• Spray granulation produces spherical SiCP/AlSi10Mg composite powders with improved flowability, overcoming limitations of conventional mechanical mixing.
• In-situ reaction during LPBF forms Al4SiC4 reinforcing phases, enabling a mixed strengthening mechanism with residual SiCP.
• Optimizing laser power (310 W) minimizes porosity and achieves superior microhardness (265.38 HV) and wear resistance.
• The fabricated composites exhibit enhanced hardness compared to AlSi10Mg and other reported SiCP/AlSi10Mg composites with similar SiC volume fractions.