High entropy (HfTiZrVNb)B₂ ceramic particulate reinforced Al matrix composites: Synthesis, mechanical, microstructural and thermal characterization

This study aims to introduce a novel type of particulate reinforced Al matrix composite. High entropy (HfTiZrVNb)B₂ ceramic particulate reinforced Al matrix composites were produced via a combined process of different powder metallurgy methods. Firstly, boride compounds (HfB₂, TiB₂, ZrB₂, VB₂, NbB₂) were synthesized in the laboratory scale using the related metal oxide, boron oxide, and magnesium by mechanochemical synthesis (MCS) and leaching processes under optimum conditions. Secondly, the synthesized and purified boride powders were mixed in equimolar ratios using a planetary ball mill for 72 h, and they were sintered at 2000 °C under 30 MPa via spark plasma sintering (SPS). Thirdly, equimolar high entropy (HfTiZrVNb)B₂ bulks were crushed, converted into powder forms, and added into Al powders at different amounts as 1, 2, 5, 10, and 15 wt %. Lastly, these powder blends were mechanically alloyed in a vibratory ball mill for 6 h, cold pressed and pressureless sintered at 630 °C for 2 h. For characterization techniques, X-ray diffractometry (XRD), thermal analysis, scanning electron microscopy/energy dispersive spectrometry (SEM/EDS), density measurements using pycnometer and Archimedes' methods, microhardness and dry sliding wear tests were conducted on the sintered composites. The highest hardness (∼1.5 GPa) and the lowest wear rate (∼0.0012 mm³/Nm) were obtained in the Al-15 wt % (HfTiZrVNb)B₂ sample.