Microscope (SEM). This study will help to identify the input parameters for sustainable machining of AMMC for different reinforcements with WEDM.