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In this study, two-step stir process was used to synthesis aircraft Al2030 alloy reinforced composites with 3 and 6 weight percentages of B4C particles. This innovative two-step stir casting process improves the wettability of Al2030 and B4C particles. SEM and EDS were used to characterize the microstructures of the Al2030 alloy with B4C composites. Different mechanical features of Al2030 alloy composites were investigated to determine the impact of B4C particle addition on hardness, ultimate strength, yield strength, and ductility. In addition, the wear behavior of the produced Al2030 alloy with B4C composites was investigated utilizing a pin-on-disc apparatus with variable normal load and sliding velocity over a constant 2000 m sliding distance. SEM micrographs demonstrated homogeneous particle distribution, while EDS patterns validated the elements in the B4C reinforced Al composites. The addition of B4C particles increased mechanical characteristics; further improvement was obtained by increasing the weight fraction of B4C particles in the Al2030 matrix alloy. On the other hand, reduced ductility of the composites was observed due to the incorporation of B4C particles in the soft Al matrix. To determine the effect of B4C particles on tensile failure, wear surface of the composites, fractography and worn surface analyses were performed.

Mechanical and Wear Characterisation of Boron Carbide Particles Reinforced Al2030 Alloy Composites Developed by Two Stage Stir cast Method