In this study, aluminum matrix composites (AMCs) were developed using two different techniques, conventional stir casting and ultrasonic assisted stir casting. The drawbacks of the conventional stir casting technique were eliminated by employing an alternative process to produce the composite, wherein ultrasonic energy was introduced into the molten metal using an ultrasonic probe. AMCs were produced by using different concentrations of SiC (3%, 5%, 8%, and 10%) microparticles with a size of 40 μm. Mechanical and physical properties of the composites developed using both techniques were examined and compared. Moreover, the effect of filler inclusion on AMC density was assessed. The microstructural investigation revealed that SiC microparticles were dispersed homogeneously in the matrix material when the ultrasonic probe was used. Furthermore, test results indicated that mechanical and physical characteristics improved with the ultrasonic-assisted stir casting process. Display omitted •The Aluminum matrix composites were fabricated with varying weight percentage of SiC micro particles.•Two fabrication process, conventional stir casting and ultrasonic assisted stir casting, were used to fabricate the AMCs.•The effect of reinforcement weight percentage on the mechanical and physical properties was determined.•The effect of two different fabrication techniques on the mechanical properties and performance were assessed and compared.