The SiCp/Al composite was fabricated by a plasma spraying technique. By mean of OM SEM, TEM, XRD, SAED, EDS techniques, the microstructures for sprayed SiCp/Al composite were investigated in detail. The composite consisted of SiC and Al, along with single crystal Si and amorphorous Si, and tiny Al2O3. On the whole, the interfaces between SiC particle and Al bonded well, and tiny reactants like Al2O3 can be found near the interfaces. The mechanisms of chemical reactions were given during spraying. The nano-Al grains and nano-Al particles were seen in the sprayed composite. The formation mechanism of nano-Al grains and particles of SiCp/ Al composite was explained. Some interface relationships existed in the sprayed composite.

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