Friction stir processing (FSP) is a novel process for refinement of microstructure, improvement of material’s mechanical properties and production of surface layer composites. In present investigation, composite reinforced with using Zn/ MoS2 powder in as-cast alloy were developed at tool rotational speed of 664 rpm and tool transverse speed of 26 mm/min using FSP. Microstructural observation of MoS2/Zn reinforced composites confirmed the fine and equiaxed grains in the stir zone (SZ) and distribution of fine reinforced particles of MoS2/Zn in SZ. Moreover, agglomeration of MoS2/Zn particles were not observed. The ultimate tensile strength was measured to be 113 ± 9 and 82 ± 7 MPa for MoS2and Zn reinforced Al-Si alloy, respectively. The sliding wear was studied using pin-on-disk tribometer and it was found that FSP enhanced the wear resistance of the as-cast alloy. The MoS2 reinforced composite showed superior wear resistance than Zn reinforced composite and base material. To understand the acting wear mechanism, the field emission scanning electron microscope (FESEM) of worn out surfaces were performed. © 2018, Springer Science+Business Media B.V., part of Springer Nature.