Influence of Nano-Sized Ceramic Reinforcement Content on the Powder Characteristics and the Mechanical, Tribological, and Corrosion Properties of Al-Based Alloy Nanocomposites

In this study, B4C nanoparticles were incorporated into AA2024, one of the aluminum alloys with superior mechanical and wear properties, with the aim of further enhancing its mechanical, tribological, and corrosion performance. The nanocomposites were produced using mechanical milling followed by powder metallurgy techniques. The effects of nano-sized B4C additions on powder characteristics, microstructure, and physical, mechanical, tribological, and corrosion properties were systematically investigated through microhardness, density, SEM, XRD, bulk hardness, wear, and corrosion tests. B4C was added at weight fractions of 0–2 wt.%, and all samples were mechanically milled for 8 h. The results revealed a gradual reduction in powder particle size and a corresponding increase in particle microhardness with increasing B4C content. The sample reinforced with 2 wt.% nano-B4C exhibited an approximately 80% increase in hardness and around a 55% improvement in tensile strength compared to the unreinforced alloy. Wear resistance was significantly enhanced, showing up to an 8-fold improvement under a 5 N load and a 6-fold improvement under a 25 N load. Furthermore, corrosion resistance nearly doubled with the addition of B4C nanoparticles.