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Abstract:The present work deals with the effect of semisolid processing on microstructure and mechanical properties of Al-4.5 % Cu -5% TiB 2 in-situ cast composites. The composite was prepared by flux assisted synthesis in which TiB 2 particles were formed in-situ through an exothermic reaction between K 2 TiF 6 and KBF 4 halide salts. Al-4.5wt% Cu alloy and Al-4.5%Cu-5 % TiB 2 composite samples were forged in semisolid state with 0.3 volume fraction of liquid. Semisolid forging was carried out for two forge reductions (30% and 50% forge reductions). Microstructure studies show that the semi-solid forging results in uniform distribution of TiB 2 particles and Al 2 Cu particles in the composite. Further, TiB 2 particles play a dual role as grain refiners as well as reinforcements of composites. EBSD and nano indentation studies shows that semisolid forging results in dynamic recrystallization of grains in the composite with significant grain refinement which leads to a marked increase in hardness and elastic modulus of the alloy as well as the composite.