Abstract: A TiC/A1-20Si-5Fe composite is fabricated by melt in situ reaction spray forming and effect of in situ TiC particulate on the microstructure of spray-deposited Al-20Si-5Fe alloy is studied. Both theoretical and experimental results have shown that some Al-Si-Fe intermetallic phases with needle-like structure exist in the spray-deposited Al-20Si-5Fe alloy, which is harmful to the tensile properties of the composites. The needlelike intermetallic phases can be entirely absent in the final product after 5%Tic (mass fraction) particulates are in situ formed in spray-deposited Al-20Si-5Fe alloy.