There is a requirement of lightweight structures in daily life. Metal matrix composites (MMCs) with aluminum as matrix material are predominantly used in industries like aerospace, sporting goods, automobiles, and military. Among the various methods for producing MMCs based on aluminum, the stir-casting route is predominantly used since it is a fast and affordable. The main problems with the stir casting method include porosity and an uneven distribution of reinforcing particles. Squeeze casting process is an effort to address these problems. In the current work, lightweight AA6061-TiB₂ composites were produced utilizing the squeeze casting method with varying reinforcement levels (0, 1.5, 3, and 4.5 wt.%) after process variables such melt temperature, stirring speed, and reinforcement percentage were optimized. The primary goals of this investigation are to examine the hardness, tensile strength and microstructure along with wear rate of MMCs. In contrast to the basic alloy, an increase of 33.27% in hardness and 26.12% increase in tensile strength were noted from the study. The findings of the wear test demonstrate that adding TiB₂ particles increased wear resistance.

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