Machine Learning–Based Wear Prediction of Recycled Magnesium Matrix Composites Reinforced With Ceramic Fibers

ABSTRACT This study deals with an integrated experimental‐machine learning framework for wear estimation in functionally graded composites made from recycled magnesium machining chips, using low‐cost ceramic fibers as reinforcement with the radial Modeling technique. The primary hurdle that is being addressed is the accurate prediction of wear behavior in spatially graded magnesium matrix composites, while simultaneously avoiding extensive experimental testing. Under varying degrees of applied loads (4.4 to 39 N), sliding speeds (0.45 to 4.5 m/s), and sliding distances (500 to 4500 m), the wear performance was experimentally assessed. Results demonstrate a hardness increment of 26.26% in the outer region compared to the inner region, while resistance to wear was enhanced by 19.8% in the outer zone due to the grading of ceramic fibers. A limited experimental dataset consisting of wear measurements from the inner, middle, and outer zones of the composite was utilized in developing and validating four machine‐learning models for wear rate prediction. The tree‐based ensemble methods significantly outperformed deep‐learning strategies, with the LightGBM model providing the best prediction performance across all zones and achieving optimization with a maximum tree depth of 5, 480 leaves, and a feature fraction of 0.05. Moreover, zone‐specific XGBoost models were also developed, employing customized learning rates and minimal loss reduction parameters in order to elevate prediction accuracy. The proposed machine‐learning framework thus provides a pathway for rapid and reliable wear rate estimation for ceramic fiber‐reinforced magnesium composites, significantly lessening experimental burden. Results highlight that recycled magnesium waste, when combined with ceramic reinforcement, can be effectively employed to produce sustainable and economically viable materials with improved wear resistance, particularly for automotive and industrial applications.