Zircon sand particles of different size and amount have been incorporated in Al-4.5 wt% Cu alloy by stir casting route. Coarser particles of size between 90 and 135 mu m can be dispersed in substantial amounts (up to 30 wt%), where as finer particles of size 15 and 65 mu m have limited dispersion, 10 and 20 wt%, respectively. The matrix of the composites has cellular structure, where the size of the cell depends on zircon particle size and its amount in the composite. Segregation of copper rich phase (CuAl2) has been found in the vicinity of the particle-matrix interface. The abrasive wear resistance of the composite improves with the increase in amount or decrease in size of zircon particles.