The matrix material AA2219 aluminum alloy is considered and the reinforcements were equally distributed thought out the matrix. Zirconium dioxide (ZrO₂)-coal ash reinforcements were widely known as alternative materials in aerospace mainframe structures, fuselage body in defence and aviation industry. Four different samples were fabricated by varying the ZrO₂ weight percent as (2, 4, 6, and 8 wt.%) with constant 10% coal ash reinforcement powders were prepared and used as reinforcement powders in fabricating AA2219 metal matrix composites (MMCs). The surface morphology of the fabricated samples was studied using the scanning electron microscope (SEM) and the mechanical properties were studied using the universal testing machine (UTM). Specimen with 8% ZrO₂ + 10% coal ash exhibited a good morphology with fine granular structure. From the tensile results it is found to be an elevation of tensile strength on increase of the ZrO₂ reinforcement. The tensile strengths are increased as 85, 96, 102, and 105 MPa with 2, 4, 6, and 8% of ZrO₂ filler. A substantial upsurge in mechanical properties has been pragmatic in the cases of 2 to 8% weight percentage accumulation of reinforcement of ZrO₂ with 10% coal ash constant. 8% weight addition exhibited a high durability. Thus, the optimum specimen can be used as an alternative material for airframe modules.

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