Traditional monolithic materials are limited in their ability to provide a suitable balance of strength, stiffness, toughness, and ductility. Composites are rapidly being employed in a variety of high-performance applications to address these drawbacks and fulfil rising property demands. There are a variety of applications for Metal Matrix Composites (MMCs) that have effective grouping of qualities such as higher specific modulus and strength; raised temperature characteristics; wear and abrasion resistance; as well as superior abrasion resistance properties. Massive effort has been put into the creation of Al<inf>2</inf>O<inf>3</inf> and zircon particle reinforcements, which are among the many different forms of particulate reinforcements that have been studied. Age toughens AA6061 alloy/zircon composites made using the stir casting process which were studied in this study to control the impact of particle size on ageing behaviour. Reinforcing AA6061 alloy with zircons of varying sizes and weight percentages resulted in the composites. Solution treatment and age hardening at 170 °C were employed to examine the impact of zircon particles on the ageing behaviour of cast samples. After that, the samples’ microstructure and mechanical characteristics were examined. The ageing reaction of the matrix alloy was shown to be accelerated by the addition of zircon. Boost in wt.% and reduction in zircon particle size were also shown to increase peak hardness. Zircon particle size and wt.% both lowered the time it took to reach peak hardness. Hardness, compressive strength, and impact strength were all improved in the composites. The corrosion behaviour of unreinforced alloys and their composites in 1N HCl corrosive medium was investigated. In all composites, we discovered that weight loss decreased with time due to the information provided by the sample's passive oxide layer. With these findings, it may be stated that composites are more resistant to corrosion than uncoated alloys. © 2024 Elsevier B.V., All rights reserved.