<p>Tuning the interfacial interaction between the filler and the matrix is essential to fabricate high-performance polymer nanocomposites. Epoxy resin-based composites face inherent matrix limitations in tribological applications. Nanosilica (nano-SiO₂) shows promise as a nano-filler for enhancing the mechanical properties of epoxy resin, but its poor dispersibility, agglomeration tendency, and limited compatibility with epoxy present challenges. A multifaceted approach is needed to improve anti-wear and friction reduction properties while enhancing mechanical attributes. This study investigates the integration of silane-modified nano-SiO₂ and basalt flakes (BFs) as fillers in epoxy resin (EP) formulations. Various filler ratios were used to create nano-SiO₂/BFs/EP composite coatings. When basalt flakes were added at 30% and nanosilica at 5%, the resulting composite exhibited optimal friction reduction and anti-wear properties, with the coefficient of friction and wear rate decreasing by 64.3% and 56.2%, respectively, compared to pure epoxy coatings. Scanning electron microscopy (SEM) analysis revealed enhanced interfacial adhesion among nano-SiO₂, basalt flakes, and epoxy, along with improved fracture toughness. This improvement is attributed to the participation of amine-functionalized nano-SiO₂ in the curing process of epoxy, which, when mixed with basalt flakes, reduces adhesion between the flakes, promotes better dispersion, and enhances the overall performance of the epoxy matrix. During friction and wear, the lamellar structure of the basalt flakes and the "ball effect" of nano-SiO₂ facilitate rolling friction, while the layered structure of wear debris provides excellent lubrication properties.</p> Graphical Abstract <p></p>