Aluminum-based metal matrix composites (MMCs) have gained significant attention in advanced engineering applications due to their superior strength-to-weight ratio and enhanced mechanical performance. In the present study, the influence of hybrid reinforcement using Boron Carbide (B₄C) and Titanium Dioxide (TiO₂) particles on the mechanical and tribological properties of Al6061 alloy is experimentally investigated and optimized. The composites were fabricated through the stir casting technique by varying the weight percentages of B₄C (2–6 wt %) and TiO₂ (1–3 wt%) under controlled processing conditions.

The developed hybrid composites were subjected to comprehensive characterization, including tensile strength, hardness, wear behavior, and microstructural analysis. The results indicate that the incorporation of B₄C significantly enhances hardness and wear resistance due to its high hardness and load-bearing capability, while TiO₂ improves particle distribution, interfacial bonding, and thermal stability of the matrix. However, excessive reinforcement content leads to particle agglomeration and porosity, which adversely affects tensile properties.

Statistical optimization was performed using the Taguchi method and analysis of variance (ANOVA) to identify the most influential parameters and determine the optimal combination of reinforcement and processing variables. The analysis revealed that B₄C content has the highest contribution toward improving hardness and wear resistance, followed by TiO₂ content and stirring parameters. The optimal composition was found to provide a balanced improvement in mechanical and tribological performance compared to the base alloy.