Manjunatha, C.Varun, K.R.Nagaraja, K.C.Soni, P.K.Kumar, R.S.Prasad, C.Kumar, P.Nithesh, K.G.2026-02-032025Journal of The Institution of Engineers (India): Series D, 2025, 106, 3, pp. 1841-185022502122https://doi.org/10.1007/s40033-024-00792-8https://idr.nitk.ac.in/handle/123456789/19911Two or more elements with different physical and chemical characteristics make up the composite material. The composite may be prepared using a variety of methods, but stir casting is a popular choice since it is easy to use and reasonably priced. In this investigation, stir casting was used to create AA6061-Boron Carbide (B<inf>4</inf>C) composites. Composites with 10% weight percentage of B<inf>4</inf>C were selected for wear analysis. The Taguchi technique was applied to the wear study in order to identify the ideal values. Utilizing a Pin-on-Disk testing device under dry sliding circumstances, anthropological investigations were carried out. With B<inf>4</inf>C content and wear depth as the system output, the three factors load (N), sliding distance (SD), and sliding velocity (SV) were evaluated using the L27 orthogonal array. To comprehend the impact of factors and how they contribute to wear loss, analysis of variance was used. Experimental tests were conducted to validate the analysis results using the optimal values. Scanning Electron Microscopic (SEM) analysis of the samples revealed both abrasive and adhesive wear on the contact surfaces of the specimens, aiding in understanding the wear mechanisms in the composites. © The Institution of Engineers (India) 2024.AdhesivesBoron carbideScanning electron microscopyAa6061Composites materialOptimisationsOptimization of processing parametersPhysical and chemical characteristicsReasonably pricedStir castingTaguchiTaguchi methodologyWear performanceWear of materials