In-situ processing of tungsten aluminide and tungsten reinforced aluminium matrix composites from elemental tungsten (W) and aluminium (Al) was investigated by thermal analysis and pulsed current processing (PCP). The formation mechanism of tungsten aluminides in 80 at.% Al-20 at.% W system was controlled by atomic diffusion. The particle size of W and Al in the starting powder mixture regulated the phase formation and microstructure. PCP of micron sized elemental Al and W resulted in formation of particulate reinforcements, W, Al₄W and Al₁₂W, dispersed in Al matrix. W particles were surrounded by a ~3 μm thick dual-layer structure of Al₁₂W and Al₄W. The hardness of Al matrix, containing Al₁₂W reinforcements, was increased by 50% compared to pure Al, from 0.3 GPa to 0.45 GPa and W reinforcements showed a hardness of 4.35 GPa. On PCP of 80 at.% Al-20 at.% W mixture with particle size of W and Al ~70 nm, resulted in formation of Al₄W as major phase along with small fractions of Al₅W and unreacted W phase. This suggested strongly that the particle size of the starting elemental Al and W could be the controlling parameter in processing and tailoring of phase evolution, microstructure of particulate reinforced Al matrix composite.