AbstractAcceptance of metal matrix composites for industrial applications depends upon improving properties using an economic production route, which includes the processing design. Two powder metallurgical routes have been used in the manufacture of Al 6061 metal matrix composites. The first involves blending, vacuum canning, and hot pressing from prealloyed powders and the second involves blending of elemental powders, liquid phase sintering, and subsequent hot rolling. These composites comprise 7·5 or 15 vol.-% of 7, 23, or 45μm SiC particles. In this paper, the composite microstructure at each stage of the different processing routes has been examined and the aging behaviour investigated. Effects on the tensile properties of fabrication techniques, SiC particle size, and volume fraction are presented and discussed.MST/3020