*Corr. Author’s Address: Wollo University, Kombolcha Institute of Technology, School of Mechanical and Chemical Engineering, Ethiopia, drahlenin@kiot.edu.et 275
Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283 Received for review: 2022-10-24
© 2023 The Authors. CC BY 4.0 Int. Licensee: SV-JME Received revised form: 2023-02-06
DOI:10.5545/sv-jme.2022.423 Original Scientific Paper Accepted for publication: 2023-03-20
Wear Behaviour of a Cu-Ni-Sn Hybrid Composite Reinforced  
with B
4
C prepared by Powder Metallurgy Technique
Allasi, H.A. – Chidambaranathan, V .S. –  Soosaimariyan, M.V .
Haiter Lenin Allasi
1,*
 – Vettivel Singaravel Chidambaranathan
2
 – 
 
Mary Vasanthi Soosaimariyan
3
1 
WOLLO University, Kombolcha Institute of Technology, School of Mechanical and Chemical Engineering, Ethiopia 
2 
Chandigarh College of Engineering and Technology, Department of Mechanical Engineering, India 
3 
St Xavier’s Catholic College of Engineering, Department of Electronics and Communication Engineering, India
Cu matrix composites benefit from the high electrical and thermal conductivities of Cu and the mechanical wear/erosion resistance of hard 
reinforcement. In this study, an attempt has been made to determine the effect of the addition of reinforcement B
4
C in Cu-Ni-Sn. The B
4
C is 
reinforced to form a hybrid Cu matrix composite with powder metallurgy technique. The hybrid composites are obtained by milling, blending, 
and compacting the powders to obtain a fine grain-sized particle without aggregation. The grain size and particle nature were characterized 
using scanning electron microscope (SEM) and X-ray diffraction (XRD) techniques, respectively. The microstructure, density, hardness, and 
wear rate of the composites were studied. The pin-on-disc method is equipped to study the wear behaviour and coefficient of friction. The 
sintered density of the prepared Cu-15%Ni is 98.25 %, Cu-8%Sn is 98.20 %, Cu-15%Ni-8%Sn is 98.10 % and Cu-15%Ni-8%Sn-2%B
4
C is 95.26 
% and lower specific wear rate has been recorded for Cu-15Ni-8Sn-2B
4
C 121×10
-6
 mm
3
/(Nm) and the addition of  reinforcement B
4
C in Cu-Ni-
Sn displays remarkable changes in wear rate and friction coefficient.
Keywords: powder metallurgy, copper, wear, characterization, density, composites
Highlights
• 	 The sintered density of the prepared Cu-15%Ni is 98.25 %, Cu-8%Sn is 98.20 %, Cu-15%Ni-8%Sn is 98.10 % and Cu-15%Ni-
8%Sn-2%B
4
C is 95.26 %.
• 	 The addition of reinforcement B
4
C in Cu-Ni-Sn displays remarkable changes in wear rate and friction coefficient.
• 	 The lower specific wear rate has been recorded for Cu-15Ni-8Sn-2B
4
C is 121×10
-6
 mm
3
/(Nm).
• 	 The severe plastic deformation and cracks are reduced with the addition of B
4
C. 
0  INTRODUCTION
Metal matrix composites (MMCs) are newer 
materials made in response to increased demand 
due to emerging applications in the fields of aircraft, 
space, defence, automotive, and transport because of 
their good strength and light weight [1] to [4]. The 
MMCs of different varieties are prepared with powder 
metallurgy techniques, which is suitable for bulk 
production. However, due to the existence of residual 
porosity and exhibited poor mechanical properties, 
it is used because of its non-wetting behaviour of 
MMCs.
Cu matrix composites benefit from the high 
electrical and thermal conductivities of Cu and 
the mechanical wear/erosion resistance of the 
reinforcement, such as WC. In addition to Cu–WC, 
other potential materials for similar applications are 
Cu– Mo, Cu–Al
2
O
3
, Ag–Mo, Ag–W, Cu-SiC, Cu-TiC, 
Cu-Sn, Cu-Ni and Ag–CdO [5]. 
Senthil Kumar et al. studied the tribological 
behaviours of Cu–6Sn–6Zn–3Pb alloy sliding against 
AISI 321 stainless steel under sea water, distilled 
water and dry sliding conditions are studied on a pin-
on-disc tester. Generally, the friction coefficient in 
distilled water is the largest and the smallest in dry 
sliding. The wear mechanism is a micro-plough and 
plastic deformation in distilled water and under dry 
sliding [6]. 
Vettivel et al. studied the development of Cu-
reinforced SiC particulate composites; SiC particles 
as reinforcement were blended with unmilled and 
as-milled Cu powder with reinforcement contents 
of 10 vol. %, 20 vol. %, 30 vol. %, and 40 vol. % 
using powder metallurgy. X-ray diffraction of all 
the composites was done in order to determine the 
various phases in the composites. Scanning electron 
microscopy (SEM) and EDS (electron diffraction 
X-ray spectroscopy) were carried out for the 
microstructure analysis of the composites. Cu-SiC 
composites containing higher vol. % of the SiC show 
better wear resistance [7]. 
The microstructure and tensile properties of Cu 
alloy reinforced with boron carbide (B
4
C) using a 
stir-casting technique. The hardness of the composites 
increased gradually by adding the reinforcement 
compared to the base alloy properties. The yield 
strength also increases by adding the B
4
C particulates 
into the Cu alloy matrix [8]. Another study confirmed 
that mechanical and thermal properties of multi-

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
276 Allasi, H.A. – Chidambaranathan, V.S. –  Soosaimariyan, M.V.
walled carbon nanotubes (CNT) reinforced Cu–10Sn 
alloy composites. Microstructural observations 
showed that CNTs were retained in the composite 
matrix after laser processing. The addition of CNTs 
showed improvement in strain hardening, mechanical, 
and thermal properties of Cu–10Sn alloy. Composites 
with 12 vol. % CNTs showed more than an 80 % 
increase in the Young’s modulus and a 40 % increase 
in the thermal conductivity of Cu–10Sn alloy [9] and 
[10]. 
Cu is used as a primary matrix and Ni and Sn as 
a secondary matrix and 2 % B
4
C as reinforcement 
added to the alloy (Cu-15%Ni-8%Sn). These spindle 
alloys cover excellent bearing properties and are thus 
used in a wide range of applications [11]. Copper an 
electrolytic ally processed and precipitated metal 
is taken and coated with nickel and tin with volume 
fractions of 15 % and 8 % respectively. Nickel is 
compatible and provides better reinforcement and 
adhesion to the carbide materials [12]. 
In this study, copper, nickel, tin and boron 
carbide are reinforced to form hybrid MMCs via a 
powder metallurgy technique. The hybrid composites 
are obtained by milling, blending, and compacting 
powders to obtain a fine grain-sized particle without 
aggregation. The effect of the addition of B
4
C in 
mechanical and tribological behaviour has been 
studied.
1  METHODS
Electrolytic copper powder with density 8.92 g/cm
3
 
at 20 ºC, nickel with 8.9 g/cm
3
 at 20 ºC and tin with 
7.3 g/cm
3
 at 20 ºC, whereas boron carbide 2.52 g/
cm
3
 at 20 ºC is reinforced to the metals. These are 
mechanically alloyed to the micron range and the 
samples are fabricated with a powder metallurgy 
technique to prepare MMCs. Then, the obtained 
MMC is sintered to high temperature of about 900 ºC. 
The sintered density of the Cu-15%Ni is 98.25 %, Cu-
8%Sn is 98.20 %, Cu-15%Ni-8%Sn is 98.10 % and 
Cu-15%Ni-8%Sn-2%B
4
C is 95.26 %.
The morphology and size of the particles are 
examined for individual metals and alloys, also after 
a)          b) 
c)          d) 
Fig. 1.  SEM image of unreinforced materials: a) Copper (Cu), b) Nickel (Ni), c) Tin (Sn, and d) 2% Boron carbide (B4C)

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
277 Wear Behaviour of a Cu-Ni-Sn Hybrid Composite Reinforced with B4C prepared by Powder Metallurgy Technique 
reinforcement added to the materials (i.e., MMC using 
SEM). The crystal structure and the phase change of 
the materials are studied using an X-ray diffractometer 
(XRD) with respect to the intensity peaks and 
materials diffraction angle 2 θ. The hardness, strength 
and wear of the composites are determined using a 
pin-on-disc apparatus with which the sliding distance, 
sliding velocity, load, and speed are applied to the 
composites by varying these parameters.
The SEM image shows the particle sizes are 100 
µm, 30 µm, 20 µm, and 10 µm for all metals such 
as Cu, Ni, Sn and B
4
C, respectively. The MMCs 
Cu-15%Ni, Cu-8%Sn, Cu-15%Ni-8%Sn and Cu-
15%Ni-8%Sn-2%B
4
C also exhibit smaller sizes. The 
morphology and grain nature of the materials are 
visualized using SEM and are obtained in different 
morphological forms. The Cu metal looks like 
cylindrical short tubes and have a slightly adhesive 
nature, whereas Ni, Sn and B
4
C show solid spherical 
balls with much less agglomeration.
The mixed MMCs after 2 % B
4
C is reinforced 
exhibit good morphology and fine-grain nature. 
Fig. 2a and b show the SEM images of Cu and Ni, 
respectively. and the diameter of the particles ranges 
from 5 µm to 20 µm, whereas Fig. 2c and d exhibit 
foamy and short fibrous materials, respectively. 
The MMC of Cu-15%Ni-8%Sn-2%B
4
C exhibits 
improved shape, with cylindrical tubes and spherical 
balls compressed against one another more evenly 
and resembling a very fine dispersion of particles 
with diameters ranging from 1 µm to 10 µm. The 
composites are well mixed, while the powders are 
crushed and blended to obtain good compaction of 
materials.
The X-ray diffractometer analysis of the particles 
in Fig. 3 reveals good crystal structure and phase 
development in the lattice fringes. Cu and Ni have a 
peak that corresponds to the (111) hkl lattice plane 
(Fig. 2a and b) and shows pure materials that have 
not been reacted with by the atmosphere, but Sn and 
B
4
C have illogical peaks that show fewer impurities. 
For Sn and B
4
C, the hkl lattice planes are 200 and 
024, respectively, due to the amorphous nature of the 
particles.
a) 
Ni
   b) 
Sn
c) 
Ni
Sn
        d) 
Ni
Sn
B4C
Fig. 2.  SEM images of reinforced materials; a) Cu-Ni, b) Cu-Sn, c) Cu-Ni-Sn, and d) Cu-Ni-Sn-2%B4C

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
278 Allasi, H.A. – Chidambaranathan, V.S. –  Soosaimariyan, M.V.
materials are used for wear-resistant applications 
because they have good sliding interaction with the 
abrasive particles [13]. This research describes the 
wear rate of metals Cu, Ni and Sn individually and 
then alloy Cu-Ni-Sn and also for MMCs Cu-Ni-
Sn-B
4
C, which exhibits better resistance to wear 
compared to alloy. The wear rate varies according 
to the variable parameters and contribution of the 
materials volume concentration.
The specific wear rates of the unreinforced and 
reinforced composites are analysed by changing the 
process parameters, mainly weight percentage or 
volume concentration, sintering temperature, load, 
sliding distance, sliding velocity, friction coefficient 
and volume loss of the composite material. Vettivel et 
al. [14], analysed the friction coefficient and specific 
wear rate by ANOVA (Analysis of Variance) method 
and found that the result mainly depends on the type 
and size of the reinforcement phase of the particles. 
Also, the metal-on-metal contact that takes place at 
the initial stage is relatively low at the steady state 
[15].
a)         b) 
c)           d) 
Fig. 3.  XRD patterns for unreinforced materials; a) Copper (Cu), b) Nickel (Ni), c) Tin (Sn, and d) Boron carbide (B
4
C)
The materials have incorporated each other 
into copper metal and then B
4
C is reinforced to the 
composites and the composites are structurally 
characterized by XRD, which explores the hkl lattice 
planes with respect to the intensities and 2 θ shown in 
Fig. 4. The materials are produced by mechanically 
alloying and composites are fabricated by Powder 
Metallurgy PM technique, milled, crushed, and then 
blended. Finally, the compaction of the material is well 
fitted by uniform dispersion of particles and sintered 
to a high temperature of about 900 ºC to avoid further 
grain growth. Thus, the lattice parameters of the 
composites are uniformly distributed for Cu-Ni, Cu-
Sn and Cu-Ni-Sn. While the reinforced composites 
contain carbon particles (B
4
C), the peaks point at 
another 2 θ position and all other materials represent 
peaks in the same 2 θ position.
2.1 Wear test
The pin-on-disc instrument is equipped to study the 
hardness and wear rate of the composites. Ultra-hard 

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
279 Wear Behaviour of a Cu-Ni-Sn Hybrid Composite Reinforced with B4C prepared by Powder Metallurgy Technique 
2  RESULTS AND DISCUSSION
2.1  Effect of Sliding Distance on Specific Wear Rate
Fig. 5 represents the specific wear rate increases 
with the sliding distance significantly. There is a 
gradual and linear raise in specific wear rate due 
to the hardness of the composites according to the 
constituents added to it [16] to [18]. From Fig. 5a, 
pure copper metal is tested for a specific wear rate, 
which shows 78×10
-5
 mm
3
/(Nm) to 340×10
-6
 mm
3
/
(Nm), at a constant sintering temperature of 900 ºC 
and sliding speed 20.94 m/s and variable parameters 
like sliding distance and load applied is 400 m to 1000 
m and 10 N to 25 N, correspondingly. Also, a specific 
wear rate is experienced for alloy Cu-15Ni and Cu-
8Sn, which reveals that 130×10
-6
 mm
3
/(Nm), also for 
Cu-15Ni-8Sn alloy shows 127×10
-6
 mm
3
/(Nm) with 
that a constant temperature and sliding speed and 
variable parameters of sliding distance at 1000 m and 
load applied of about 25 N. Here, we can infer that 
the alloy can have the intense effect in specific wear 
rate compared to pure metal, which is at very heavy 
loading and high sliding distance. If the reinforcement 
B
4
C is added to that matrix alloy, the composite Cu-
15Ni-8Sn-2B
4
C exhibits a reduced wear rate of about 
121×10
-6
 mm
3
/Nm. In this work, only 2%B
4
C is 
added as reinforcement resulted with a good reduction 
in specific wear rate compared to metal and matrix 
alloy. The lower specific wear rate has been recorded 
for Cu-15Ni-8Sn-2B
4
C. The decrement in specific 
wear rate is due to the addition of B
4
C in the Cu-15Ni-
8Sn. The results are in good agreement with other 
studies [9] and [14].
2.2  Worn Surface and Microstructure
The worn surface analysis of the MMCs in various 
volume fractions was investigated using SEM. The 
samples were tested by placing it in a holder inside the 
vacuum chamber. The image displayed information 
about the composites after the load was applied to it. 
Along the sliding direction, the materials withstand 
and prevent deformation and formation of oxide 
a)              b) 
c)                   d) 
Fig. 4.  XRD patterns of reinforced composites; a) Cu-Ni, b) Cu-Sn, c) Cu-Ni-Sn, and d) Cu-Ni-Sn-2%B
4
C

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
280 Allasi, H.A. – Chidambaranathan, V.S. –  Soosaimariyan, M.V.
debris at the interface region or at the contact surface; 
thus grooves, shear wedges, depth of penetration to 
wear, ploughing, and cracks can be observed. Due to 
the wear, the materials are abraded [19]. 
The worn surface of the unreinforced specimen 
is caused by the removal of material from the surface 
during the wear test. To avoid the rolling of the 
specimen, during the test the material was held in the 
testing machine [20]. Ling. et al. [20] analysed the 
microstructure nature of the Al-SiC composites; they 
found that while adding reinforcement to the matrix, 
big pores were found, due to the low volume fraction 
and grain size of the reinforcement added to the 
composites [21]. The particles are in heterogeneous 
distribution and are so large that the worn surface 
can be seen; the durable bonding between the 
a)      b) 
c)      d) 
e) 
Fig. 5.  The effect of sliding distance on specific wear rate of metal, matrix and composites;  
a) Cu, b) Cu-15Ni, c) Cu-8Sn, d) Cu-15Ni-8Sn, e) Cu-15Ni-8Sn-2B
4
C

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
281 Wear Behaviour of a Cu-Ni-Sn Hybrid Composite Reinforced with B4C prepared by Powder Metallurgy Technique 
reinforcement and matrix resulted in particle 
accumulation and grain boundaries [22] and [23]. 
The worn surface of the unreinforced Cu at 
constant load and wearing time is shown in Fig. 
6a, it has long smooth patches consisting of cracks 
and wear grooves. At the centre of the specimen, 
long shear wedges can be seen. Copper shows 
short and discontinuous pitting steps because of 
the unreinforced and heterogeneous distribution of 
particles with irregular size. From Fig. 6b and c, it can 
be inferred that Cu-Ni and Cu-Sn are unreinforced; 
the worn surface can be seen with shear wedges and 
wear grooves. Fig. 6d shows matrix alloy Cu-15Ni-
8Sn exhibiting wear at constant load, time and sliding 
direction. Here also carbide material is not reinforced 
with this matrix and exhibits long and continuous 
smooth patches, cracks, and reduced wear grooves; 
it can withstand stress at high temperatures. Fig. 6e 
shows the morphology of the worn surface of the 
composite (reinforcement of carbide materials) Cu-
15Ni-8Sn-2B
4
C at constant load and time. The wear 
occurs according to the sliding direction and has 
a)               b)  
c)              d) 
e) 
Fig. 6.  SEM image of worn surface for unreinforced and reinforced composites;  
a) Cu-Ni, b) Cu-15Ni, c) Cu-8Sn, d) Cu-15Ni-8Sn, and e) Cu-15Ni-8Sn-2B
4
C

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
282 Allasi, H.A. – Chidambaranathan, V.S. –  Soosaimariyan, M.V.
approximately 7.6 g/cm
3
 density. The matrix Cu-
15Ni display 7.8 g/cm
3
, while the metal matrix and 
composite (Cu-15Ni-8Sn and Cu-15Ni-8Sn-2B
4
C) are 
at 7.5 g/cm
3
 and 7.52 g/cm
3
 respectively. From this, 
we can infer that the higher the weight fraction, the 
better the density of the material.
2.3  Hardness Test
The Rockwell hardness is a test method, and ASTM 
E-18 is the commonly used method to be equipped. 
The hardness is determined with the help of an 
indenter present in equipment that measures the size 
of impression and depth of penetration of the indenter, 
performed by the composite material at the surface of 
the material to be loaded for testing. The Rockwell 
hardness test method is more accurate than other 
types of testing methods and is used for all metals and 
composites. 
The present study investigated integrated the 
various compositions and tested for hardness and 
found the Rockwell hardness number. The material 
is heated to a sintering temperature of 900 ºC, the 
powders were compacted, and the load is applied to 
it. Based on the hardness of the material, it withstands 
the load.. From Fig 7b, hardness number is high for 
the reinforced material. Even though, the addition of 
boron carbide volume fraction is less, the hardness of 
the composite is enhanced. The Rockwell hardness 
number of the unreinforced Cu-15Ni-8Sn and MMC 
Cu-15Ni-8Sn-2B4C is 5 and 23, respectively.
3  CONCLUSIONS
The unreinforced copper, Cu-Ni, Cu-Sn and Cu-Ni-
Sn-B4C composites were prepared using the powder 
metallurgy technique. The morphology, grain size 
and uniform dispersion of the composites were 
characterized using SEM and XRD. The tribological, 
hardness and density of the specimens were tested, 
and the following conclusions are drawn. 
•	 The SEM images confirm that the Sn, Ni and B
4
C 
particles are distributed uniformly throughout the 
matrix.
•	 The sintered density of the prepared Cu-15%Ni is 
98.25 %, Cu-8%Sn is 98.20 %, Cu-15%Ni-8%Sn 
is 98.10 % and Cu-15%Ni-8%Sn-2%B
4
C is 95.26 
%
•	 Cu-15Ni-8Sn-2B
4
C exhibits lower wear rate of 
about 121×10
-6
 mm
3
/(Nm) compared to the other 
prepared samples. It is mainly due to the nature 
and the addition of hard reinforcement B
4
C in the 
Cu-15Ni-8Sn.
rough patches with large amounts of wear grooves 
compared to unreinforced material and matrix alloy. 
The morphology clearly infers that cracks are fewer, 
and pitting is continuous with long shear wedges 
and so it withstands wear resistance, and the surface 
is not damaged while increasing the temperature. 
The composite after reinforcing with B
4
C with less 
volume fraction at 2 % resulted in a negative effect 
on the wear of the material and provided hardness and 
strength to the composite.
2.2  Sintered Density Test
Sintering is the principal factor for controlling the 
density of the composite materials; sintering time 
and temperature play major roles. When there is a 
huge variation in load and temperature, the density 
affects extensively [17]. The increase in experimental 
density is a consequence of enhancing the mechanical 
property of the specimen. The higher the density, the 
better the strength of the composites; this is because 
the reduced size of pores reduces the defect of the 
material.
a) 
b) 
Fig. 7.  Effect of composition on:  
a) sintered density, and b) hardness
In this work, the performance of the composite is 
good, but the experimental density is less for MMC 
Cu-15Ni-8Sn-2B
4
C. Here, the contribution of carbide 
is less (volume fraction 2 %), but the copper matrix 
contribution is normal, so better in other performances 
and meagre in experimental density. The bar plot 
shown in Fig. 7a represent the effect of sintered density 
at 900 °C. The unreinforced copper and Cu-8Sn show 

Strojniški vestnik - Journal of Mechanical Engineering 69(2023)5-6, 275-283
283 Wear Behaviour of a Cu-Ni-Sn Hybrid Composite Reinforced with B4C prepared by Powder Metallurgy Technique 
•	 Worn surface confirmed that there is a reduction 
of plastic deformation and cracks due to the 
addition of B4C. 
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