IMPROVED WEAR CHARACTERISTICS OF Al–B₄C COMPOSITES FABRICATED BY ULTRA-SONIC ASSISTED STIR CASTING TECHNIQUE

This work investigates the development and tribological performance of aluminum (Al) matrix composites reinforced with boron carbide (B 4 C) particles at 2, 4, and 6[Formula: see text]wt.%. These composites were fabricated using a novel ultrasonic-assisted stir-casting approach. The inclusion of B 4 C, a ceramic material known for its hardness and thermal stability, aimed to enhance the wear resistance of the Al matrix. Ultrasonic-assisted stirring ensured uniform dispersion of B 4 C particles and reduced agglomeration, addressing a common issue in composite production. The developed composites with varying B 4 C[Formula: see text]wt.% were subjected to dry sliding wear testing using a pin-on-disc device and a Box-Behnken design of response surface methodology, incorporating variables such as load, sliding distance, and reinforcement wt.%. XRD analysis confirmed the presence of B 4 C in the Al–B 4 C composite. A slight peak shift was observed as the weight percentage of B 4 C increased. The 2% Al–B 4 C composite exhibited a 29% decrease in porosity compared to cast Al 6061. The inclusion of 2[Formula: see text]wt.% B 4 C resulted in a significant 33% improvement in the composite’s hardness, reaching 86.6[Formula: see text]HV. Severe plastic flow and subsequent strain hardening were responsible for this increase in hardness. The ANOVA results primarily influenced the wear rate, with sliding distance and reinforcement weight percentage following closely behind. This study highlights the potential of Al–B 4 C composites in applications requiring exceptional wear performance, such as the automotive and aerospace industries.