Wear Track Surface Research Articles

Reinforcing polyvinyl alcohol films with layered double hydroxide and tannic acid to enhance tensile strength, tribological performance, and corrosion resistance in biomedical coating applications

Abstract This study investigates the synergistic effects of incorporating layered double hydroxide (LDH) and tannic acid (TA) into polyvinyl alcohol (PVA) films to enhance their mechanical, tribological, and corrosion resistance properties for biomedical applications. Composite coating films were prepared by blending PVA with LDH and TA in various concentrations. The addition of LDH and TA significantly increased the crystallinity index of the composite films, with the highest crystallinity observed at 66.3% for the sample containing 1 wt% TA and 2 wt% LDH (PVA/TA1/LDH2). This enhancement in crystallinity contributed to improved mechanical performance, as demonstrated by tensile tests, where the PVA/TA1/LDH2 composite exhibited the highest tensile strength among all samples. Tribological testing revealed that the PVA/TA1/LDH2 composite also achieved the lowest coefficient of friction (COF), along with a minimal wear rate, indicating superior wear resistance. SEM analysis of the wear scars confirmed a narrow wear track and smoother surface morphology for this composite, which suggests effective load distribution and reduced surface degradation. The addition of TA was further shown to improve the corrosion resistance of the PVA composite films, with the PVA/TA1/LDH1 sample exhibiting the lowest corrosion current density (Icorr) of 0.36 μA cm−2, representing a significant improvement over neat PVA. These findings highlight the potential of PVA/LDH/TA films for coating applications in biomedical devices, where enhanced mechanical strength, wear resistance, and corrosion protection are critical. The synergistic effects of LDH and TA provide a pathway for developing durable and functional coatings, expanding the practical utility of PVA films in demanding biomedical environments.

Study on the tribological behavior of TiN-VN/PAO composite lubricant system: ZIF-8 as a lubricating additive

Safety and reliability of mechanical systems are compromised by the lubricant degradation and excessive wear on contact surfaces. In response, a TiN-VN/PAO lubrication system was developed, and zeolitic imidazolate frameworks-8 (ZIF-8) nanoparticles with highly ordered pore structures were introduced to improve friction performance. The findings indicate that the addition of ZIF-8 significantly reduces the friction coefficient and wear rate in the composite system. The outstanding anti-friction performance is attributed to the heterogeneous TiN-VN nanolaminates material, which provides exceptional deformation tolerance and interface friction products. XPS analysis reveals the formation of a low shear strength Magnéli phases (V2O5) on the wear track surface, while TEM observations demonstrate that a ∼18 nm Zn-rich layer was developed at the interface, acting as a lubricating barrier layer.

PEO of additively manufactured Al10SiMg alloy: Effects of α-Al2O3 particles on energy consumption and wear behaviour

Plasma electrolytic oxidation (PEO) coatings were developed on an additively manufactured Al10SiMg alloy pre-treated with hard anodizing (HA). The influence of α−Al2O3 particles incorporated during PEO was evaluated in terms of energy consumption, coating morphology, composition and wear behaviour. Combining a 20 μm-thick HA precursor and a PEO electrolyte with suspended α−Al2O3 particles resulted in the highest energy savings (∼60%). Wear volume loss measurements and wear track characterization revealed that the PEO coating with added particles (PEOP) outperformed the coating without particles and a conventional hard anodizing layer. This superiority was attributed to the partial sealing of the outer porous layer by the incorporated α−Al2O3 particles as well as the reduced SiO2 content and the formation of a W-rich tribolayer on the wear track surface.

Comparative Study of the Tribocorrosion Performance of NiTiNOL60 in Acidic, Alkaline, and Saline Environments

AbstractIn order to enhance the durability of tribological interfaces, an investigation into the synergistic effects of sliding wear, corrosion, and their interactions is crucial. This study focuses on understanding the deformation mechanisms of NiTiNOL60, a nickel-rich nickel-titanium alloy, during sliding against Al2O3 in different corrosive environments, including acidic, alkaline, and saline mediums. The pH of the environments is found to play a significant role in the tribocorrosion process, leading to electromechanically induced transformations and various wear patterns. Plastic deformations are observed on the wear track surfaces, particularly in the severe and mild wear regimes. In an alkaline environment, depassivation of the oxide layer triggers oxidational wear, with the depassivation rate dependent on factors like contact pressure, sliding velocity, and passive film properties. The wear volume is highest in saline environments, with contributions from mechanical wear, corrosion, and third-body abrasion. Grain deformations occur in the alkaline environment due to shear forces, while in the acidic medium, corrosion accelerates mild wear involving abrasion and delamination. The findings provide insights into wear mechanisms and localized corrosion, highlighting the influence of H+ and OH− groups (pH values) on corrosive wear and crack propagation.

Influence of Proteins and Building Direction on the Corrosion and Tribocorrosion of CoCrMo Fabricated by Laser Powder Bed Fusion.

Cobalt-chromium-molybdenum (CoCrMo) alloys are common wear-exposed biomedical alloys and are manufactured in multiple ways, increasingly using additive manufacturing processes such as laser powder bed fusion (LPBF). Here, we investigate the effect of proteins and the manufacturing process (wrought vs LPBF) and building orientation (LPBF-XY and XZ) on the corrosion, metal release, tribocorrosion, and surface oxide composition by means of electrochemical, mechanical, microscopic, diffractive, and spectroscopic methods. The study was conducted at pH 7.3 in 5 g/L NaCl and 5 mM 2-(N-morpholino) ethanesulfonic acid (MES) buffer, which was found to be necessary to avoid metal phosphate and metal-protein aggregate precipitation. The effect of 10 g/L bovine serum albumin (BSA) and 2.5 g/L fibrinogen (Fbn) was studied. BSA and Fbn strongly enhanced the release of Co, Cr, and Mo and slightly enhanced the corrosion (still in the passive domain) for all CoCrMo alloys and most for LPBF-XZ, followed by LPBF-XY and the wrought CoCrMo. BSA and Fbn, most pronounced when combined, significantly decreased the coefficient of friction due to lubrication, the wear track width and severity of the wear mechanism, and the tribocorrosion for all alloys, with no clear effect of the manufacturing type. The wear track area was significantly more oxidized than the area outside of the wear track. In the reference solution without proteins, a strong Mo oxidation in the wear track surface oxide was indicative of a pH decrease and cell separation of the anodic and cathodic areas. This effect was absent in the presence of the proteins.

Friction and wear behavior of molybdenum-disulfide doped hydrogen-free diamond-like carbon films sliding against Al2O3 balls at elevated temperature

Diamond-like carbon (DLC) films quickly experience lubrication failure due to oxidation and mechanical degradation when used above 300 °C, which limits their application. Molybdenum disulfide (MoS2) doping is considered as a feasible method to improve high-temperature properties of DLC films. However, the effect of MoS2 doping on the high-temperature friction behavior of MoS2-DLC composite films and its mechanism remain unclear. Here, MoS2-DLC composite films with different contents of MoS2 were synthesized by a superimposed deposition system consisting of high-power impulse magnetron sputtering (HiPIMS) and direct current magnetron sputtering (DCMS). The MoS2 content in the films was controlled by varying the number of MoS2 pellets in the graphite-MoS2 (C–MoS2) mosaic target. The effect of MoS2 doping content on the structure and mechanical properties of MoS2-DLC films was analyzed. In addition, the friction and wear behavior and mechanism of MoS2-DLC composite films sliding against Al2O3 balls at 25–450 °C were studied. The results indicated that MoS2 was successfully incorporated into DLC matrix, and the content of Mo in the films ranged from 0 to 6.15 at. %. The as-deposited MoS2-DLC composite films exhibited a dense and featureless structure. The doping of MoS2 improved the adhesion strength and released the internal stress of MoS2-DLC composite films, but reduced the hardness and elastic modulus of the films. In particular, MoS2-DLC composite films with 3.78–6.15 at. % Mo maintained excellent anti-friction and anti-wear performances in the temperature range of 25–450 °C. Abrasive wear and fatigue wear occurred in the friction test of the films at different temperatures. However, the friction mechanism of the films varied with the temperature of friction test. At 25 °C, MoS2-DLC composite films showed excellent lubrication and anti-wear abilities due to the carbon suspension bond was passivated by H2O molecules. At 250 °C, MoS2 phase precipitated on the surface of the films, resulting in low friction. At 350 °C, MoS2-xOx solid solution was generated on the surface of the wear track to maintain lower friction and wear. Interestingly, MoS2-DLC composite films with high Mo content still achieved relatively low coefficient of friction and wear rate up to 450 °C due to the continuous availability of MoS2-xOx generated on the surface of wear track.

High-temperature sliding wear performance of HVAF sprayed WC-based coatings with alternative binders

The wear performance of HVAF sprayed WC-based composite coatings with Co-lean or Co-free binders was evaluated as an alternative to conventional WC-CoCr wear-resistant layers. The coatings were characterized for microstructure and tested for their micro and nano hardness. Their tribological behavior was studied for reciprocating sliding wear at room and elevated temperature (∼300 °C). Using nanoindentation, the hardness of carbide grains was measured to be between 18 GPa and 25 GPa. Nanoindents that fell in the binder phases had a hardness of 15 GPa–18 GPa, which, due to the fine scale of the microstructure, represents some average mixture of the binder and carbide. Using Vickers indentation at higher loads, the hardness values of the coatings at room temperature were found to be between 1000 and 1200 HV0.3, which decreased by ∼200 HV0.3 when tested at elevated temperatures. The wear performance of all coatings with alternative binders at room temperature was comparable to that of the reference WC-CoCr. However, the specific wear rates of the coatings tested at elevated temperature was higher by 1–2 orders of magnitude compared to those performed at room temperature. With the exception of WC-FeNiCrMoCu, the other three coatings exhibited comparable high-temperature wear performance. Ripple-like patterns were the prominent feature observed on the room temperature wear tracks. At elevated temperatures, wear tracks showed macro cracking and micro fatigue cracks, as well as pitting and oxide formation on the surface of wear track.

Anodik Polarizasyon ve Kayma Aşınmasının Gemi İnşa Alüminyum Alaşımı 5083'ün Çukurcuk Korozyonu Davranışına Etkisi

This study aimed to characterize the pitting corrosion and simultaneous wear-corrosion (tribocorrosion) mechanisms of shipbuilding aluminum alloy 5083 under sliding wear and different anodic polarization conditions in simulated seawater. A tribocorrosion experimental setup was provided for the study under a 3 N load and different anodic potentials in a 3.5% NaCl solution. In the study, many grooves, parallel scratches and transverse cracks were determined on the wear track surface due to the low hardness of the test material. Chloride ions played a decisive role in the corrosion and tribocorrosion behavior of AA 5083. The dissolution of AA5083 increased from open circuit potential to higher anodic potentials. A half-cube mechanism, similar to the pitting corrosion of pure aluminum, and an intergranular pitting corrosion mechanism were observed under high anodic potentials.

Tribological behavior of MoS2/a-C:Si composite films in high-temperature air and vacuum environments

MoS2/a-C:Si composite films doped with different contents of carbon (C) and silicon (Si) were deposited using a hybrid deposition system consisting of a superimposed high-power impulse magnetron sputtering (HiPIMS)-direct current magnetron sputtering (DCMS) and a mid-frequency magnetron sputtering (MFMS). The content of C and Si elements in the films was controlled by changing the direct current (DC) of the graphite-silicon (C-Si) mosaic target. The effects of C and Si doping on the microstructure and mechanical properties of the films were investigated. In addition, the tribological behavior of the films in high-temperature air (up to 350 °C) and vacuum environments was evaluated in detail. The results suggested that MoS2/a-C:Si composite films exhibited excellent tribological properties in both high-temperature air and vacuum environments. MoS2/a-C:Si composite films doped with C and Si elements exhibited low coefficient of friction (COF) and wear rate (WR) at elevated temperatures due to the improved thermal stability. In particular, MoS2/a-C:Si composite film with 40.37 at% C displayed a low COF of 0.051 and a low WR of 1.47 × 10 −6 mm3/(N·m) at 350 °C in air. Moreover, MoS2/a-C:Si composite film also exhibited excellent tribological properties under vacuum conditions due to the precipitation of C on the wear track surface. The COF of MoS2/a-C:Si composite film with 40.37 at% C under vacuum conditions was as low as 0.018, and the WR of the film was as low as 1.99 × 10 −7 mm3/(N·m).

Synthesis of Polymer-Grafted Carbon Dots Serving as Multifunctional Lubricant Additives with Excellent Tribological Performance and Additional Rust Resistance Function for Steel/Steel Contact.

Poly(bis(2-ethylhexyl) phosphoric) methacrylic anhydride-grafted carbon dots (CD-g-PEPMA) have been controllably synthesized and used as multifunctional lubricant additives of poly(ethylene glycol) (PEG200). The polymers on the surfaces of CD-g-PEPMA not only endow them with particularly excellent dispersion stability but also enhance their adsorbability on the steel surface and embedded stability between the rubbing surfaces. Hence, CD-g-PEPMA as an additive showed outstanding rust resistance and tribological performance. Among CD-g-PEPMA-X (X represents the polymerization time), CD-g-PEPMA-2 (X = 2 h) exhibited the best tribological performance. At the optimum c of 2.0 wt %, CD-g-PEPMA-2 reduced the coefficient of friction and wear volume of PEG200 by 60.1 and 74.0%, respectively. The striking friction-reducing and antiwear functions of CD-g-PEPMA as additives can be attributed to the synergistic lubrication effect of carbon cores and polymers. The rolling, polishing, and mending effects of carbon cores combined with the favorable adsorbability and reactivity of polymers on steel surfaces synergistically induced the formation of boundary lubrication films on wear track surfaces. The films are composed of tribochemical reaction products such as Fe2(CO3)3, Fe3C, and FePO4 embedded with carbon cores, tremendously reducing the friction and wear of the friction pair. The research results can provide substantial theoretical guidance and data support for designing and developing high-efficiency polymer-CD integrative multifunctional nanoadditives toward PEG.

Late-model N, B, and P-co-doped carbon dots as additives for friction-reduction and anti-wear

Carbon dots (CDs), a kind of burgeoning carbon-based nanomaterial, were widely used as high-efficiency lubricant additives for promoting the friction-reduction and anti-wear behaviors of green PEG-based lubricating oils. Undoubtedly, advances in CDs-based lubricant additives play a crucial role in enhancing their application prospect and utility value. Recent studies suggest that doping CDs with heteroatoms, especially multiple heteroatoms could remarkably promote their tribological performance. Therefore, the state-of-the-art N, B, and P-co-doped CDs (N,B,P-CDs) with a diameter of approximately 3.8 nm and composed of amorphous structures were synthesized by conveniently “one-step” pyrolyzing the corresponding carbon sources and dopants. Noticeably, the synthetic procedures of N,B,P-CDs were uninvolved in any pre-processing and post-processing techniques, showing favorable large-scale preparation potential. Adding suitable concentrations of N,B,P-CDs, the friction-reduction, anti-wear, and load-supporting functions of PEG200 base oil can be maximally increased by 38.1 %, 86.2 %, and 66.7 %, respectively, showing outstanding tribological performances. In addition, the tribological behaviors of N,B,P-CDs are evidently better than that of N,B-CDs and P-CDs under identical test conditions, exhibiting a multiatomic synergistic lubrication effect. According to the wear track surface analysis results and previous reports, the excellent tribological performance of N,B,P-CDs attributes to their favorable film-forming ability and nano-lubrication effect in the different friction stages.

Influence of the Matrix Material and Tribological Contact Type on the Antifriction Properties of Hybrid Reinforced Polyimide-Based Nano- and Microcomposites.

This paper addresses peculiarities in the formation and adherence of a tribofilm on the wear track surface of antifriction PI- and PEI-based composites, as well as a transfer film (TF) on a steel counterface. It is shown that during hot pressing, PTFE nanoparticles melted and coalesced into micron-sized porous inclusions. In the PEI matrix, their dimensions were much larger (up to 30 µm) compared to those in the PI matrix (up to 6 µm). The phenomenon eliminated their role as effective uniformly distributed nanofillers, and the content of 5 wt.% was not always sufficient for the formation of a tribofilm or a significant decrease in the WR values. At the loaded content, the role of MoS2 and graphite (Gr) microparticles was similar, although filling with MoS2 microparticles more successfully solved the problem of adhering to a PTFE-containing tribofilm in the point tribological contact. This differed under the linear tribological contact. The higher roughness of the steel counterpart, as well as the larger area of its sliding surface with the same PTFE content in the three-component PI- and PEI-based composites, did not allow for a strong adherence of either the stable PTFE-containing tribofilm on the wear track surface or the TF on the steel counterpart. For the PEI-based composites, the inability to shield the steel counterpart from the more reactive polymer matrix, especially under the conditions of PTFE deficiency, was accompanied by multiple increases in the WR values, which were several times greater than that of neat PEI.

Tribological performance and lubrication mechanism of carbon nitride nanosheets as novel and high-efficiency additives for water lubrication

Recently, water-based nano-additives have attracted more attention with the resurrection of water lubrication owing to the increasing awareness of environmental protection and energy-saving. Highly water-dispersible carbon nitride nanosheets (C3N4 nanosheets), obtained via a high-yield and low-cost hydrothermal approach, were first used as a novel and environmentally-friendly nano-additive for water-based lubrication. The tribotest results exhibited that the tribological performances of C3N4 nanosheets in the water-based lubricant are highly sensitive to their adding concentrations. It was found that a C3N4 nanosheet concentration of 0.2 wt% could decrease the friction and wear in steel-steel contacts by 49.0% and 54.2%, respectively. The lubrication performances of C3N4 nanosheets as additives were much better than those of C3N4, attributed to their regular shape, good water dispersibility, and high reactivity. In addition, C3N4 nanosheets as additives exhibited a long service life even under harsh lubrication conditions. In addition, the molecular dynamics (MD) simulation technique was first employed to study the lubrication performances and lubrication regimes of C3N4 nanosheets. By combining the results of MD simulations and wear track surface analyses, the formation of water-based lubricating film and tribochemical film (mainly composed of organic compounds, metal nitrides, iron oxides, metal carbonates, and C3N4 nanosheets) coupled with the interlayer sliding and polishing effects of C3N4 nanosheets were primarily responsible for the excellent tribological performances of C3N4 nanosheets.

Tribocorrosion behaviour of NiTiNOL60 alloy in an alkaline environment

NiTi-based alloys subjected to aggressive tribocorrosion working conditions can deteriorate by the combined action of mechanical and chemical wear. The synergistic interaction under sliding contact and corrosive environment formed the basis of the current study. This study employed a linear reciprocating tribometer coupled with an electrochemical cell of a three-electrode configuration to investigate the behaviour of NiTiNOL60 alloy sliding against an alumina ball (Al2O3) in a NaOH environment. The resulting wear track surfaces were examined using a scanning electron microscope, optical microscope, energy dispersive spectroscopy (EDS), and stylus profilometry. While the synergistic interactions reveal that abrasive and oxidative wear mechanisms exist concurrently, an increase in applied load reduces the corrosion potential, thereby leading to a higher wear volume and increased corrosion rate. The experimental results showed that a higher corrosion rate and wear volume occurred at a higher load. The wear track analysis illuminated the various wear mechanisms at play, including abrasion, debris adhesion, pitting, delamination, ploughing, and cracking. These mechanisms were influenced by both mechanical and chemical wear, the latter notably due to corrosive attacks. EDS elemental analysis showed an increase in oxygen content at higher loads, which suggests increased corrosion due to the delamination of the oxide layer during the reciprocating sliding.

Tribological dissimilarity and solid-liquid interaction of WS2-Al film combining with different space oils in vacuum

Proper solid-liquid lubricating materials can generate synergistic effect, achieving long life under harsh operating condition for space equipment. Herein, the solid-liquid systems were constructed by WS2-Al film and typical space lubricating oils with different molecules (P201 and PFPE). The results indicate that the systems markedly prolong the life and firstly appear obvious tribological dissimilarities. Especially, WS2-Al/P201 system exhibits more longer life exceeding 6 × 105 r. It is attributed that the compact tribolayer consisting of numerous nanosheets lied flat on wear track surface and good transfer film are well formed. Differently, WS2-Al/PFPE system is found to happen more serious tribo-oxidation and only generate numerous floccule-like debris. Eventually, interactions between WS2-Al crystals and oil molecules are essentially revealed during friction process.

Transformations of the Microstructure and Phase Compositions of Titanium Alloys during Ultrasonic Impact Treatment Part III: Combination with Electrospark Alloying Applied to Additively Manufactured Ti-6Al-4V Titanium Alloy

Scanning electron microscopy, 3D optical surface profilometry, as well as X-ray diffraction and electron backscatter diffraction analysis were implemented for studying the effects of both ultrasonic impact treatment (UIT) and ultrasonic impact electrospark treatment (UIET) procedures on the microstructure, phase composition, as well as the mechanical and tribological properties of Ti-6Al-4V samples fabricated by wire-feed electron beam additive manufacturing. It was shown that he UIET procedure with the WC-6%Co striker enabled to deposit the ~10 µm thick coating, which consists of fine grains of both tungsten and titanium-tungsten carbides, as well as titanium oxide. For the UIET process, the effect of shielding gas on the studied parameters was demonstrated. It was found that the UIET procedure in argon resulted in the formation of a dense, continuous and thick (~20 µm) coating. After the UIET procedures in air and argon, the microhardness levels were 26 and 16 GPa, respectively. After tribological tests, wear track surfaces were examined on the as-built sample, as well as the ones subjected to the UIT and UIET procedures. It was shown that the coating formed during UIET in air had twice the wear resistance compared to the coating formed in argon. The evidence showed that the multiple impact of a WC-Co striker with simultaneous electrical discharges was an effective way to improve wear resistance of the Ti-6Al-4V sample.

Microstructural Characteristics and Wear Behavior of Sintered Ni-Modified Ti–xTiB2 Composites

AbstractTitanium matrix composites were manufactured using pulsed plasma sintering with the addition of 5 wt.% Ni and TiB2 (x = 5, 10, 15, 20 wt.%) particles at a sintering temperature of 1000 °C, a heating rate of 100 °C/min, and a holding time (300 s) at an applied pressure of 50 MPa. The study examines the densification, phase evolution, hardness, microstructure, and wear behavior of Ti–Ni alloys with different ceramic (TiB2) contents. The results show that increasing TiB2 content decreases relative density from 99 to 97% while increasing hardness from 229 to 586 HV0.1. The addition of Ni particles resulted in laminar α-Ti with well-defined β-Ti grain boundaries. Furthermore, the microstructural studies have revealed a dual-phase beta and alpha Ti phase with uniformly dispersed TiB2 content. As a result of the interactions between β-Ti and Ni during sintering, an intermetallic (Ti2Ni) eutectoid phase was formed. The presence of Ni and TiB2 particles reduces the average coefficient of friction, wear volume, and wear rate. Therefore, the reinforced titanium matrix composites wear track surfaces exhibited a combination of abrasive and adhesive wear modes.

Tribological and electric contact resistance properties of pulsed plasma duplex treatments on a low alloy steel

Low friction low cost tribology systems involve most often use of lubricants, which must be periodically refurbished and often present environmental issues. Furthermore, use of liquid lubricants is a non-starter in many critical applications.In this work, the performance of single process duplex tribo-conditioning treatments is explored. The treatments are based on pulsed low-pressure plasma treatments, where nitriding processes are complemented with the deposition of carbonaceous solid lubricating top layers. The duplex treatments are carried out sequentially in the same chamber.The study comprised, among others, exploring the use of different residual gas mixes and pulse frequencies. Roughened blasted 42CrMo4 low alloy steel (AISI 4140 equivalent) was used as substrate. Resulting surface properties were studied with nano-indentation, profilometry and contact angle measurements. Besides, tribological studies were carried out against 100Cr6 steel at different humidities. The evolution of the coefficient of friction and the electrical contact resistance (ECR) was assessed for each test, as well as the wear rates.Results showed tribological outcomes heavily dependent of ambient conditions, and ECR of the wear track surface condition, i.e. the amount of remaining coated surfaces. The use of pulsed plasmas generated comparatively softer, smoother and more hydrophobic surfaces.

Nano-eutectic structure induced oxide layer improving the wear resistance of CoCrxNiMoCB laser-clad coating

CoCrxNiMoCB coatings with different contents of Cr were prepared by laser cladding. While the microhardness was increased with the increased addition of Cr, the wear resistance exhibited a decreasing trend. Based on the wear tracks analysis, it was concluded that the oxide layers formed on the surface of the wear tracks with low Cr content coatings were the reason for their the low wear volume losses. The nano-eutectic structure was proved to be beneficial for the formation of the oxide layer that adhered to the wear track surfaces.

Enhanced Mechanical and Anti-Wear Properties of Magnesium by Alloying and Subsequent Extrusion–Aging Treatment

In this work, the microstructure, mechanical, and anti-wear properties of the alloyed-extruded-aged Mg-8.3Gd-4.5Y-1.4Zn-0.3Zr (wt%) alloys were investigated by X-ray diffraction (XRD), scanning electron microscope (SEM), nanoindentation, and wear tests. Results showed that the alloying—extrusion processing induced a significant grain refinement of magnesium resulting in the formation of bulk Mg24(GdYZn)5 at the grain boundaries. The grain size decreased from 116 μm in pure magnesium to 17 μm in alloyed-extruded magnesium, while the grain refinement, solid solution and second phase strengthening led to a hardness enhancement from 0.67 GPa in pure magnesium to 1.64 GPa in alloyed-extruded magnesium. Aging treatment further drove the structural homogenization of the alloyed-extruded magnesium resulting in an enhanced hardness of 1.83 GPa. During the sliding wear tests, a large-area plastic deformation layer formed on the wear track surface of pure magnesium, leading to an unstable friction coefficient and a high wear rate of 2.64 × 10−3 mm3·N−1·m−1. The alloying—extrusion—aging treatments effectively inhibited the formation of the plastic deformation layer. The wear rate of the alloyed-extruded material decreased to 1.60 × 10−3 mm3·N−1·m−1. In contrast, the alloyed-extruded-aged material showed a lower wear rate of 1.16 × 10−3 mm3·N−1·m−1. The wear failure mechanisms of all fabricated materials were further discussed according to the characterization results.