Aluminum nanocomposites, known for their superior properties, have gained significant attention in modern industries. This research employed a hybrid of wire arc additive manufacturing (WAAM) and friction stir processing (FSP) to fabricate aluminum nanocomposites incorporating zirconia (ZrO 2) nanoparticles. Aluminum specimens were created with seven layers of WAAM, and a groove was machined into each sample, filled with zirconia nanoparticles. The groove was then sealed using pinless FSP and then subjected to FSP with a pin tool in 2, 3, and 4 passes. Control samples included a two-pass FSP sample and a raw WAAM sample. Microstructure was conducted using optical microscopy (OM), field-emission scanning electron microscopy (FE-SEM), and X-ray diffraction (XRD). Mechanical properties were evaluated through tensile and microhardness testing, tribological properties via the pin-on-disk test, and corrosion resistance using electrochemical polarization testing. Results revealed that in the four-pass FSP nanocomposite sample, the grain size diminished by 92.36% to 3.4   µm, while the microhardness increased by 64% to 95.32 HV. The yield and tensile strength rose to 305 ± 18 and 469 ± 24   MPa, respectively. The friction coefficient and wear rate decreased, while the wear mechanism shifted from a mixed adhesive-abrasive wear to predominantly abrasive wear. The corrosion rate decreased to 17.52   µm.y -1.