| Summary: | In this study, Al-BiSn composites were synthesized by a combination of microwave sintering and hot extrusion processes. The structural, morphological, mechanical, and thermal properties were investigated to elucidate the role of Bi<sub>60</sub>Sn<sub>40</sub> (BiSn) alloy content (5, 10, and 15 wt.%) in modifying the properties of Al-BiSn composites. The X-ray diffraction (XRD) patterns confirmed the presence of aluminum and BiSn particles. Distribution of BiSn particles in Al-BiSn composites was confirmed by field emission scanning electron microscopy associated with energy dispersive X-ray analysis (FE-SEM-EDX). Results indicated that hot extruded Al-(15 wt.% BiSn) composite exhibits maximum hardness (78 ± 4 Hv) and tensile strength (185 ± 3 MPa), which were 117% and 58% improvements, respectively, compared to pure Al. This improvement in mechanical properties can be attributed to the strengthening effect of BiSn particles. A decline in the values of the coefficient of thermal expansion (CTE) with an increasing amount of BiSn particles reflects the enhanced thermal stability of developed Al-BiSn composites. The promising properties of Al-BiSn composites make them suitable for many industrial applications.
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