Mechanical Characterization of Al6061 Hybrid Composites Reinforced with Boron Carbide and Fly Ash via Stir Casting

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 1711 1719
    By

    Borigorla Venu,

  • Devunuri Suresh,

  • Sai Sarath Kruthiventi,

  • Gurram Narendra Santosh Kumar,

  • Durga Hemanth Kumar K,

  1. Assistant Professor, Department of Mechanical Engineering, Vignan’s Foundation for Science Technology & Research Deemed to be University, Hyderabad Campus Deshmukhi, Telangana, India
  2. Assistant Professor, Department of Automobile Engineering, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, Telangana, India
  3. Assistant Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Greenfields, Guntur, Andhra Pradesh, India
  4. Placement officer, MNR University, Fasalwadi, Sangareddy, Hyderabad, Telangana, India
  5. Assistant Professor, Department of Mechanical Engineering, Sagi Rama Krishnam Raju Engineering College (A), Bhimavaram, Andhra Pradesh, India

Abstract

The growing demand for lightweight, cost-effective, and high-performance materials in structural and automotive sectors has accelerated the development of hybrid metal matrix composites (HMMCs). This study investigates Al6061 alloy as the matrix material, reinforced with varying weight fractions of boron carbide (B₄C), a high-hardness ceramic, and fly ash, an economical industrial byproduct, to assess their synergistic effects on mechanical properties. Hybrid composites were synthesized using the stir casting technique to ensure uniform dispersion of reinforcements. Five compositions were evaluated: the base alloy, 5 wt.% B₄C + 5 wt.% fly ash, 7.5 wt.% B₄C + 7.5 wt.% fly ash, 10 wt.% B₄C + 10 wt.% fly ash, and 12.5 wt.% B₄C + 12.5 wt.% fly ash. Mechanical performance was assessed through hardness testing, tensile strength analysis, and compressive strength evaluation. Results revealed that B₄C significantly improved hardness and strength due to its intrinsic properties and strong interfacial bonding, while fly ash contributed to weight reduction and cost efficiency. Among the tested compositions, the hybrid with 7.5 wt.% B₄C and 7.5 wt.% fly ash demonstrated superior tensile and compressive strength, indicating an optimal balance between mechanical enhancement and material sustainability. This study underscores the potential of B₄C and fly ash as effective hybrid reinforcements in Al6061 composites and promotes the sustainable integration of industrial waste in advanced engineering materials

.

Keywords: Al6061, fly ash, B₄C, stir casting, tensile.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Borigorla Venu, Devunuri Suresh, Sai Sarath Kruthiventi, Gurram Narendra Santosh Kumar, Durga Hemanth Kumar K. Mechanical Characterization of Al6061 Hybrid Composites Reinforced with Boron Carbide and Fly Ash via Stir Casting. Journal of Polymer & Composites. 2026; 14(01):1711-1719.
How to cite this URL:
Borigorla Venu, Devunuri Suresh, Sai Sarath Kruthiventi, Gurram Narendra Santosh Kumar, Durga Hemanth Kumar K. Mechanical Characterization of Al6061 Hybrid Composites Reinforced with Boron Carbide and Fly Ash via Stir Casting. Journal of Polymer & Composites. 2026; 14(01):1711-1719. Available from: https://journals.stmjournals.com/jopc/article=2026/view=238807


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Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 26/11/2025
Accepted 20/12/2025
Published 21/03/2026
Publication Time 115 Days
61

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