Lack Of Efficient Mixing Technology To Achieve A Uniform Distribution Of Fine Size Reinforcement Within The Matrix And The High Cost Of Producing Components Have Hindered The Widespread Adoption Of Particulate Metal Matrix Composites For Engineering Applications. The Conventional Methods Often Produce Agglomerated Structures, Exhibiting Lower Strength And Ductility Where Clusters Of Particles Or Plate-Like Primary Silicon Phase Act As Stress Concentration Sites. In Addition To The Low Ductility, The Conventional Processing Methods Are Not Economical For Producing Engineering Components Due To Poor Wettability Between The Matrix And Reinforcements. To Extend The Possibilities Of Using Composites As Structural Materials, A New Processing Method, The Melt Conditioning High Pressure Diecasting (Mc-Hpdc) Process, Has Been Developed For Manufacturing Near Net Shape Components Of High Integrity. The Key Step In This Process Is The Application Of A Sufficient Shear Rate On Particulate Clusters Embedded In The Liquid Metal To Overcome The Average Cohesive Force Of The Clusters. The Systems Studied Herein Are Commercially Available Aluminum Alloys Such As Lm24 And Lm25 Reinforced With Non-Coated Particulates Of Sic And Graphite. In Situ Composite Structures, Such As Hypereutectic Aluminum-Silicon Alloy Formed By Solidification Have Also Been Studied. Proof Of Concept Experiments Reveal That, Under A High Shear Rate And Turbulent Conditions, Liquid Penetrates The Clusters And Disperses The Individual Particles Within The Cluster, Thus Leading To A Uniform Microstructure. . In The Present Study Effort Has Been Undertaken To Quantify The Influence Of Different Processing Variables On The Resultant Reinforcement Distribution In Cast Composites. The Melt Conditioning Process Adopted Significantly Improved The Distribution Of The Reinforcement In The Matrix With A Strong Interfacial Bond Between The Two. The Characteristic Fluid Flow Of The Melt Conditioning Process Improves The Morphology Of Primary Silicon In The Hypereutectic Alloy. Compared To Those Composites Produced By Conventional High Pressure Diecasting (Hpdc), Mc-Hpdc Samples Have A Much Improved Tensile Strength And Ductility And Wear Resistance Due To Uniform Distribution Of Reinforcement. Keywords: Metal Matrix Composites, Agglomerates, Intensive Shearing, Particle