Tribomechanical Performance of AA6061/B4C–Gr Nanocomposites Fabricated by A Combined Stir-Ultrasonic-Squeeze Casting Process Utkarsh Pandey, Bappa Acherjee, Gayatri Paul, Joyjeet Ghose Chemistryselect, 2025 This work presents the manufacturing and detailed evaluation of AA6061‐based aluminium metal matrix hybrid nanocomposites (AMMHNCs) reinforced with boron carbide (B 4 C) and graphite (Gr) nanoparticles, produced through an integrated stir–ultrasonic–squeeze (S + U + Sq) casting process. Eight compositions were fabricated with B 4 C varied from 1–4 wt.% and a constant 2 wt.% Gr, including single (B 4 C/ Gr) and hybrid (B 4 C + Gr) nanocomposites. The influence of reinforcements (both hybrid and single reinforcement) on the microstructure, hardness, tensile strength, and dry sliding wear behavior was systematically investigated. The integrated casting process enabled uniform nanoparticle dispersion, refined equiaxed grains, and minimized porosity. The A3B2G composite (3 wt.% B 4 C + 2 wt.% Gr) achieved peak hardness (68.61 BHN) and tensile strength (232.59 MPa), while the A2B2G variant (2 wt.% B 4 C + 2 wt.% Gr) offered the best balance of strength and wear resistance, with lower wear rate and friction. These results validate the process efficiency and highlight the importance of reinforcement optimization for various applications.
A novel integrated stir-ultrasonic-squeeze casting route for fabricating AA6061-based metal matrix hybrid nanocomposites with enhanced tribomechanical properties Utkarsh Pandey, Bappa Acherjee, Gayatri Paul, Joyjeet Ghose Journal of Micromechanics and Microengineering, 2025 This study introduces a novel integrated stir–ultrasonic–squeeze casting technique for fabricating high-performance aluminium metal matrix hybrid nanocomposites (AMMHNCs) based on AA6061 alloy, reinforced with 3 wt.% boron carbide (B4C) and 2 wt.% graphite (Gr) nanoparticles. Existing fabrication methods often suffer from nanoparticle agglomeration, poor dispersion, and high porosity, which compromise mechanical and tribological performance. The proposed approach overcomes these limitations by combining mechanical stirring for initial dispersion, ultrasonic agitation for deagglomeration and uniform distribution, and squeeze casting for densification and improved interfacial bonding. Microstructural analysis confirmed significant grain refinement and homogeneous reinforcement distribution, particularly in the integrated process. The fabricated AMMHNCs exhibited enhanced mechanical properties, achieving a Brinell hardness of 68.61 BHN, ultimate tensile strength of 175.91 MPa, and elongation of 5.09%. Tribological testing revealed the lowest wear rate and coefficient of friction among all compared processes. These improvements are attributed to the synergistic effects of Hall–Petch grain boundary strengthening and Orowan dislocation pinning mechanisms enabled by nanoscale reinforcements and optimised processing. Compared to conventional stir casting, ultrasonic-assisted casting, and other methods, the proposed hybrid technique offers a scalable, cost-effective, and superior route for producing lightweight, wear-resistant nanocomposites for advanced engineering applications.
Rheological properties and tribological performance of tungsten disulfide nanosheet dispersed nanofluids A Gaurav, P Jha, A Roy, G Paul Nano-Structures & Nano-Objects 46, 101683 , 2026 2026
by Combined Stir-Ultrasonic-Squeeze Casting P Verma, G Paul, J Ghose, V Pandey Advances in Structural Integrity for Mechanical, Civil, and Aerospace … , 2026 2026
Comparative study of tribomechanical properties of B 4 C/Gr and SiC/Gr reinforced AA6061 hybrid nanocomposites via stir-ultrasonic-squeeze casting U Pandey, P Verma, D Ghosh, G Paul, B Acherjee, B Kumar, J Ghose Composite Interfaces, 1-29 , 2026 2026
Tribomechanical Performance of AA6061/B 4 C–Gr Nanocomposites Fabricated by A Combined Stir‐Ultrasonic‐Squeeze Casting Process U Pandey, B Acherjee, G Paul, J Ghose ChemistrySelect 10 (42), e04662 , 2025 2025 Citations: 4
High-Temperature Sliding Wear Behavior of Laser Clad Martensitic Stainless Steel on AISI 4140 Steel N Mohite, G Paul, I Manna Metallurgical and Materials Transactions A 56 (11), 4854-4872 , 2025 2025
Temperature-responsive tribological performance of ball milled graphene oxide dispersed nanolubricants under sliding reciprocation A Gaurav, G Paul Journal of Molecular Liquids, 128710 , 2025 2025 Citations: 1
A novel integrated stir–ultrasonic–squeeze casting route for fabricating AA6061-based metal matrix hybrid nanocomposites with enhanced tribomechanical properties U Pandey, B Acherjee, G Paul, J Ghose Journal of Micromechanics and Microengineering 35 (9), 095017 , 2025 2025 Citations: 6
Mechanical and Tribological Performance of AA6061 Hybrid Nanocomposites Produced by Stir-Ultrasonic-Squeeze Casting Method U Pandey, J Ghose, B Acherjee, G Paul Journal of Materials Engineering and Performance, 1-15 , 2025 2025 Citations: 6
Structure-property correlation of alumina pyramidoids fabricated by direct ink writing A Kumar, R Singh, S Mandal, G Paul, B Maji, M Mallik Manufacturing Letters , 2025 2025
Performance Evaluation of T6 Heat-Treated AA6061-Hybrid Nanocomposite Cam versus Actual Chilled Cast-Iron Automotive Cam U Pandey, A Priyanshu, B Acherjee, G Paul, J Ghose Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2025 2025 Citations: 4
Enhanced tribological performance of nanolubricants dispersed with mechanically exfoliated graphene oxide nanosheets A Gaurav, G Paul Diamond and Related Materials 153, 112097 , 2025 2025 Citations: 6
Enhanced mechanical and tribological performance of AA2014-SiC metal matrix nanocomposites fabricated by a novel stir-ultrasonic-squeeze casting process P Verma, J Ghose, G Paul, V Pandey, U Pandey International Journal of Cast Metals Research 38 (1), 21-35 , 2025 2025 Citations: 8
Instability in the Propagation of the Quench Front during Rewetting by Bottom Flooding due to External Exit Obstructions G Paul, PK Das, I Manna Interfacial Phenomena and Heat Transfer 13 (2), 49-61 , 2024 2024
INVESTIGATION OF MECHANICAL AND TRIBOLOGICAL PROPERTIES OF ALUMINIUM HYBRID NANOCOMPOSITE PRODUCED BY NOVEL STIR-ULTRASONIC-SQUEEZE CASTING METHOD. U PANDEY, J GHOSE, B ACHERJEE, G PAUL MM Science Journal , 2024 2024 Citations: 7
Synthesis and Characterization of Graphene Oxide Nanosheets by Mechanical Exfoliation Using Ball Milling A Gaurav, G Paul Journal of Physics: Conference Series 2818 (1), 012034 , 2024 2024 Citations: 5
Laser flash technique as an efficacious assessment approach for thermal conductivity of tungsten disulphide nanofluids G Paul, P Jha, A Roy, I Manna Journal of Molecular Liquids 404, 124996 , 2024 2024 Citations: 7
Mechanical and wear properties of graphite reinforced aluminum metal matrix composites processed by ultrasonic-stir-squeeze casting P Verma, G Paul, J Ghose, V Pandey Journal of Materials Engineering and Performance 33 (11), 5319-5330 , 2024 2024 Citations: 18
Effect of molybdenum disulfide dispersed nanolubricants on the tribological properties of mating stainless steel pair G Paul, P Jha, A Jha, A Roy Journal of Materials Engineering and Performance 33 (11), 5291-5305 , 2024 2024 Citations: 9
Mechanical and Tribological Properties of Al/n-Al 2 O 3 Composites Processed by Combined Stir-Ultrasonic-Squeeze Casting P Verma, G Paul, J Ghose, V Pandey Structural Integrity Conference and Exhibition, 161-174 , 2022 2022
Chrono-photographic visualization and characterization of the flow regimes in rewetting by bottom flooding G Paul, PK Das, I Manna Experimental Thermal and Fluid Science 139, 110727 , 2022 2022 Citations: 5
MOST CITED SCHOLAR PUBLICATIONS
Techniques for measuring the thermal conductivity of nanofluids: a review G Paul, M Chopkar, I Manna, PK Das Renewable and Sustainable Energy Reviews 14 (7), 1913-1924 , 2010 2010 Citations: 530
Synthesis, characterization, and thermal property measurement of nano-Al95Zn05 dispersed nanofluid prepared by a two-step process G Paul, J Philip, B Raj, PK Das, I Manna International Journal of Heat and Mass Transfer 54 (15-16), 3783-3788 , 2011 2011 Citations: 266
Nanolubricants dispersed with graphene and its derivatives: an assessment and review of the tribological performance G Paul, H Hirani, T Kuila, NC Murmu Nanoscale 11 (8), 3458-3483 , 2019 2019 Citations: 194
Thermo-physical property measurement of nano-gold dispersed water based nanofluids prepared by chemical precipitation technique G Paul, T Pal, I Manna Journal of colloid and interface science 349 (1), 434-437 , 2010 2010 Citations: 159
Tribological behavior of dodecylamine functionalized graphene nanosheets dispersed engine oil nanolubricants G Paul, S Shit, H Hirani, T Kuila, NC Murmu Tribology International 131, 605-619 , 2019 2019 Citations: 121
Concentration and size dependence of nano-silver dispersed water based nanofluids G Paul, S Sarkar, T Pal, PK Das, I Manna Journal of colloid and interface science 371 (1), 20-27 , 2012 2012 Citations: 111
Assessment of the process of boiling heat transfer during rewetting of a vertical tube bottom flooded by alumina nanofluid G Paul, PK Das, I Manna International Journal of Heat and Mass Transfer 94, 390-402 , 2016 2016 Citations: 68
Synthesis, characterization and studies on magneto-viscous properties of magnetite dispersed water based nanofluids G Paul, PK Das, I Manna Journal of Magnetism and Magnetic Materials 404, 29-39 , 2016 2016 Citations: 59
Enhanced thermal conductivity of nano-SiC dispersed water based nanofluid O Manna, SK Singh, G Paul Bulletin of Materials Science 35 (5), 707-712 , 2012 2012 Citations: 53
Droplet oscillation and pattern formation during Leidenfrost phenomenon G Paul, PK Das, I Manna Experimental Thermal and Fluid Science 60, 346-353 , 2015 2015 Citations: 38
Nanoparticle deposition from nanofluid droplets during Leidenfrost phenomenon and consequent rise in transition temperature G Paul, PK Das, I Manna International Journal of Heat and Mass Transfer 148, 119110 , 2020 2020 Citations: 28
Nd: YAG laser micromachining of alumina–aluminium interpenetrating phase composite using response surface methodology AS Kuar, G Paul, S Mitra International Journal of Machining and Machinability of Materials 1 (4), 432-444 , 2006 2006 Citations: 26
Rewetting of Vertical Pipes by Bottom Flooding Using Nanofluid as a Coolant G Paul, PK Das, I Manna Journal of Heat Transfer 137 (12), 121009 , 2015 2015 Citations: 24
Formation, growth, and eruption cycle of vapor domes beneath a liquid puddle during Leidenfrost phenomena G Paul, I Manna, P Kumar Das Applied Physics Letters 103 (8) , 2013 2013 Citations: 24
Mechanical and wear properties of graphite reinforced aluminum metal matrix composites processed by ultrasonic-stir-squeeze casting P Verma, G Paul, J Ghose, V Pandey Journal of Materials Engineering and Performance 33 (11), 5319-5330 , 2024 2024 Citations: 18
Motion, deformation and pearling of ferrofluid droplets due to a tunable moving magnetic field G Paul, PK Das, I Manna Soft Matter 16 (6), 1642-1652 , 2020 2020 Citations: 10
Effect of molybdenum disulfide dispersed nanolubricants on the tribological properties of mating stainless steel pair G Paul, P Jha, A Jha, A Roy Journal of Materials Engineering and Performance 33 (11), 5291-5305 , 2024 2024 Citations: 9
Enhanced mechanical and tribological performance of AA2014-SiC metal matrix nanocomposites fabricated by a novel stir-ultrasonic-squeeze casting process P Verma, J Ghose, G Paul, V Pandey, U Pandey International Journal of Cast Metals Research 38 (1), 21-35 , 2025 2025 Citations: 8
INVESTIGATION OF MECHANICAL AND TRIBOLOGICAL PROPERTIES OF ALUMINIUM HYBRID NANOCOMPOSITE PRODUCED BY NOVEL STIR-ULTRASONIC-SQUEEZE CASTING METHOD. U PANDEY, J GHOSE, B ACHERJEE, G PAUL MM Science Journal , 2024 2024 Citations: 7
Laser flash technique as an efficacious assessment approach for thermal conductivity of tungsten disulphide nanofluids G Paul, P Jha, A Roy, I Manna Journal of Molecular Liquids 404, 124996 , 2024 2024 Citations: 7