Microstructural and tribological investigation of B4C-reinforced Al6061 composites: insights from SEM and wear analysis

Abstract The functionality of aluminum metal matrix composites (AMMCs) treated with micro-sized boron carbide (B 4 C) particles is investigated in this work, specifically for automotive, aerospace, and defense applications. It addresses the critical need for enhanced mechanical properties to improve durability and reliability under demanding conditions. Al6061 alloy composites containing 10 weight % of B 4 C particles (40 and 90 microns in a 1:1 ratio) were fabricated using a cost-effective stir casting method. Tribological tests were conducted using a tribometer to evaluate the effects of applied load, wear temperature, and sliding velocity on wear rate and friction coefficient. Scanning Electron Microscopy (SEM) provided insights into wear mechanisms and particle dispersion. Multi-criteria optimization was performed using the Taguchi L9 orthogonal array and Grey Relational Grade (GRG) techniques. Python programming was used to automate GRG calculations and perform hyperparameter tuning of the experimental factors to determine the optimal conditions for minimizing wear and friction. The optimized composite showed a 50.8% reduction in wear rate and a 26.1% decrease in friction coefficient compared to the baseline Al6061 alloy, demonstrating significant enhancement in tribological performance. This work presents a comprehensive methodology combining material characterization and computational optimization, offering valuable guidance for designing high-performance AMMCs for industrial applications.