A　novel　in　situ　reaction　technique　is　developed　to　prepare　TiC/7075　composites.　This　technique　provides　a　new　approach　overcoming　the　problems　of　loss　and　agglomeration　of　reinforcement　particles　when　they　are　in　situ　formed　in　a　molten　metal　first　and　then　injected　into　the　spray　cone　of　molten　droplets　during　the　spray　forming　process.　Experimental　results　have　shown　that　the　presence　of　strip　or　rectangular-like　Al3Ti,　which　is　detrimental　not　only　to　the　fracture　toughness,　but　also　to　the　stability　of　the　microstructure,　can　be　avoided　completely　from　the　final　product　by　using　a　proper　Ti:C　molar　ratio　in　the　Ti-C-Al　performs.　The　mechanisms　of　formation　or　absence　of　Al3Ti　phase　in　the　TiC/7075　composites　are　explained　based　on　thermodynamics　of　the　system.　The　modification　of　the　microstructure　of　the　spray-formed　7075　alloy　can　be　understood　in　the　light　of　atomic　diffusion.　The　wear　results　showed　that　the　wear　rates　of　the　spray-formed　7075　alloy　and　its　composites　increased　with　applied　loads.　At　higher　applied　loads,　the　7075　alloy　exhibited　superior　wear　resistance　than　that　of　the　composites.　This　is　attributed　to　increased　microcracking　tendency　of　the　composites　than　the　matrix　alloy.　(C)　2011　Elsevier　B.V.　All　rights　reserved.