Al7075 Aluminium Matrix Composites: Processing, Properties, Wear Behaviour and Applications- A Comprehensive Review

Al7075 aluminium alloy is widely recognized for its exceptional strength-to-weight ratio, fatigue resistance, and machinability, making it a preferred material for high-performance structural applications. However, its relatively poor wear resistance and tribological stability under severe operating conditions limit its broader utilization. To overcome these limitations, extensive research has focused on the development of Al7075-based aluminium matrix composites (AMCs) reinforced with ceramic, metallic, and solid-lubricant phases. This review paper presents a comprehensive and critical assessment of the processing methods, microstructural characteristics, mechanical properties, corrosion behaviour, and tribological performance of Al7075 aluminium matrix composites, with particular emphasis on silicon carbide (SiC) and copper (Cu) reinforced systems. Various fabrication techniques—including stir casting, powder metallurgy, friction stir processing, and in-situ synthesis—are discussed, highlighting their influence on reinforcement distribution, interfacial bonding, and defect formation. The effects of reinforcement type, particle size, morphology, and weight fraction on hardness, tensile strength, wear rate, and coefficient of friction are systematically analyzed. Special attention is given to wear mechanisms, mechanical mixed layer formation, and hybrid reinforcement strategies aimed at achieving a balance between strength enhancement and friction reduction. Al7075 composites' corrosion behavior and suitability for use in defense, automotive, marine, and aerospace applications are also examined. Finally, existing research gaps and future research directions—such as nano-reinforced systems, hybrid composites, corrosion–wear interaction, and advanced manufacturing routes—are identified to guide the development of next-generation Al7075 aluminium matrix composites for demanding engineering applications