Friction Stir Process (FSP) was employed to develop Cupro-Nickel/Zirconium Carbide (Cu-Ni/ZrC) surface composites. Five different groove widths ranging from 0 to 1.4 mm were made in CuNi alloy plate to incorporate different ZrC volume fraction (0, 6, 12, 18 and 24 %) to study its influence on the structure and properties of Cu-Ni/ZrC composite. Processing was performed at a Tool Rotational Speed (TRS) of 1300 rpm, Tool Traverse Speed (TTS) of 40 mm/min with a constant axial load of 6 KN. The study is performed to analyse the influence of ZrC particles and the volume fraction of ZrC particles on the microstructural evolution, microhardness, mechanical properties, and tribological characteristics of the Cu-Ni/ZrC composite. The fracture and worn-out surfaces are analysed using Field Emission Scanning Electron Microscope (FESEM) to identify the fracture and wear mechanisms. The results demonstrated a simultaneous increase in microhardness and tensile strength of the developed composite because of grain refinement, uniform dispersion, and excellent bonding of ZrC with the matrix. Besides, the wear resistance increases with increase in volume fraction of ZrC particles in the composite. The surface morphology analysis revealed that the wear mechanism transits from severe wear regime to mild wear regime with increase in volume fraction of ZrC particles.