Encapsulate-fed AA6061/c-BN/SiC squeeze-cast composites for automotive applications: wear behaviour

Ceramic reinforcement may not improve the wear resistance of AA6061/c-BN/SiC (AMMC) composites due to difficulties in homogenous mixing, uniform distribution, and optimal interface wetting during stir casting. This study shows that Encapsulation-Fed two-step blending with squeeze-setup can improve microstructural alterations and composite quality. The Pin-on-Disc test followed ASTM G99 for optimal performance. This test measured wear losses over a set distance with 3–5 kg weights. The composite with 8% aluminium oxide demonstrated reduced wear losses than the 6% and 9% c-BN/SiC composites as load rose. The 6% c-BN/SiC composite demonstrated better wear durability due to its more homogeneous dispersion. The composite becomes harder and more wear-resistant with c-BN/SiC particles. This shows AMMC wear and performance. When compared to a composite with a normal 3% c-BN combination and 3% silicon carbide reinforcement, a hybrid composite with 6% silicon carbide reinforcement exhibits better tensile characteristics, hardness, and tribological capabilities.