Investigation of tribological and mechanical properties of aluminium boron carbide composites using response surface methodology and desirability analysis

Purpose - Aluminium metal matrix composites are used in automotive and aerospace industries because of their high performance and weight reduction benefits. The current investigation aims to focus on the development of the stir cast aluminium-boron carbide composites with enhanced mechanical and tribological properties. Design/methodology/approach - The aluminium-boron carbide composites are produced by stir casting process. Aluminium alloy A356 is chosen as the matrix material and three sets of composites are produced with different weight fractions of boron carbide particles. Higher particle size (63 mm) of boron carbide is chosen as the reinforcement material. Aluminium-boron carbide composites are tested for mechanical and tribological properties. The effect of process parameters like load, speed and percentage of reinforcement on the wear rate are studied using the pin-on-disc method. The interaction of the process parameters with the wear rate is analysed by DesignExpert software using RSM methodology and desirability analysis. The coded levels for parameters for independent variables used in the experimental design are arranged according to the central composite design. The worn surface of the pin is examined using a scanning electron microscope. The phases and reaction products of the composites are identified by X-ray diffraction (XRD) analysis. Findings - Aluminium-boron carbide composites reveal better mechanical properties compared to monolithic aluminium alloys. Mechanical properties improved with the addition of strontium-based master alloy Al10Sr. The ultimate tensile strength, hardness and compressive strength increase with an increase in the reinforcement content. The wettability of the boron carbide particles in the matrix improved with the addition of potassium flurotitanate to the melt. Uniform dispersion of particles into the alloy during melting is facilitated by the addition of magnesium. Wear resistance is optimal at 8 per cent of boron carbide with a load 20 N and sliding speed of 348 RPM. The wear rate is optimized by the numerical optimization method using desirability analysis. The amount of wear is less in Al-B4C composites when compared to unreinforced aluminium alloy. The wear rate increases with an increase in load and decreases with the sliding speed. The wear resistance increases with an increase in the weight fraction of the boron carbide particles. Practical implications - The produced Al-B4C composites can retain properties at high temperature. It is used in nuclear and automotive products owing its high specific strength and stiffness. The main applications are neutron absorbers, armour plates, high-performance bicycles, brake pads, sand blasting nozzles and pump seals. Originality/value - Al/B4C composites have good potential in the development of wear-resistant products.