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.
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