In this research work, the effect of mechanical alloying time on the microstructural, physical, and mechanical properties of Al-ZrB2 metal matrix composites (MMCs) was evaluated. A mixture of Al and ZrB2 powders was mechanically alloyed at different times, and then the resulting composite powder was heated, consolidated and turned into bulk material by warm equal channel angular pressing (ECAP) at the temperature of 250°C. SEM micrographes indicate that the size of the obtained particles decreases by increasing the time of mechanical alloying up to 18 hours. However, after this time, the particle size has increased. By means of mechanical alloying for 18 hours, the average size of fine particles reached 823 nm, while coarse particles were 8 µm. The calculation of the size of crystallites by the use of XRD examination implys that the rate of crystallite size reduction after 12 hours of mechanical alloying is gradually reduced, and that is reached its lowest level after 18 hours. After that, increasing the time of mechanical alloying has led to an increase in the size of the crystallites and a decrease in the lattice strain. The Al-ZrB2 MMC bulk samples processed by the ECAP method, with an optimum amount of ZrB2 (5 wt.%) had a relative density, hardness, and ultimate shear strength of 99.3%, 170 HV, and 151 MPa, respectively, using powders which have been mechanically alloyed up to 24 hours.