Investigating the influence of carbide reinforcements on the mechanical, corrosion, and tribological properties of recycled magnesium turnings based hybrid composites

• A novel vacuum-assisted stir casting technique was used to fabricate Mg-based composites with minimized oxidation and improved particle dispersion. • SEM and XRD analyses confirmed uniform dispersion of SiC and B₄C, and absence of intermetallic compounds or agglomeration. • The research establishes a clear link between reinforcement ratio, microstructure, and functional performance. • The Mg–2.5SiC–2.5B₄C composite is ideal for aerospace and automotive applications requiring high strength, wear, and corrosion resistance. In order to endorse sustainable and cost-effective manufacturing, the present study focuses on the fabrication of magnesium-based hybrid nanocomposites reinforced with silicon carbide (SiC) and boron carbide (B₄C), created using a unique vacuum-assisted stir casting technique. One of the major aspects of fabricating these composites is to make use of magnesium turnings as a recycling process. Four compositions, S0 (Pure Mg), S1 (Mg-2 wt.% SiC-3 wt.% B₄C), S2 (Mg-3 wt.% SiC-2 wt.% B₄C), and S3 (Mg-2.5 wt.% SiC-2.5 wt.% B₄C), were designed to analyze the impact of reinforcement ratios on mechanical, microstructural, corrosion, and tribological properties. The microstructural study demonstrated homogeneous particle dispersion without agglomeration. S3 had the highest ultimate tensile strength, increased microhardness, and greater wear resistance due to balanced reinforcement distribution. Corrosion testing revealed that S3 had the lowest corrosion rate (54.54 µm/year) and the longest resistance length (216 hours), whereas S2, with the highest SiC concentration, had the highest corrosion rate (130 µm/year). Tribological study revealed that S3 had the least coefficient of friction, implying superior frictional resistance under test conditions. These findings highlight S3 as the most promising composite for high-performance aerospace and automotive applications, providing an ideal balance of strength, corrosion resistance, and wear performance.