<p>Al6061 plays a major role in the development of light weight components in the applications of structural, marine, automobile and aerospace. It is evident from the literature that, reinforcing with ceramics like SiC, Al₂O₃, B₄N, TiC, etc., had significantly improved the mechanical properties of Al6061 by varying amounts of the reinforcement. However, such additions often reduce ductility due to the finer grain size that may results in catastrophic failures due to brittleness posing challenges for real-time applications. Current study employs a novel ultrasonic-assisted stir casting process by reinforcing with nano Al₂O₃ particles in the Al6061 matrix, aiming to improvise its mechanical properties without compromising the ductility of the composite. The distribution of nano Al₂O₃ particles, grain refinement, and fracture characteristics of the composites are examined using scanning electron microscopy (SEM) and optical microscopy. Results revealed that, at 2.5&#xa0;wt.% nano Al₂O₃ reinforcement of Al6061, the tensile strength and flexural strength improved by 48.8 and 75%, respectively, simultaneously improving the hardness by 45.9% highlighting that the ductility of the composite sustained; fractography analysis further reveals a predominant ductile mode of failure.</p>