Design/methodology/approach The magnesium composite was manufactured using a squeeze casting process with varying weight percentage of tungsten disulphide (WS2) particles. The wear characteristics were analysed in dry environments, applying an array of applied loads to the material to understand the wear mechanism using scanning electron microscopy, X-ray diffraction, 3D surface roughness and Raman spectroscopy. Findings The microstructure shows consistent WS2 particle distribution, grain refinement and squeeze pressure-induced fewer casting flaws. A larger weight percentage of WS2 particles in the mechanically mixed lubrication layer improves wear resistance on AZ91D/WS2 composites. Oxidation and adhesion were important wear mechanisms in a higher wt.% of the reinforced composite, while unreinforced alloy plastic deformation and sub-surface delamination were noticed. The AZ91D/7.5 wt.% WS2 composite may have better wear resistance due to WO3, and Fe2O3 self-lubricating layer. Originality/value The research on self-lubricating magnesium composite wear testing needs a deep analysis. The research is currently examining the impact of different level of reinforcement, as well as the role of tungsten disulphide in developing a strong tribolayer. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2024-0373/