Multi-response optimisation of wear parameters of B 4 C reinforced Al-Fe-Si composites: Using Taguchi-grey relational analysis

The current research investigates the effect of boron carbide (B₄C) reinforcement on the mechanical and sliding wear behaviour of Al-Fe-Si (AA8011) composites, fabricated using an ultrasonic-assisted stir-casting technique with varying B₄C weight fractions from 0% to 10%. Microstructural analysis, including SEM and EDS, confirmed the presence of reinforcement, improved particle dispersion, and grain refinement. The study found that the density of AA8011–B₄C composites decreases while porosity increases with higher B₄C content. Notably, the AA8011-6 wt.%B₄C composite exhibited a significant improvement in mechanical properties, with yield strength, tensile strength, and hardness rising by 91%, 55%, and 38%, respectively, compared to the unreinforced alloy. The optimisation of wear test parameters of AA8011-6 wt.% B₄C composites using Taguchi-grey relational analysis and analysis of variance, revealed that the lower wear and coefficient of friction were achieved at a load of 30 N, a disc velocity of 5 m/s, and a sliding distance of 1000 m. The wear test optimisation achieved a 95.67% grey relational grade improvement within the 95% predicted confidence interval.