This study investigated the wear behavior and microstructure of aluminum (Al) matrix composites reinforced with nanostructured Cu-coated cBN particles. Microstructural analysis revealed a uniform distribution of Cu-coated cBN nanoparticles, grain refinement of the Al-matrix, and increased porosity with higher reinforcement content. The wear resistance was progressively enhanced with an increase in the Cu-coated cBN content under testing conditions involving wear loads ranging from 5 to 20 N and sliding distances between 350 and 650 m. Worn surface analysis revealed a transition from severe adhesive-delamination in unreinforced Al to mild micro-abrasive wear in Al reinforced with 10 wt. % Cu-coated cBN composite. Debris analysis corroborated this transition, with the composite generating smaller and more uniform reinforcement particles, characteristic of controlled micro-abrasive wear.
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