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Present investigation deals with pin-on-disk type of tribometer used to conduct abrasive wear testing of in situ Al–4.5%Cu–xTiB2 composites for enhanced understanding of the physical wear phenomenon. Characterization studies for comprehending ceramic TiB2 reinforcement distribution and wear surface topology analysis of Al–4.5%Cu–xTiB2 composites were executed through field emission scanning electron microscopy, X-ray diffraction, and high-resolution atomic force microscopy techniques. Experimental design based on full factorial method and Taguchi's orthogonal array has been employed in the study to conduct wear experimental runs and study control parameters that are affecting the wearing phenomenon. Taguchi's loss function method along with the assistance of MINITAB 17 software was used to optimize various control parameters involved in the experiment. ANOVA method was employed further to identify percentage contribution of various control parameter combinations affecting the output parameters. Furthermore, regression model was developed to assist in calculation of output response parameters based upon the existing wear experimental results. Consequently, this in-depth investigation on wear characteristics can immensely help in understanding the true influence of various parameters and their effects on the wear phenomenon of Al–4.5%Cu–xTiB2 composites. [ABSTRACT FROM AUTHOR]