This project aims to increase the wear resistance of aluminium alloy 5052 (AA5052), which has very good corrosion resistance, ductility, excellent thermal and electrical conductivity. Composites were fabricated using AA5052 reinforced with silicon carbide 3% and alumina 3 & 4% by weight of the matrix, melting temperature 700 & 750 °C and stirring time 3 & 5 min. Maximum micro-hardness and tensile Strength were achieved for the combination of silicon carbide—3%, alumina—4%, melting temperature—750 °C and stirring time—3 min. Composite fabricated for the above said condition is used for wear analysis. The design of experiments was planned in full factorial method with load, speed, time and track diameter as input factors and wear as the response or output factor. The test was performed in pin-on-disc tribometer as per design of experiments. The process parameter combination of 2 kg load, 500 rpm speed, 5 min time and 70 cm track diameter was found to be the optimum condition for minimum wear of the fabricated hybrid composite. Wear resistance was increased by 51%. Speed has the maximum influence with 45.52% contribution, whereas time has the least influence with 7.02% contribution. © 2020, Springer Nature Singapore Pte Ltd.