Conventional manufacturing methods are sub-optimal for nano-composites fabrication. Inhomogeneous dispersion of the secondary phase and scalability issues are the main issues. This work focuses on an innovative method where the reinforcement is formed in-situ in the melt. It involves the reaction of the molten aluminum with a nitrogen- bearing gas injected through the melt at around 1273 K. AlN particles are expected to form through this in situ reaction. A model has been developed to predict the amount of reinforced phase. Experiments have been carried out to confirm the feasibility of the process and the mechanism of AlN formation discussed. The detrimental effect of oxygen in the melt which hinders the nitridation reaction has been proved. The effect of process times and the addition of alloying elements (Mg and Si) have also been investigated
