In this work the effect of powder forming process parameters of zirconia reinforced alumina composites on micro hardness and compressive strength was studied. The weight percentages of zirconia added to alumina, compaction pressure and sintering temperature are the process parameters selected for this analysis. Using Box-Behnken technique in Response Surface Methodology (RSM), seventeen experimental runs are developed. The sintering temperature and weight percentage of zirconia added to alumina are found to influence the responses. The influencing parameters were identified by using analysis of variance and Grey Relational Analysis (GRA). The regression model for both micro hardness and compressive strength are developed. The increasing amount of zirconia added to alumina matrix is found to enhance the compressive strength of the composite and reduces the hardness of composite. Also, multi response optimization to obtain higher hardness and compressive strength are done using both RSM and GRA. © 2015 Elsevier Ltd. All rights reserved.