This study presents a comparative analysis of the microstructure and reciprocating wear behavior of AZ91D magnesium alloy and its friction stir processed (FSP) composites reinforced with novel dual ceramic combinations: Y₂O₃/HA, HA/ZrO₂, and Y₂O₃/ZrO₂. Reciprocating wear tests were performed under dry conditions using a ball-on-disc tribometer. TEM analyses confirmed homogeneous dispersion of reinforcements, Mg-based oxide precipitation, and substantial grain refinement. Among the composites, AZ91D/Y₂O₃/ZrO₂ exhibited the maximum wear resistance, with a 29.7% enhancement against SS440 compared to the base alloy, along with the lowest coefficient of friction. XRD, SEM, and EDS characterization of the worn surfaces and debris revealed a transition in the dominant wear mechanism from adhesive-abrasive in the AZ91D alloy to abrasive-erosive in the reinforced composites.
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