In this work, an attempt has been made to fabricate hybrid Cu-SiC-Zn composites by friction stir processing technique. Through this investigation the different number of passes was applied to assess the effect of pass adding on the mechanical, microstructural and dislocation density behavior of the specimens. Formation of the intermetallic phases between the copper matrix and Zn particles was discovered through the processed specimens. According to the obtained results, the higher passes led to obtain more uniform dispersion of the SiC particles and intermetallic phases. This higher level of particles and intermetallic phases' distribution causes remarkable reduction of grain sizes through the composites. Dislocation density for the processed specimens was determined by using the hardness measurement method. The calculated values for the dislocation densities showed that presence of SiC particles and intermetallic phases could rise up the dislocation values. Measured microhardness values for the composites exhibit that they enhanced rather than base metal and these results were confirmed by dislocation densities values of the specimens.