This study investigates the effect of mechanical ball milling with Al2O3 powders on the wear resistance of 440C steel balls. A specially-designed grinding jar was employed for the mechanical ball milling process, allowing for the comparison of samples treated with Al2O3 powders and without Al2O3 powders, as well as the heat-treatment samples. The roughness, microhardness, residue stress, and wear resistance of treated samples were investigated and compared. The results reveal that the addition of Al2O3 powders leads to significant grain refinement, increased dislocation density, and the presence of nano-structured staking faults. The treated samples exhibit a strengthened layer exceeding 200 µm, with maximum microhardness reaching 753 HV and residual stress measuring − 237 MPa. Furthermore, the treated samples demonstrate reduced coefficient of friction, wear volume, and improved wear resistance compared to the other samples. These findings highlight the efficiency of mechanical ball milling with Al2O3 powders in enhancing the wear resistance of ball mechanical components, thereby offering potential benefits for industrial applications.