Many industrial applications necessitate lightweight materials that possess better tribological behaviour. Whilst aluminium based nanocomposites are proposed owing to their lightness, their tribological characteristics must be improved which are dominantly influenced by the selection of reinforcements, manufacturing process and heat treatments. In this research, an aluminium hybrid nanocomposite is produced using a novel molten salt processing and subjected to different heat treatments. Their tribological behaviour is assessed under different operating conditions viz. load, sliding velocity and material condition of the pin. Regression models are formulated to predict the tribological behaviour of developed hybrid composite under different heat treatments. The most significant parameter and optimum level for each of these operating parameters are determined using analysis of variance, main and interaction plots and response surface methodology in the end. The integrated approach helps in deciding the optimum parameter setting for the development of nanocomposite with ameliorated tribological behaviour. Under the optimized conditions, the hybrid nanocomposite could able to reduce the wear resistance by about 63% and the coefficient of friction by 18.5% than unreinforced alloy. © IMechE 2020.