A336 Al matrix composites containing different volume fraction and mean mass particle size of SiC particles as the reinforcing phase were synthesised by evaporative pattern casting (EPC) route. The process consisted of fabricating of EPS/SiCp composite pattern followed by EPC of A336 Al alloy. The EPS/SiCp pattern was made by blending SiC particles with expandable polystyrene (EPS) beads and placing them in expanding mould heating with steam until EPS beads expand completely. Uniform distributed SiC particles around the EPS beads and locally movement of them during pouring and degradation leads to homogenous distribution of particles in final Al/SiCp composite. Higher modulus, strength and hardness were observed in the composites than the unreinforced Al alloy part. The fracture surfaces of the composite samples exhibited dimple surfaces and fracture in SiC particles.

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