The importance of aluminium surface composites in material processing has significantly increased as a result of their superior tribological properties. The reinforcing of surface composites with hard ceramics improves their tribological characteristics even further. In the current study, hybrid aluminium surface composites containing TiO2 and SiC particles were fabricated by cooling assisted friction stir processing, and they were expected to have improved tribological behaviour. The AA5083 was reinforced with TiO2 and SiC powder particles in a 50:50 ratio by employing the groove method. Microstructural examination revealed significant grain size reduction from 72 μm to 3 μm due to dynamic recrystallization, mechanical stirring, plastic deformation, and grain refinement. The uniform dispersion of reinforcement particles throughout the processed zone demonstrated the efficacy of FSP over conventional methods. Microhardness measurements showed a substantial increase from 61.58 HV to 103.27 HV with the use of cooling-assisting media and a combination of TiO2 and SiC particles. Erosion wear analysis indicated a 73% reduction in wear rate, from 5.3 gm/min * 10–3 to 1.4 gm/min * 10–3, attributed to the enhanced hardness and hybrid reinforcement strategy, effectively mitigating abrasive and adhesive wear mechanisms.