The paper details the studies carried out on a dual-size particulate composite prepared by stir casting using A 356 aluminum alloy and B4C powders. Three composite compositions, viz., A356 plus 2% B4C (44µm size and 105µm size in 1:1 ratio), 4% B4C (3:1 ratio), and 6% B4C (1:3 ratio) were cast in finger molds, from which test specimens were prepared for hardness and tensile tests as well as for metallography. Vickers hardness tests, tensile tests and microstructure analysis using an optical microscope were conducted. The results obtained indicated that the B4C particles were evenly distributed in the alloy matrix. EDS also revealed the presence of B4C in all the three composites. In general, the hardness and tensile strengths increased with increase in concentration B4C powders. While the increase in hardness was increases less than 15%, there was significant increase (more than 35 %) in tensile strength. However, the ductility represented by % elongation, which was already very low in A 356 cast alloy (24.2%,), further decreased in composites. Tensile fractography results shows inter crystalline fracture where the breakage in the B4C particle instead of deboning were observed.
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