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This study examines the impact of the size and wt.% of reinforcement particles on the wear characteristics of Al2021 alloy composites. Composites of Al2021 reinforced with B4C particles of varied sizes (45 and 90 microns) were synthesised utilising a unique two-stage stir cast technique. The composites were primed with B4Cc content of 5 and 10 wt.%. The microstructural characterisation of Al2021 alloy with B4C composites of 45 and 90-micron sizes was conducted using Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS). In addition, wear and worn morphology tests were conducted to examine the impact of particle size on the behaviour of Al2021 alloy. Furthermore, another set of wear studies was conducted with the load maintained at 40N and the sliding speeds changed from 100 to 400 rpm. The microstructural analysis disclosed that the particles in the Al2021 alloy were evenly distributed, and the presence of elements was verified using EDS spectra. Using B4C particles of different sizes enhanced wear characteristics with resistance to wear. The load and the speed affected the wear behaviour of every prepared sample. The morphological analysis of the worn samples recognised multiple wear mechanisms. [ABSTRACT FROM AUTHOR]