In the current study the effects of reinforcing cowpat ash (CPA) in aluminium 7075 alloy are briefly reported. CPA was reinforced in varying the weight percentage by 3, 6 and 9 using double stir casting technique. The effects of CPA particles are analysed and compared with base material through physical and tribological behaviours. Bonding and distribution of CPA particles were examined by optical microscope and scanning electron microscope. Mechanical and tribological properties was carried out in produced samples. The micro structural images disclosed that the CPA particles were uniformly distributed in the aluminium matrix. The fabricated composite materials density was decreasing while increasing CPA particles, but on the other hand the porosity was increasing. The ultimate tensile strength and hardness of samples increased up to 6% of CPA reinforcement and extra addition in particles has reduced their strength. The base alloy exhibited better impact strength than the composite material. Maximum decrease in wear rate was attained at 6% CPA reinforcement. The fracture SEM images exhibited cracks, voids, dimples for tensile and impact specimens and micro cuttings, micro ploughing in the worn-out surface. The corrosion rate decreased with increase in CPA particles

Keywords: Double stage stir casting, Optical & SEM microscope, Mechanical and tribological properties, Fractured and worn SEM analysis.