Investigation and Enhancement in Mechanical Properties of Aluminium 6063 by Silicon Carbide and Boron Carbide

Abstract

The current study utilised the stir casting procedure to create four distinct samples of Al-6063/ SiC/ B4C hybrid MMCs. The samples included varying weight percentages of SiC (0%, 8%, 6%, and 4% wt) and B4C (0%, 2%, 4%, and 6% wt ). Tests for the mechanical characteristics of Al-6063/SiC/B4C hybrid composites were conducted, including tensile, impact, hardness, and XRD analyses. Based on the results of the microstructural investigation performed using the X-ray Diffraction technique, the distribution of the reinforcing particles inside the aluminium matrix is rather uniform, and there is negligible porosity. Among the tested samples, sample-3 had the highest values for tensile strength (188.65 N/mm2), elongation (23.89 percent), impact energy (38 J), and hardness (62.1 HV). The mechanical tests showed that the Ultimate Tensile Strength (UTS) was 47% higher with 4% and 6% SiC and B4C reinforcement compared to the base alloy. & shortens the length. Results show that the created composite can replace heavier materials in high-friction parts like engine pistons and brake rotors.

Introduction

Composite materials are engineered by combining two or more distinct materials to achieve superior properties compared to individual components. Among these, Aluminium Metal Matrix Composites (AMMCs) have gained significant attention due to their lightweight nature, corrosion resistance, high strength-to-weight ratio, and improved mechanical performance. Reinforcements such as Silicon Carbide (SiC) and Boron Carbide (B4C) are commonly added to aluminium alloys to enhance hardness, strength, wear resistance, and durability. The stir casting process is widely used for manufacturing AMMCs because it is economical, simple, and suitable for large-scale production.

The study focuses on the fabrication and evaluation of AA6063 aluminium alloy reinforced with SiC and B4C particles using the stir casting technique. Previous research has shown that ceramic reinforcements such as Al?O?, TiO?, SiC, and B4C significantly improve the mechanical and microstructural properties of aluminium composites. However, further comparison of different reinforcement combinations at similar percentages is needed to identify the optimal composition.

Four composite samples were prepared:

• S1: 100% AA6063 (unreinforced)
• S2: 90% AA6063 + 8% SiC + 2% B4C
• S3: 90% AA6063 + 6% SiC + 4% B4C
• S4: 90% AA6063 + 4% SiC + 6% B4C

The stir casting process involved melting AA6063 aluminium at 900°C, preheating reinforcement particles to 500°C, stirring at 200 rpm for 10 minutes, and adding 1% magnesium to improve wettability between the matrix and reinforcement particles. The molten composite was then poured into molds and machined into standard specimens for tensile, compressive, hardness, impact, and XRD testing.

The experimental results demonstrated that reinforcement significantly improved the mechanical properties of the aluminium alloy. Among all compositions, Sample S3 (90% AA6063 + 6% SiC + 4% B4C) showed the best overall performance:

• Tensile Strength: Increased from 127.79 MPa (S1) to 188.65 MPa (S3).
• Compressive Strength: Increased from 172.4 MPa (S1) to 198.95 MPa (S3).
• Micro Vickers Hardness: Increased from 53.4 HV (S1) to 62.1 HV (S3).
• Impact Strength: Increased from 31 J (S1) to 38 J (S3).

Although S4 contained a higher percentage of B4C, its properties were slightly lower than S3, indicating that the 6% SiC and 4% B4C combination provides the most effective reinforcement balance. X-ray diffraction (XRD) analysis further confirmed the uniform distribution of SiC and B4C particles within the aluminium matrix, indicating successful composite fabrication.

Conclusion

Following conclusions are derived from the results: - 1) Aluminium metal matrix composite successfully produced by liquid stir casting technique by adding SiC (0%, 8%, 6%, and 4% wt) and B4C (0%, 2%, 4%, and 6% wt). 2) From the tensile test it was concluded that tensile strength is maximum at reinforcement of SiC (6%) & B4C (4%) added with the maximum tensile strength of 188.65 N/mm2 for sample-3. 3) The results from Table 5.1 shows that percentage elongation nearly increases with increase in percentage of reinforcement of B4C added and hence ductility also increases in the same manner. 4) Impact energy absorbed by the samples initially showed the increasing trend from sample-1 to sample-3 and then decreased for sample-3. Therefore, sample-3 and sample-1 have the maximum and minimum toughness respectively. 5) Hardness increases with the addition of reinforcement particles. Thus sample-3 was the hardest one having a hardness of 62.1 HV. 6) Results of the XRD test for the investigation of elements present in the different samples was satisfactory. The presence of reinforcements is found in the samples.

References

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Copyright

Copyright © 2026 Abhishek GUPTA, Dr. Pradeep Kumar Sharma, Surendra Kumar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.