The current study investigates the erosion wear behavior of Iron-Mud / Glass Fiber Reinforced Epoxy Composite. It highlights the possible utilization of iron mine wastes for developing a new class of wear resistant hybrid polymer composites. In the present research, the composites were fabricated through hand-layup process by reinforcing woven glass fibers in epoxy polymer filled with different weight proportions of iron-mud. It was found in general that wear resistance of the fabricated composites improved with the fillers addition. The experimental runs were performed according to the Box-Behnken design of experiment methodology and ANOVA tests were carried out to determine statistical significance and percentage contribution of the control factors. The response surface methodology (RSM) optimization revealed the minimum erosion value of 1.5049 mm3/kg at the optimal parametric combination of 20% iron mud content, 70 m/s erodent velocity, 12 g/min erodent discharge rate and 90° impinging angle. Further validation tests showed a close relationship with experimental and theoretical data.
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