Experimental and ANOVA-Based Assessment of Wear, Density, and Thermal Conductivity in Al6005–B₄C Composites

The research examines that adding Boron Carbide (B₄C) particles to Al6005 alloy will create better mechanical properties and tribological characteristics and thermal performance. The composites with 2% and 4% and 6% B₄C through optimized die-casting parameters that included controlled casting temperature and stirring speed for achieving complete particle distribution. The systematic study of how different reinforcement levels affected wear rate, density, thermal conductivity and microstructural characteristics under 10N and 30N loading conditions. The experimental results indicates, increasing B₄C content through 6% B₄C composite produced the lowest wear rate under heavy load conditions because wear resistance improved with higher B₄C content. The microstructural analysis demonstrated that higher reinforcement levels resulted in better particle distribution which reduced structural defects such as cracks and voids that enhanced strength and durability. B₄C addition caused density to increase until reaching 4% and then the density decreased at 6% B₄C addition. The thermal conductivity of the material depends on both reinforcement levels and processing conditions because it reaches its highest value through optimal matrix–reinforcement interaction while showing minor changes at elevated reinforcement levels due to interfacial resistance. The statistical analysis through ANOVA revealed that composite composition served as the primary determinant which affected wear behavior. The regression models developed for wear rate and density and thermal conductivity achieved high predictive accuracy (R2 > 90%) while maintaining prediction errors below 10%. The optimized Al6005-B₄C composites possess superior wear resistance together with improved structural integrity which enables their use in high-load thermally demanding applications across automotive and aerospace and advanced manufacturing industries.