This research delivers a detailed experimental characterization and theoretical examination of heat transfer within the 2D flow of a hybrid nanofluid over an expanding sheet embedded in a porous medium. The study comprised examining the physical and optical properties, morphology, elemental structure by means of XRD, SEM paired with EDS, along with UV-Vis spectroscopy. The Fe3O4-ZrO2 hybrid composite was synthesized via the co-precipitation method. The governing equations, which incorporate chemical reactions, radiation, Joule heating, and variable viscosity, were reformulated using similarity variables and solved numerically through the BVP4C method. The impact of various parameters on flow dynamics and transport characteristics was analysed and depicted graphically. The XRD analysis has verified the existence of Fe3O4 and ZrO2 phases, highlighting subtle structural variations, while SEM-EDS showcased a consistent presence of Fe, Zr, and O elements throughout the composite. Optical evaluation indicated that the hybrid material possesses a bandgap of 2.25 eV, thereby enhancing its absorption capabilities in comparison to its individual constituents. The results imply that boosting thermal conductivity causes a decline in heat transfer efficiency, while more intense chemical reactions assist in mass transfer enhancement. Furthermore, drag force rises with increased viscosity but diminishes with higher porosity. The analysis concluded that the addition of ZrO2 into the Fe3O4 composition brought forth a hybrid composite with amplified structural, morphological, and optical benefits.