Influence of B4C and ZrB2 reinforcements on microstructural, mechanical and wear behaviour of AA 2014 aluminium matrix hybrid composites

Considering their affordability and high strength-to-weight ratio, lightweight aluminium alloys are the subject of intensive research aimed at improving their properties for use in the aerospace industry. This research effort aims to develop novel hybrid composites based on AA 2014 alloy through the use of liquid metallurgy stir casting to reinforce dual ceramic particles of Zirconium Diboride (ZrB₂) and Boron Carbide (B₄C). The weight percentage (wt%) of ZrB₂ was varied (0, 5, 10, and 15), while a constant 5 wt% of B₄C was maintained during this fabrication. The as-cast samples have been assessed using an Optical Microscope (OM) and a Scanning Electron Microscope (SEM) with Energy Dispersive Spectroscopy (EDS). The properties such as hardness, tensile strength, and wear characteristics of stir cast specimens were assessed to examine the impact of varying weight percentages of reinforcements in AA 2014 alloy. In particular, dry sliding wear behaviour was evaluated considering varied loads using a pin-on-disc tribotester. As the weight % of ZrB₂ grew and B₄C was incorporated, hybrid composites showed higher hardness, tensile strength, and wear resistance. Notably, the incorporation of a cumulative reinforcement consisting of 15 wt% ZrB₂ and 5 wt% B₄C resulted in a significant 31.86% increase in hardness and a 44.1% increase in tensile strength compared to AA 2014 alloy. In addition, it has been detected that wear resistance of hybrid composite pin (containing 20 wt% cumulative reinforcement) is higher than that of other stir cast wear test pins during the whole range of applied loads. Fractured surfaces of tensile specimens showed ductile fracture in the AA 2014 matrix and mixed mode for hybrid composites. Worn surfaces obtained employing higher applied load indicated abrasive wear with little plastic deformation for hybrid composites and dominant adhesive wear for matrix alloy. Hence, the superior mechanical and tribological performance of hybrid composites can be attributed to dual reinforcement particles being dispersed well and the effective transmission of load at this specific composition.