Zirconium-cordierite ceramic composites have been synthesized by a co-precipitation method using MgCl2·6H2O, NaAlO2, Na2SiO3·5H2O, and ZrOCl2·8H2O as starting materials. XRD, FT-IR, and SEM techniques were employed to study the effect of zirconium on the crystal structure and microstructure of the samples. XRD results revealed that spinel MgAl2O4 and t-ZrO2 phases were predominant in the samples with low Zr4+ content (10 wt.%), whereas zircon ZrSiO4 was predominant with high Zr4+ content (≥15 wt.%). The densification behavior was improved from 30.4 to 44.6% of the theoretical density (2.6 g/cm3) at 15 wt.% of Zr4+. However, microhardness of the sintered samples was enhanced from 7.1 to 7.5 GPa with increasing the Zr4+ dose from 0 to 25 wt.%. On the other hand, the gradual increase in Zr4+ content from 0 to 25 wt.% led to suppression in the electrical resistivity (ρ) from 16.6 to 2.8 × 109 Ω/cm, respectively. In addition, the dielectric permittivity (e) of the pure cordierite was decreased with Zr4+ ion addition. The maximum dielectric permittivity (e) at low frequencies (10 MHz) was 18.7 at 10 wt.% Zr4+ content, whereas at high frequencies (1 GHz) it was 38.8 at 15 wt.% Zr4+ content.
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