Abstract: An approach named direct reaction synthesis (DRS) has been developed to fabricate particulate composites with an extremely fine reinforcement size. ID situ Al matrix composites were fabri-cated by DRS. Extensive analysis of the composites microstructure using SEM and TEM identify that the reinforcement formed during the DRS process is Ti carbide (TiC) particle, generally less than 1.0 μm. The reacted, semisolid extruded samples exhibit a homogeneous distribution of fine TiC particles in Al-Cu matrix, Mechanical property evaluation of the composites has revealed a very high tensile strength relative to the matrix alloy. Fractographic analysis indicates ductile failure although the ductility and strength are limited by the presence of coarse titanium aluminides (Al3Ti).