<p>The current study involves the synthesis of Al6061 alloy reinforced with B₄C particle composites. This is achieved by optimising factors such as the size and addition level of B₄C particulates, as well as the preheating temperature of the particulates and the processing temperature of the composite. Ceramic B₄C particulates are added with an addition level of 5, 7 and 11 wt%. In this study, a new method involving two stages of mixing, as well as preheating of the reinforcing particles along with K₂TiF₆ are adopted to accomplish better dispersion. XRD and SEM/EDAX examinations are used to describe the produced composites. Also, the composites’ mechanical and wear properties are tested in normal settings. A new method was used to make B₄C particles spread out better in liquid Al. The incorporation of B₄C particles resulted in a significant improvement in mechanical and tribological properties. Compared to the unreinforced Al6061 alloy, the composite containing 11 wt% B₄C exhibited an increase of ~ 113% in microhardness and ~ 38% in ultimate tensile strength, along with a reduction in wear rate of up to ~ 42% under dry sliding conditions. Microstructural and XRD analyses confirmed successful particle incorporation and the presence of reaction products. The results demonstrate that controlled processing combined with two-stage particle addition effectively enhances the performance of Al6061–B₄C composites.</p>