The weight loss model of aluminium alloy composites with 10wt.% SiC particles by molten metal mixing method was developed in terms of abrasive grain size, reinforcement size used in the composite, applied load and sliding distance using the Taguchi method. The two-body abrasive wear behaviour of the specimen was investigated using pin-on-disc method where the samples slid against various size of SiC abrasive grits under different conditions. The orthogonal array, signal-to-noise ratio and analysis of variance were employed to study the optimal testing parameters on composites with 50 and 100 mu m particle sizes. The experimental results demonstrate that the abrasive grain size was the major parameter on abrasive wear, followed by reinforcement size. The sliding distance and applied load, however, were found to have a neglecting effect. Moreover, the optimal combination of the testing parameters could be predicted. The predicted weight loss of the composite samples was found to lie close to that of the experimentally observed ones. (c) 2005 Elsevier B.V. All rights reserved.