The presented study investigates the effects of weight percentages of boron carbide reinforcement on the wear properties of aluminum alloy composites. Composites were fabricated via ball milling and the hot extrusion process. During the fabrication of composites, B₄C content was varied (0, 5, and 10 wt.%), as well as milling time (0, 10, and 20 h). Microstructural observations with SEM microscopy showed that with an increase in milling time, the distribution of B₄C particles is more homogeneous without agglomerates, and that an increase in wt.% of B₄C results in a more uniform distribution with distinct grain boundaries. Taguchi and ANOVA analyses are applied in order to investigate how parameters like particle content of B₄C, normal load, and milling time affect the wear properties of AA2024-based composites. The ANOVA results showed that the most influential parameters on wear loss and coefficient of friction were the content of B₄C with 51.35% and the normal load with 45.54%, respectively. An artificial neural network was applied for the prediction of wear loss and the coefficient of friction. Two separate networks were developed, both having an architecture of 3-10-1 and a tansig activation function. By comparing the predicted values with the experimental data, it was demonstrated that the well-trained feed-forward-back propagation ANN model is a powerful tool for predicting the wear behavior of Al2024-B₄C composites. The developed models can be used for predicting the properties of Al2024-B₄C composite powders produced with different reinforcement ratios and milling times.

This investigation is dedicated to producing hybrid nanocomposites based on AA2024, achieved through the utilization of powder metallurgy methods encompassing mechanical milling and hot pressing. The research focused on studying how changes in B₄C content influence the mechanical, wear, and corrosion behavior of AA2024/h-BN/B₄C hybrid nanocomposites. The findings revealed that as the B₄C content increased, the relative density values decreased, and higher porosity values were observed in the hybrid nanocomposite samples. Among the tested samples, the hybrid nanocomposite with 4 wt% B₄C exhibited the most favorable properties. It demonstrated significantly higher hardness and ultimate tensile strength compared to AA2024 matrix alloy, with values of 161 HB and 372 MPa, respectively. In contrast, the matrix alloy showed hardness and ultimate tensile strength values of 105 HB and 237 MPa, respectively. Furthermore, the wear resistance of hybrid nanocomposite with 4 wt% B₄C displayed approximately 14 times greater wear resistance under 40 N load compared to the unreinforced AA2024 matrix alloy. The corrosion test results have revealed that the corrosion resistance of the hybrid nanocomposite reinforced with 4wt% B₄C is nearly 47% higher compared to the corrosion resistance of the unreinforced AA2024 alloy. This nanocomposite exhibits the highest polarization resistance of 5.21 Ω.cm².