To enhance the comprehensive performance of BN–SiC–ZrO 2 composite, MgAl 2O 4 particles via in-situ Al 2O 3–MgO reaction are investigated for effects on microstructure, mechanical and service properties. The reinforced composite exhibits flexural strength of 237 ± 10.8 MPa, fracture toughness of 4.05 ± 0.11 MPa·m 1/2, and Vickers hardness of 1.83 ± 0.05 Gpa, surpassing the baseline by 25.4%, 108.8%, and 64.9%, respectively. These enhancements are attributed to the pinning effect of MgAl 2O 4 and its well-bonded interfaces with the matrix. Furthermore, tribological properties improve through wear mechanism shift from abrasive wear to oxidative and adhesive wear, facilitated by copper-oxygen film lubrication. The sacrificial protection mechanism–MgAl 2O 4 reacts with molten steel to form plate-like composite oxides–effectively enhances corrosion resistance. Moreover, improved oxidation resistance is attributed to the formation of a Mg–Al–Si–O glass phase with appropriate viscosity and excellent self-healing capability that effectively inhibits oxygen diffusion.
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