This study investigates the synergistic effect of boron carbide (B4C) and graphene nanoparticles (GNPs) on the mechanical and tribological properties of AA8011-based aluminum composites. Hybrid composites containing 6 wt% B4C and varying graphene contents (0.5–1.5 wt%) were fabricated via ultrasonic-assisted stir casting to ensure uniform particle distribution. Microstructural analysis confirmed homogeneous dispersion at optimal graphene loading, while excessive addition led to agglomeration. The results reveal substantial improvements in mechanical properties: hardness increased from 54.72 HV (S1) to 87.21 HV (S4), a 59.4% rise, while tensile strength improved from 107.86 MPa to 193.3 MPa (79.1% increase), and Yield strength rose from 78.16 MPa to 171.04 MPa (118.8% increase), attributed to grain refinement, and effective load transfer mechanisms. However, ductility reduced from 18.26% to 6.5%, a 64.4% drop, reflecting the strength–ductility trade-off. Tribological evaluation revealed notable reductions in wear rate by ∼55% and coefficient of friction decreased by ∼36% at 1 wt.% graphene due to the formation of a stable graphene-rich tribofilm. However, further graphene addition caused clustering, leading to a marginal decline in performance. The synergy of B4C and graphene in AA8011 alloy delivers lightweight composites with optimally balanced strength and wear resistance for advanced engineering applications.
ŞenelMCGürbüzMKoçE. Fabrication and characterization of synergistic Al-SiC-GNPs hybrid composites. Compos. Part B Eng.2018; 154: –9.
2.
ChinS. Recent progress in the development and properties of novel metal matrix nanocomposites reinforced with carbon nanotubes and graphene nanosheets. Mater Sci Eng R Rep2013; 74: 281–350.
3.
RaoRNDasS. Effect of SiC content and sliding speed on the wear behaviour of aluminium matrix composites. Mater Des2011; 32: 1066–1071.
4.
GollaCBRaoRNIsmailS. Triboinformatics Approach for Prediction of High-Stress Abrasive Wear and Coefficient of Friction in Al/TiC Nanocomposites Using Machine Learning Techniques. ASME J Tribo2025; 147. DOI: 10.1115/1.4066415
5.
TalluriBKNarasimha RaoRÖzcanM, et al.Evaluating mechanical and tribological performance of B4C reinforced aluminum composites with predictive machine learning models. Results Eng.2025; 27: 106503. DOI: 10.1016/j.rineng.2025.106503
6.
ChandrasekarPNatarajanSRamkumarKR. Influence of carbide reinforcements on accumulative roll bonded Al 8011 composites. Mater Manuf Process2019; 34: 889–897.
7.
KhakbizMAkhlaghiF. Synthesis and structural characterization of Al-B4C nano-composite powders by mechanical alloying. J Alloys Compd2009; 479: 334–341.
8.
BaradeswaranAElaya PerumalA. Influence of B4C on the tribological and mechanical properties of Al 7075-B4C composites. Compos. Part B Eng.2013; 54: 146–152.
9.
ChenHSWangWXLiYL, et al.The design, microstructure and tensile properties of B4C particulate reinforced 6061Al neutron absorber composites. J Alloys Compd2015; 632: 23–29.
10.
ArunJAnsalam RajTGReby RoyKE, et al.Fatigue life, distortion behavior of AA 8011- nano B4C composite using simulated acoustic emission technique – an experimental and statistical appraisal. Int J Fatigue2022; 164: 107168.
11.
WangC, et al.Microstructure and Properties of Aluminum–Graphene–SiC Matrix Composites after Friction Stir Processing. Materials (Basel)2024; 17: 979. DOI: 10.3390/ma17050979
12.
KumarBSP, et al.Optimization and Wear Properties for the Composites of Metal Matrix AA8011/Boron Nitride Using Taguchi Method. J Nanomater2022; 2022. DOI: 10.1155/2022/6957545.
13.
GudipudiSNagamuthuSSubbianKS, et al.Enhanced mechanical properties of AA6061-B4C composites developed by a novel ultra-sonic assisted stir casting. Eng. Sci. Technol. an Int. J.2020; 23: 1233–1243.
14.
LeeCWeiXKysarJW, et al.Of monolayer graphene. Science (80-.)2008; 321: 385–388.
15.
Prasad ReddyAVamsi KrishnaPRaoRN. Tribological behaviour of Al6061–2SiC-xGr hybrid metal matrix nanocomposites fabricated through ultrasonically assisted stir casting technique. Silicon2019; 11: 2853–2871.
16.
MoghadamADSchultzBFFergusonJB, et al.Functional metal matrix composites: self-lubricating, self-healing, and nanocomposites-an outlook. Jom2014; 66: 872–881.
17.
VeličkovićSGarićSStojanovićB, et al.Tribological properties of aluminium matrix nanocomposites. Appl. Eng. Lett.2016; 1: 72–79.
18.
LakshmaiyaN, et al.Dual-Scale evaluation of hybrid al-SiC/graphene composites: mechanical properties and deep learning-driven machinability insights. Results Eng.2025; 25: 105742. DOI: 10.1016/j.rineng.2025.105742
19.
SabryIGhafaarMAMouradAHI, et al.Stir casted SiC-Gr/Al6061 hybrid composite tribological and mechanical properties. SN Appl. Sci.2020; 2: –8.
20.
ParkBLeeDJoI, et al.Automated quantification of reinforcement dispersion in B4C/Al metal matrix composites. Compos. Part B Eng.2020; 181: 107584.
21.
SinghJChauhanA. Characterization of hybrid aluminum matrix composites for advanced applications - A review. J Mater Res Technol2016; 5: 159–169.
22.
BalamuruganK, et al.Effect of TiC/RHA on solid particle erosion of Al6061 hybrid composites fabricated through a 2-step ultrasonic-assisted stir casting process. J Mater Res Technol2023; 25: 4888–4900.
23.
ToptanFKilicarslanAKaraaslanA, et al.Processing and microstructural characterisation of AA 1070 and AA 6063 matrix B4Cp reinforced composites. Mater Des2010; 31: S87–S91.
24.
ShorowordiKMLaouiTHaseebASMA, et al.Microstructure and interface characteristics of B4C, SiC and Al2O3 reinforced Al matrix composites: a comparative study. J Mater Process Technol2003; 142: 738–743.
25.
RajRRYoganandhJSaravananMSS, et al.Effect of graphene addition on the mechanical characteristics of AA7075 aluminium nanocomposites. Carbon Lett.2021; 31: 125–136.
26.
KhalidMYUmerRKhanKA. Review of recent trends and developments in aluminium 7075 alloy and its metal matrix composites (MMCs) for aircraft applications. Results Eng.2023; 20: 101372.
27.
LiuSWangYMuthuramalingamT, et al.Effect of B4C and MOS2 reinforcement on micro structure and wear properties of aluminum hybrid composite for automotive applications. Compos. Part B Eng.2019; 176: 107329.
LakshmaiyaNVijethaKDossASA, et al.Dual-scale evaluation of hybrid Al-SiC/graphene composites: mechanical properties and deep learning-driven machinability insights. Results Eng.2025; 27: 105742.
30.
ZengXYuJFuD, et al.Wear characteristics of hybrid aluminum-matrix composites reinforced with well-dispersed reduced graphene oxide nanosheets and silicon carbide particulates. Vacuum2018; 155: 364–375.
31.
TalluriBKRaoRN. Multi-response optimisation of wear parameters of B4C reinforced Al-Fe-Si composites: Using Taguchi-grey relational analysis. Proc Inst Mech Eng Part E J Proc Mech Eng2024. DOI: 10.1177/09544089241284024
32.
IdrisiAHMouradAHI. Conventional stir casting versus ultrasonic assisted stir casting process: mechanical and physical characteristics of AMCs. J Alloys Compd2019; 805: 502–508.
33.
TalluriBKRaoRN. D-Optimal design approach for screening, optimization, and interaction analysis of abrasive wear parameters in AA8011 / B 4 C composites. Proc Inst Mech Eng Part J J Eng Tribol2025. DOI: 10.1177/13506501251390290
34.
RaoRNDasS. Effect of matrix alloy and influence of SiC particle on the sliding wear characteristics of aluminium alloy composites. Mater Des2010; 31: 1200–1207.
35.
ShangFChenSZhangC, et al.The effect of si and B on formability and wear resistance of preset-powder laser cladding W10V5Co4 alloy steel coating. Opt Laser Technol2021; 134: 106590.
36.
HasanMSWongTRohatgiPK, et al.Analysis of the friction and wear of graphene reinforced aluminum metal matrix composites using machine learning models. Tribol Int2022; 170: 107527.
37.
KumarDSeetharamRPonappaK. Synergic effects of interfacial compounds and strengthening mechanisms in enhancing mechanical strength of al-B4C-GNPs hybrid nanocomposite. Met Mater Int2025; 31: 1836–1857.
38.
WangXJiangXSunH, et al.Microstructure and mechanical properties of bioinspired laminated Al matrix hybrid reinforced with B4C and graphene nanoplatelets. Mater Charact2022; 193: 112307.
39.
ZhaoLLuHGaoZ. Microstructure and mechanical properties of al/graphene composite produced by high-pressure torsion. Adv Eng Mater2015; 17: 976–981.
40.
BharathirajaPXaviorAM. Effect of B4C and graphene on the microstructural and mechanical properties of Al6061 matrix composites. J Mater Res Technol2024; 31: 496–505.
41.
Veeresh KumarGB, et al.Investigation of the tribological characteristics of aluminum 6061-reinforced titanium carbide metal matrix composites. Nanomaterials2021; 11: 1–17.
42.
RenrengIArsyadHTarminsyahT. Comparative analysis of microscale and nanoscale alumina reinforcement in al-cu-mg-Al2O3 composites: impacts on density, porosity, and hardness. Rev. des Compos. des Mater. Av.2023; 33: 399–409.
43.
AqidaSNGhazaliMIHashimJ. Effect of porosity on mechanical properties of metal matrix composite: an overview. J. Teknol2012; 40. DOI: 10.11113/jt.v40.395
44.
AlanemeKKAdemiluaBOBodunrinMO. Mechanical properties and corrosion behaviour of aluminium hybrid composites reinforced with silicon carbide and bamboo leaf ash. Tribol. Ind.2013; 35: 25–35.
45.
CaoH, et al.The stress concentration mechanism of pores affecting the tensile properties in vacuum die casting metals. Materials (Basel)2020; 13: 3019. DOI: 10.3390/ma13133019
46.
MansouriK, et al.Numerical Modeling and Optimization of Mechanical Properties in Porous Aluminum Matrix Composites Reinforced with SiC Particles. Mater Res2025; 28. DOI: 10.1590/1980-5373-MR-2024-0474
47.
Bawa’nehHLababnehBMalkawiAM, et al.Investigation of the mechanical properties of an aluminum (Al 6061-T6)/graphene/bentonite hybrid nanocomposite experimentally and through finite element analysis study. Mater. Adv.2024; 6: 1031–1041.
48.
MaddaiahKCKumarGBVPramodR. Studies on the Mechanical, Strengthening Mechanisms and Tribological Characteristics of AA7150-Al2O3 Nano-Metal Matrix Composites. J Compos Sci2024; 8: 97. DOI: 10.3390/jcs8030097
49.
BannaravuriPKBirruAK. Strengthening of mechanical and tribological properties of Al-4.5%Cu matrix alloy with the addition of bamboo leaf ash. Results Phys2018; 10: 360–373.
50.
MahakurVKBhowmikSPatowariPK. Tribo-informatics evaluation of dry sliding friction of silanized jute filler reinforced epoxy composites using machine learning techniques. Tribol Int2023; 183: 108388.
51.
ZhangJZhaoXYangM, et al.Microstructural evolution and mechanical properties of titanium matrix composites with second-phase dendritic TiC improved through B4C additions. Ceram Int2024; 50: 17482–17491.
52.
KuppusamyAKGovindaswamyS. Influence of ZrB2 on the Tribomechanical Properties of Aluminium Matrix Composites: A Review. Results Eng2025; 26: 104943. DOI: 10.1016/j.rineng.2025.104943
53.
VenkatramanMXaviorMA. Microstructural study and property evaluation of graphene reinforced AA2195 metal matrix composites. Results Eng.2025; 25: 104492.
54.
NietoAYangHJiangL, et al.Reinforcement size effects on the abrasive wear of boron carbide reinforced aluminum composites. Wear2017; 390–391: 228–235.
55.
KumarPKumarBPratapS, et al.Synthesis and predictive modelling of wear behaviour in hybrid aluminum composites. Results Eng.2025; 26: 104612.
56.
SharmaSK, et al.Progress in Aluminum-Based Composites Prepared by Stir Casting: Mechanical and Tribological Properties for Automotive, Aerospace, and Military Applications. Lubricants2024; 12: 421. DOI: 10.3390/lubricants12120421
57.
NaikSNWalleySM. The Hall–petch and inverse Hall–petch relations and the hardness of nanocrystalline metals. J Mater Sci2020; 55: 2661–2681.
58.
BabuCRaoRNIsmailS, et al.Development of hybrid aluminum nanocomposites for automotive applications : an in-depth analysis using experimental approaches and predictive machine learning techniques. J. Mater. Res. Technol.2025; 36: 4383–4399. DOI: 10.1016/j.jmrt.2025.04.114
59.
LinF, et al.Characterisation of microstructure, microhardness and tribological properties of Al matrix hybrid nanocomposites reinforced with B4C and in-situ GNSs. Wear2023; 522: 204691.
60.
SachitTSBongaleAKumarS, et al.Wear performance analysis of B4C and graphene particles reinforced Al-Cu alloy based composites using Taguchi method. J Mech Behav Mater2023; 32. DOI: 10.1515/jmbm-2022-0274
61.
ÇelebiMÇanakçıAGülerO, et al.A study on the improvement of wear and corrosion properties of ZA40/Graphene/B4C hybrid nanocomposites. J Alloys Compd2023; 966: 171628. DOI: 10.1016/j.jallcom.2023.171628
62.
RaoRNDasSTulasi DeviSL. Seizure pressure and sliding velocity diagrams on tribological behavior of Al alloy composites in as-cast and heat-treated conditions. Tribol Int2014; 80: –6.
63.
Abbas ShafqatQ, et al.Mechanical, tribological, and electrochemical behavior of hybrid aluminum matrix composite containing boron carbide (B4C) and graphene nanoplatelets. J Mater Res2019; 34: 3116–3129.
64.
BermanDErdemirASumantAV. Graphene: a new emerging lubricant. Mater Today2014; 17: 31–42.
65.
ValizadeNFarhatZ. A Review on Abrasive Wear of Aluminum Composites: Mechanisms and Influencing Factors. J Compos Sci2024; 8: 149. DOI: 10.3390/jcs8040149
66.
XuYFuKLiuK, et al.A state of the art review of the tribology of graphene/MoS2 nanocomposites. Mater. Today Commun.2023; 34: 105108.
67.
SenthilVBalasubramanianERajuGS, et al.Drilling Studies on MWCNT- and Zirconia-Reinforced Aluminium Alloy 8011 Hybrid Composite: A Machine Learning Approach. Arab J Sci Eng2024. DOI: 10.1007/s13369-024-08792-2
68.
WangXJiangXSunH, et al.Microstructures and mechanical properties of Al nanocomposites hybrid-reinforced with B4C, carbon nanotubes and graphene nanoplatelets. Mater Sci Eng B2023; 293: 116457.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
