Volume Wear Rate Research Articles

Effect of ultrasonic shot peening on microstructure and properties of Cu-Ti alloy

Abstract Modified surface layers with refined grain size and high hardness characteristics were prepared on a Cu-Ti alloy using ultrasonic shot peening (USP) by controlling the shot diameter. The phase structure and organization morphology of the modified layer were analyzed using X-ray diffraction (XRD), optical microscopy (OM) and scanning electron microscope (SEM). The hardness, wear resistance and corrosion resistance of the modified layer were systematically characterized. The results showed that the comprehensive surface properties of the sample was optimized at a shot diameter of 3.0 mm. The average grain size was refined to 12.4 nm under the high-frequency impact of steel balls. Owing to the grain refinement and work hardening, the surface hardness, wear resistance and corrosion resistance of the sample was significantly improved. Among these, the surface hardness of the sample was enhanced from 257.68 HV0.1 to 313.51 HV0.1, the volume wear rate was decreased from 0.3305 um2/N to 0.1707 um2/N, and the self-corrosion current density was also decreased from 1.658×e-5 mA/μm2 to 4.053×e-6 mA/μm2. It was shown that USP is one of the effective methods for preparing Cu-Ti alloys with excellent surface properties.

Tribological properties of graphene oxide reinforced aramid paper-based composites

Self-lubricating paper-based composites can provide technological solutions such as low friction and extended service life for the aerospace airframe kinematic mechanical components. To improve the tribological properties of aramid short fibers, this study chemically combined graphene oxide (GO) with aramid nanofibers (ANF) through intermolecular forces, creating a self-lubricating GO-reinforced aramid paper-based composite GO/ANF. Mechanical performance tests have shown that the introduction of GO can significantly improve the fracture strength, Young's modulus, and toughness of paper-based composites. The frictional performance test results show that compared with ANF, the GO/ANF paper-based composites can maintain the lowest coefficient of friction (COF) and wear under high load and high sliding rate conditions. When the amount of GO added is 1 wt%, the COF and volume wear rate of GO/ANF paper-based composites are reduced by 23 % and 89 %, respectively. Mechanism analysis indicates that synergistic effects and friction transfer films are important factors contributing to the excellent performance of paper-based composites. This GO/ANF paper-based composite has good application prospects as a good anti-wear liner material in self-lubricating sliding bearing.

Characterizing sliding wear behavior of A1100/AlFe (p) composites produced via repeated fold-forging and annealing

Abstract Aluminum matrix/aluminum-iron intermetallic composite materials pose challenges in plastic processing due to the susceptibility of hard intermetallic compound particles to fracture. This study introduces a novel fabrication method involving pure iron mesh, hot-dip aluminum plating, and solidification. Through ten consecutive folding, forging, and intermediate annealing cycles, aluminum matrix and iron undergo diffusion, leading to the formation of Fe2Al5 and FeAl3 interface reaction layers, as confirmed by X-ray diffraction analysis. Subsequent forging cycles cause the breakage or detachment of Fe2Al5 and FeAl3 particles from the interface, resulting in the formation of large-sized Fe2Al5 and small-sized Fe2Al5 intermetallic particles. FeAl3 intermetallic particles are observed via microscopic examination. These particles can be uniformly dispersed within the aluminum matrix through plastic flow, enabling the successful fabrication of A1100/Fe2Al5 and AlFe3 composite sheets. Furthermore, the study investigates the impact of intermetallic compound content, sliding speed, and forward load on the dry sliding wear of A1100/FeAl composites. It is found that Fe2Al5 and AlFe3 intermetallic compound particles effectively mitigate adhesive wear, plowing, and oxidative wear of the composites. With an AlFe intermetallic compound content of 4.3 wt.%, the volume wear rate remains low under conditions corresponding to PV = 56.652 (equivalent to a normal load of 19.6 kPa and a sliding speed of 2.87 m s−1).

Deformation strengthening mechanism of laser remelted high manganese steel

In order to further improve the deformation hardening ability of high manganese steel (HMnS) under low stress or small deformation, a low speed laser remelting technology was proposed to process the HMnS surface. Through parameters optimization, microstructure characterization, wear testing, and deformation strengthening analysis, the deformation strengthening mechanism of laser remelted HMnS (LR-HMnS) was systematically studied, and excellent wear resistance properties was also achieved. Firstly, by optimizing the parameters of laser remelting, high-quality microstructures with large remelting depth and fewer porosities were obtained. Then, the sliding wear tests showed that although the surface hardness of LR-HMnS (252.83HV0.3) was only 2.56 % higher than that of continuous casting HMnS (CC-HMnS) (246.53HV0.3), its volume wear rate (1.87×10−5 mm3/N·m) was only 10 % of CC-HMnS (18.71×10−5 mm3/N·m), which exhibited excellent wear resistance properties. Finally, for quantitative evaluating its work hardening at high strain rates, Hopkinson compression test of LR-HMnS was conduced according to the operating conditions of HMnS parts. The microstructure after small compression deformation was analyzed using EBSD and TEM. It was found that the larger grain size of LR-HMnS was helpful of reducing the nucleation stress of twins, forming high-density nano-twins, high-density stacking faults, and high-density dislocations. The synergistic effect of stacking faults, dislocations, and twins which segmented the matrix and refined the grains, and achieved the dynamic Hall-Petch effect. The superior deformation strengthening and wear resistance exhibited by larger grain HMnS were called the inverse grain size effect. Additionally, the large number of C-Mn strong bond networks formed by element segregation could enhance the pinning effect of dislocations, promote deformation hardening rate and wear resistance properties under low stress or small deformation. The research results provided a new method for pre-hardening of HMnS, and will also expand the application potential of HMnS in combined conditions of high, medium, and low impact.

Microstructure and wear properties of carbide reinforced high-entropy alloy coatings on EA4T steel via vibration assisted TIG-cladding using WC core spiral AlCuNiCrTi-CWW

Aiming at the difficulty preparing high-entropy alloy (HEA) coating by adding carbide powder using TIG-cladding, the WC core spiral CWW prefabricated vibration assisted TIG-cladding method is proposed in this work. The HEA coating (S1-coating) was prepared on the EA4T steel using AlCuNiCrTi cable-type welding wire (CWW) via TIG-cladding, then the WC reinforced HEA coating (S2-coating) was produced using spiral AlCuNiCrTi-CWW with WC powder core by TIG-cladding. Finally, another WC reinforced HEA coating (S3-coating) via vibration assistance TIG-cladding using the same material as S2-coating. The S1-coating is composed of BCC and FCC solid solutions. Except for the same phases as S1-coating, TiC appeared in the S2-coating and the S3-coating. Due to the grain refinement effect caused by vibration, the S3-coating has the maximum microhardness (725HV), lowest friction coefficient (0.42) and the smallest volume wear rate (0.1397 × 10−4 mm3/N·m). The addition of vibration assistance effectively improves the microhardness and wear resistance of the coating without changing CWW composition.

Wear Mechanisms, Composition and Thickness of Antiwear Tribofilms Formed from Multi-Component Lubricants.

The antiwear properties of tribofilms formed on steel surfaces lubricated with various multi-component lubricants were investigated at an elevated temperature and under load-speed conditions conducive to sliding in the boundary lubrication regime. The lubricants contained base oil, reduced-level (secondary) zinc dialkyl dithiophosphate (ZDDP), and nitrogenous dispersant. The wear resistance of the tribofilms produced from different oil blends was evaluated in the context of the rate of change in the sliding track volume (wear rate for material loss) and the load-bearing capacity, chemical composition, and thickness of the tribofilms. Surface profilometry and scanning electron microscopy were used to quantify the wear performance and detect the prevailing wear mechanisms, whereas X-ray photoelectron spectroscopy elucidated the chemical composition and thickness of the tribofilms. The oil blends without ZDDP did not produce tribofilms with adequate antiwear properties, whereas the oil blends containing ZDDP and dispersant generated tribofilms with antiwear characteristics comparable to those of tribofilms produced from blends with a higher ZDDP content. Although dispersants can suspend oil contaminants and preserve the cleanness of the sliding surfaces, it was found that they can also reduce the antiwear efficacy of ZDDP. This was attributed to an additive-dispersant antagonistic behavior for surface adsorption sites affecting tribofilm chemistry and mechanical properties. Among the blends containing a mixture of ZDDP and dispersant, the best antiwear properties were demonstrated by the tribofilm produced from the blend consisting of base oil, 0.05 wt% ZDDP, and a bis-succinimide dispersant treated with ethylene carbonate. The findings of this investigation demonstrate the potential of multi-component lubricants with reduced-content ZDDP and nitrogen-based dispersant to form effective antiwear tribofilms.

Enhancing wear resistance of laser-clad AlCoCrFeNi high-entropy alloy via ultrasonic surface rolling extrusion

The AlCoCrFeNi high-entropy alloy (HEA) coating was synthesized by laser cladding and subsequently processed by ultrasonic surface rolling extrusion (USRE) with varying static loads of 100 N, 200 N, and 300 N. This study aimed to explore the effects of static load on the microstructure, mechanical properties, and tribological characteristics of the coatings. The findings indicate that increased static load results in the precipitation of martensitic phases, grain refinement, enhanced microhardness, and an elevated dislocation density. Specifically, after USRE with 300 N static load, the coating's microhardness reaches 753 HV, 1.4 times greater than the un-USRE coating. This enhancement is attributed to the synergistic effect of martensite phase transformation, grain refinement, and dislocation strengthening. The volume wear rate of the coating decreases to 1.31 × 10−4 mm3·N−1·m−1 following USRE at 300 N, demonstrating superior resistance to abrasive wear due to the high microhardness. Besides, the high-density dislocations facilitate rapid migration and diffusion of oxygen elements, thereby enhancing the oxide layer's protective properties and improving the coating's resistance to oxidation wear.

The enhanced tribological performance of fabric‐reinforced resin composites by biomimetic surface modification of fillers

The poor dispersion of multiwalled carbon nanotubes (MWCNTs) and weak interfacial adhesion of fabric and resin matrix seriously affect the tribological performance of fabric‐reinforcement resin composites. Tannic acid (TA), a plant‐derived compound, which is similar to mussel‐inspired polydopamine, can adhere to various substrates under a weak basic buffer solution. Therefore, in this work, TA‐modified MWCNTs were incorporated into TA functionalized fabric composite to improve the tribological performance of the fabric composite. The results indicate that the MWCNTs and fabric were successfully modified with TA. The wear tests revealed that the TA‐MWCNTs reinforcement TA‐fabric resin composites exhibited the best tribological performance, in which the friction coefficient and volume wear rate decreased by 16.9% and 40%, respectively, compared with pristine fabric composite. The favorable interfacial bonding between fabric and resin is beneficial to the friction force transfer to the load‐bearing fabric, decreasing the stress focus and thus reducing the damage to composite materials. Meanwhile, the good dispersion of MWCNTs contributes to the excellent lubrication performance. This simple and eco‐friendly method of treating fillers with TA provides a new approach to achieve high‐performance tribological materials.

Microstructure evolution and property of high manganese steel coatings by laser shock assisted laser wire cladding

Field-assisted laser cladding (FALC) overcomes the limitations of laser cladding through the inherent advantages brought about by the use of various auxiliary energy fields (AEFs). Laser wire cladding (LWC) is limited by the common problems of laser cladding but has a promising future due to the extremely high material utilization rate. In this study, a laser shock assisted laser wire cladding (LSALWC) manufacturing process was proposed. In situ laser shock was introduced into the LWC to obtain finer grains structure and improve product performance. LSALWC does not change the composition of the coating, does not require the use of pretreatment and post-treatment, and does not reduce the efficiency of production. Using high manganese steel (HMS) as the model alloy, LSALWC was employed to achieve the expectation of reducing the proportion of columnar grains, refine the microstructure of columnar grains, and transform columnar grains into equiaxed grains. Compared with the sample (LC) manufactured by LWC, the performance of the sample (LSA) manufactured by LSALWC has been improved, the hardness increased from 285 ± 5 HV0.5 to 303 ± 6 HV0.5, the volume wear rate decreased from 2.1 × 10−4 mm3/N·m to 1.7 × 10−4 mm3/N·m, the primary dendrite spacing of the coating was reduced by 11.5%, and the heterogeneity of coating was more obvious. The cladding process under laser shock was studied using a high-speed camera, and the influence of laser shock on the coating was explained. The mechanism of the performance improvement of the LSA sample was explained. This study showed the disturbance of the molten pool was enhanced by laser shock, and the dendrites at the bottom were deflected or even broken. The broken dendrites were dispersed with the liquid flow and became new nucleation sites. Laser shock increased the supercooling during solidification by reducing the temperature gradient in the molten pool, and created an environment conducive to grain nucleation and growth. This process mitigates various issues in the casting process of HMS and provides a novel method for regulating the grain and microstructure of laser cladding. This research delves into the coupling between the AEF and the dynamic behavior of the molten pool, culminating in a model depicting the evolution of laser cladding solidification under the influence of the AEF, which will provide a new perspective for the research of FALC.

Tribological and electrochemical behaviors of FeCoNiCrMox HEA coatings prepared by internal laser cladding on 316L steel tube

In order to improve the performance of the inner wall of the 316L hydraulic cylinder, FeCoNiCrMox (x = 0.2, 0.4, 0.6) high entropy alloy coatings were prepared by laser cladding. The effects of the Mo element on the phase, microstructure, hardness, and tribological as well as electrochemical behaviors of the coating were investigated. The results show that the coatings consist of the FCC phase. The FCC phase increases, and the grain orientation becomes more complex with increased Mo element content. The coatings are mainly composed of columnar and equiaxial crystals. Mo0.4 coating has the finest grain structure, resulting in the coating with a maximum hardness of 421.99 HV, 2.11 times that of the substrate. The nanoindentation test shows that the elastic modulus of the HEA coating increases with the increase of Mo content. The dry sliding wear test shows that adding the Mo element improves the wear performance of the coating. The wear volume loss and wear rate of Mo0.4 coating were the lowest, 12.242 mg and 2.88 × 10−4 mm3•N−1•m−1, respectively. In the 3.5 wt% NaCl solution, the polarization curves and EIS results indicated that adding the Mo element improved the corrosion resistance of the coating. The FeCoNiCrMox coatings significantly improved the hardness, tribological, and electrochemical behaviors of the 316L substrate.

A Comprehensive Study on Microstructure and Wear Behavior of Nano-WC Reinforced Ni60 Laser Coating on 17-4PH Stainless Steel

The surface of 17-4PH martensitic stainless steel was laser-cladded with Ni60 and Ni60+nano-WC composites and a comprehensive investigation was conducted of the microstructure and wear mechanism. The findings demonstrate that despite the added nano-WC particles being fused and dissolved during laser cladding, they still lead to a reduction in grain size and a decrease in crystallographic orientation strength. Furthermore, the dissolution of nano-WC makes the lamellar M23C6 carbides transform into a rod or block morphology, and leads to the CrB borides becoming finer and more evenly dispersed. This microstructural evolution resulted in a uniform increase in hardness and wear resistance, effectively preventing crack formation. When the nano-WC addition increased to 20 wt.%, there was a 27.12% increase in microhardness and an 85.19% decrease in volume wear rate compared to that of the pure Ni60 coating. Through analysis of the microstructure and topography of wear traces, it can be inferred that as the nano-WC addition increased from 0 wt.% up to 20 wt.%, there was a gradual transition from two-body abrasive wear to three-body abrasive wear, ultimately resulting in adherent wear.

Characteristic Analysis and Coating Application of the Innovative HVOF System Based on the Digital Model

In view of the poor working conditions, high cost and time-consuming parameter design of the traditional spray process, an innovative HVOF thermal spray system based on the digital model has been established by this study to improve coating performance and optimize scheme design rapidly. In particular, the digital model of the oxygen/kerosene HVOF spray system is designed on the AMESim multidisciplinary simulation platform for the first time, and the engineering prototype has been successfully developed. Thus, an efficient design method based on the digital model was proposed, according to which the spray control parameters such as oxygen and kerosene flow are obtained conveniently under a combustion chamber pressure of 1.0 MPa and 2.0 MPa, respectively. The error between the simulation and experiment results was generally less than 5%, and the dynamic characteristics of the key components in the actual spray system were well predicted, suggesting that the dynamic response time of the system would generally less than 0.7 s. Additionally, the WC-12Co coatings were deposited under the working conditions of W1.0 and W2.0, respectively, the microhardness of the coating increased about 23% and the corresponding volume wear rate decreased about 18%. The results show that the increase of the pressure of the combustion chamber can further improve the coating performance, which also verifies the feasibility and reliability of the design method. It was concluded that the innovative HVOF system based on the digital model is of great theoretical value and application significance for predicting spray process parameters conveniently and providing excellent coating performance.

Preparation and wear resistance of B–Al co-permeation layers on TC4 titanium alloy surface

The surface of the TC4 titanium alloy was treated by B–Al co-permeation at 900, 1000, and 1100 °C for 4 h using the powder pack co-cementation method. The microstructure, elemental distribution, phase composition, hardness and wear resistance of the composite layers were analyzed by scanning electron microscopy, energy dispersive spectrometry, X-ray diffraction, a microhardness tester, and a multifunctional surface mechanical property tester. The results showed that the phase composition of the layers obtained under different processes includes TiB, TiB2, Ti3Al, and Al2O3. The thickness of the coatings increases with the increase of temperature, ranging from 2.00 ± 0.14–8.67 ± 0.62 μm. The outer layers are composed of Al2O3 and Ti3Al, and the inner layers are TiB and TiB2. The hardness range of the composite layers is 1168.1–1939.8 HV0.1, which is nearly 3–5 times that of the substrate. The friction and wear experiment results showed that the average friction coefficient of the B–Al composite layer is lower than that of the matrix. The friction coefficient at 1000 ℃ is the smallest, which is 0.20. The volume wear rate of the composite layer is approximately 38–44% that of the matrix. The wear mechanism of the TC4 titanium alloy is abrasive and oxidative wear, while that of the B–Al co-deposition layer is abrasive, adhesive, and oxidative wear.

Preparation and characterization of supersonic plasma sprayed Al–Al2O3–Cr2O3 composite coatings on magnesium alloy substrate

Magnesium alloys have poor wear and corrosion resistance, which limits their wider industrial applications. In order to improve wear and corrosion resistance, Al–Al2O3–Cr2O3 composite coatings with different Al, Al2O3 and Cr2O3 compositions were prepared on magnesium alloy substrate using supersonic plasma spraying technology. The surface morphology, porosity, and microstructure of Al–Al2O3–Cr2O3 coatings were analyzed. The wear and corrosion resistance of Al–Al2O3–Cr2O3 coatings were evaluated. The results showed the surface morphology of the composite coating was flat, and the cross-sectional structure had a layered structure with close interlayer bonding, and also the structure was uniform and fine. The A70A15C15 coating exhibited the lowest porosity (0.56 %), whereas the porosity of A30A35C35 coating was the highest (only 1.61 %). The wear resistance of the composite coating increased with increasing Al2O3–Cr2O3 compositions, and the A30A35C35 coating showed the best wear resistance, with a 90.58 % reduction in volume wear rate when compared with that of the magnesium alloy substrate. Based on electrochemical impedance spectroscopy testing, the A50A25C25 coating had the slowest corrosion rate and best electrochemical corrosion resistance. Therefore, the preparation of the Al–Al2O3–Cr2O3 coating by supersonic plasma spraying on magnesium alloy substrate is a promising technique for improving its wear and corrosion resistance.

Preparation and tribological property of MoS2@PDA@POSS core-shell-shell/Epoxy composite lubricating coating with good humidity adaptability

In this work, a humidity-adaptive additive of MoS2@PDA@POSS with core-shell-shell structure was designed and fabricated in the presence of polydopamine (PDA) interlayer. Then the composite coating of MoS2@PDA@POSS/Epoxy was prepared by introducing this additive into epoxy matrix, and its tribological properties under air and humid environments were subsequently evaluated in detail. Specially, the friction coefficient of MoS2 @PDA@POSS/Epoxy coating under high humid environment remained stable below 0.25, while its volume wear rate reduced by 91.91% compared to MoS2/Epoxy coating, and the humidity-adaptive response mechanism mainly depends on the improved mechanical properties, the alleviating effect on MoS2 oxidation, and the formation of transfer film. This work establishes a promising platform for the design and application of novel high-performance lubricating additives.

Bridging solvent-free polyamic acid and epoxy resin by Si-O-C hyperbranched polymer for enhanced compatibility, toughness and self-lubrication performance

Despite the great application potential of epoxy resin (EP) modified with polyamic acid (PAA), the large amount of high-boiling-point non-protonic polar solvents used to promote their compatibility cannot be completely eliminated, which affects the fabrication and application of epoxy composites in practical engineering. Herein, PAA was prepared by solvent-free ball milling method, and then the primary amine hyperbranched polysiloxane (HSiNH2) was prepared by “one-pot” method as the “bridging structure” to improve the compatibility between PAA and EP. Compared to neat EP, the flexural, impact and tensile shear strength of the epoxy composite are increased by 22.2 %, 30.0 % and 23.2 %, while the average friction coefficient and volume wear rate are reduced by 26.5% and 20.6% under the contents of PAA and HSiNH2 are 1.50 wt% and 2.0 wt%, respectively. Moreover, the material exhibits excellent thermal properties. By comprehensively analyzing the structure and properties of the epoxy composite, it is mainly ascribed to the fact that HSiNH2 with a large number of reactive groups acted as a “bridging structure” to enhance the compatibility of PAA and EP, which results in the epoxy composite having excellent mechanical, tribological and thermal properties. This research also lays the theoretical foundation for the development of high-performance epoxy composites in aerospace.

Wear behavior of novel abradable porous Yb2Si2O7-CaF2-PHB coatings fabricated by atmospheric plasma spraying

The abradable sealing coatings (ASCs) matched with ceramic matrix composites (CMCs) can improve engine efficiency and reduce fuel consumption. A study of plasma-sprayed porous Yb2Si2O7-20 vol% CaF2 with various contents of poly-p-hydroxybenzoate (PHB) as ASCs compatible with CMCs is reported. The microstructure and phase composition, Rockwell hardness, wear behaviors and abradability of the coatings were comparatively studied. The results show that the porosity increased and the hardness decreased as the PHB content was increased, and the coating containing 20 vol% PHB had a minimum hardness of about 65.2 HR45Y and a maximum porosity of about 39.2%. The friction coefficients and IDR values decreased, wear depth and volume wear rates of the coatings effectively improved with the increase of porosity. The wear mechanisms were analyzed based on the observation of the worn surfaces. This work might provide some guidance for the design and application of ASCs for CMCs.

Microstructural evolution and wear characteristics of laser-clad CoCrFeNiMn high-entropy alloy coatings incorporating tungsten carbide

CoCrFeMnNi HEA coatings incorporating WC ceramic particles with varying contents (0%, 10%, 20%, 30%, and 40%) are synthesized by laser cladding in this study. The phase evolution, strengthening mechanisms, and dry sliding wear behavior are investigated. The microstructure analysis revealed that coatings with WC content up to 20% consist of a single FCC phase, while those with WC content exceeding 30% exhibit a combination of FCC and polymorphic M3W3C phases. The microhardness increases from 169HV to 517HV with the content of WC varies from 0% to 40%. The contributions of precipitation strengthening and dislocation strengthening are the primary factors driving hardness increment. The presence of M3W3C further contributes to precipitation strengthening, resulting in enhanced hardness with increasing WC content. Moreover, the coating with 30% WC particles exhibits the most superior wear resistance, with a significantly reduced volume wear rate of 2.37 × 10−6 mm3/(N·m), which is merely 0.7% in comparison to the WC-free coating. With increased WC content, the wear mechanism of the coatings shifts from adhesive wear to oxidation wear, attributed to the hierarchical interfaces between the FCC matrix and the WC/M3W3C phase. This study offers valuable insights for enhancing the durability and performance of advanced coatings.

Microstructure and wear resistance of laser cladding a novel nickel-based alloy coating

A novel crack-free nickel-based alloy coating was successfully fabricated using laser cladding. By utilizing the TCNI (v10) commercial multi-component database of nickel-based superalloys, the equilibrium phase diagram and non-equilibrium solidification path of this novel alloy were revealed using the CALPHAD method. The substrate phase of the NiCrFeWBSiMo-CeO2 coating consists of the face centered cubic (FCC) phase, along with several strengthening phases. The coating exhibits a microhardness of ∼575 HV, while the coefficient of friction (COF) and volume wear rate measure at 0.39 and 1.1 mg respectively, indicating excellent wear resistance.

Effect of graphene on the microstructure, thermal conductivity, and tribological behavior of cast B319 Al alloy

In this research, the effect of adding 0.1 – 0.7 wt% of graphene on the microstructure, hardness, thermal conductivity, and tribological response of cast B319 Al alloy was investigated. Addition of 0.1 wt% graphene increased the hardness of cast B319 alloy from 77 to 92 HV, which was the result of grain refinement and the modification of the Si phase. At 0.3 wt% graphene, the composite achieved optimal wear resistance, as the average coefficient of friction (CoF) decreased from 0.42 to 0.20, a ∼52% reduction with respect to the base B319 alloy. Similarly, the average wear volume and specific wear rate of 0.3 wt% graphene composite showed a ∼36% (measured by weight loss) and ∼32% (measured by the laser microscopy) reduction compared to the base alloy. The improved wear resistance of the composite was attributed to its higher hardness caused by microstructural refinement, high stability of the mechanically mixed layer (MML), and the formation of a graphene-rich lubricating layer on the contact surfaces. The results obtained from this study on B319-graphene composites could pave the way for developing lightweight and high-performance wear-resistant components for next-generation automotive applications.