Comparative analysis of mechanical and tribological properties of hot pressed and heat-treated aluminium–ZrB2 nanocomposites

Purpose This study aims to provide the comparative analysis of mechanical, microstructural and tribological behaviour of Al6061–ZrB2 nanocomposites fabricated via hot pressing and subjected to T6 heat treatment. The influence of varying ZrB2 nanoparticle content on compression strength, microhardness and wear resistance was systematically evaluated to enhance the performance of Al6061–ZrB2 nanocomposites. The idea is to identify the most effective manufacturing technique. Design/methodology/approach Al6061–ZrB2 nanocomposites containing 0–2.0 Wt.% ZrB2 nanoparticles (50–100 nm) were produced through hot pressing at 510 °C and 35 kg/cm², followed by solutionizing (530 °C) and artificial aging (175 °C). Microstructural characterization was performed using FESEM, while compressive strength, microhardness and tribological behaviour were assessed through mechanical testing and pin-on-disc wear analysis. Findings FESEM analysis revealed uniform ZrB2 dispersion and refined grains, with the 2 Wt.% composite exhibiting a grain size of ∼36 nm. The heat-treated 2 Wt.% composite (HT4) achieved the highest compressive strength (106.06 ± 2 MPa) and hardness (80 ± 2 HV), reflecting 36% and 86% improvements over unreinforced Al6061. Tribological tests showed significant wear and friction reduction, with HT4 recording a wear depth of 120 µm and a coefficient of friction of 0.18. SEM of wear tracks confirmed reduced surface damage due to ZrB2-induced tribolayer formation. Originality/value This work highlights the combined effect of hot pressing and T6 heat treatment on ZrB2 reinforced Al6061 composites, offering a high-strength, wear-resistant material suitable for automotive structural applications. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2025-0515/