• Increasing Sn content up to 7.5 wt.% in Mg-Sn alloys enhances tensile strength and wear resistance due to grain refinement and Mg2Sn precipitation.
• The addition of Sn reduces casting porosity, improving overall alloy quality and structural integrity.
• Mg-7.5wt.% Sn alloy exhibits superior tribological performance with reduced wear and friction, indicating better surface durability.
• A slight reduction in microhardness is observed at higher Sn content, suggesting a trade-off between strength and hardness.