Dual‐Strategy Design of Wear‐Resistant Silicone Rubber: Nanofiller Reinforcement and Microtexture Engineering

ABSTRACT Silicone rubber (SR) is widely utilized in engineering applications, yet its poor dry friction and wear resistance often lead to premature failure. In this work, a dual‐modification strategy—combining nano‐zinc oxide (ZnO) filler incorporation and surface microstructuring—was developed to synergistically enhance the dry tribological performance of SR. Composites with varying ZnO loadings (0–6 phr) and microstructures fabricated via sieves of different mesh sizes (1600–2000) were systematically prepared and evaluated. The optimal formulation, containing 2 phr ZnO and patterned with an 1800‐mesh microstructure, exhibited a 13.3% reduction in friction coefficient and an 81.1% decrease in wear volume compared to pristine SR. Surface analysis revealed minimal wear debris, cracks, and a 46.6% lower post‐friction roughness, indicating significantly improved durability. Mechanistic investigations demonstrated that ZnO particles enhanced rubber flexibility, mitigated stress concentration, and reduced adhesion, while the microstructures minimized real contact area and facilitated debris entrapment—collectively suppressing adhesive and fatigue wear. This work provides a simple yet effective approach to designing high‐performance, wear‐resistant silicone rubber for demanding tribological applications.