Boron carbide is one of the potential neutron-shielding materials and its use can be maximized for structural shielding application by dispersing it into metal matrixes such as aluminum. Dispersion of B4C and its interfacial stability is a major issue during its processing. This investigation is on the synthesis of B4C-reinforced 6061 aluminum matrix composite by liquid–metal stir-casting technique under optimized conditions after solving the issues related to the processing, and evaluation of the structural, mechanical, and interfacial characteristics. During processing of composites, pretreatment of B4C particles is necessary to improve its dispersion. However, higher preheating temperatures above 300°C lead to particle agglomeration in the matrix due to the formation of B2O3 phase during preheating. B2O3 is formed due to the surface oxidation of B4C particles above 300°C and this glassy phase leads to particle sintering and lump formation. Incorporation of particles preheated at 250°C has shown uniform distribution of particles in the composite. Interfacial characterization of the composite and the extracted B4C particles from the matrix has shown the presence of interfacial reaction products such as AlB2, Al3BC, AlB12, and AlB10.

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Composites have played a key role in revolutionizing the automobile, marine, and aerospace industries. There is a constant attempt for the development of low‐density composite materials with superior mechanical and corrosion‐resistant properties for elevated temperature applications. Herein, an attempt is made to develop a nature‐inspired unique aluminum‐based composite with low‐density polymer (polyethylene terephthalate, i.e., soft material) reinforcement, which shows an enhancement in strength and toughness. The composite is processed using the easily scalable and simple friction stir processing technique. Mechanical properties of the uniformly reinforced aluminum composite show double ultimate strength and fivefold improvement in plasticity. The ultimate strength of the composite increases at elevated temperatures. The experimental observations are further supported by theoretical calculations and molecular dynamics simulations.

The study focuses on the effect of mono and combined addition of metallic and ceramic reinforcement particles on the microstructural and corrosion behavior of surface composites fabricated by friction stir processing. Molybdenum, possessing higher corrosion resistance compared to aluminum, is used as the metallic reinforcement, and boron carbide is used as ceramic reinforcement. Combined addition of boron carbide and molybdenum is used to study the effect of hybrid reinforcement on the corrosion behavior of Al 1050 surface composites. The effect of friction stir processing and reinforcement type on the electrochemical behavior of surface composites is analyzed through potentiodynamic polarization and impedance analysis. Reinforcement particles distributed on the Al matrix through friction stir processing affect the pitting corrosion behavior of surface composites. Post-corrosion microscopy analysis is carried out to understand the effect of the reinforcement particles on the pitting corrosion. The surface composites fabricated are free from any intermetallics. Surface composites with second processing pass showed better corrosion resistance due to more homogeneously distributed finer Mo particles in Al-Mo surface composites. Mono-reinforced surface composites exhibited an increase in the corrosion resistance, whereas the combined addition of reinforcements induced more galvanic effect in the surface composite leading to more severe corrosion.