The flux-cored wires containing Al60V40, TC4, and TiB 2 powders were prepared and used to fabricate gradient TiBw/TC4 composites through the wire arc direct energy deposition (WA-DED) process. During the deposition, the in-situ reaction-synthesized TiB whiskers (TiBw) were remelted and diffused into the upper deposition layers. The diffusion behavior of TiBw and its influence on the microstructure and mechanical properties were investigated in depth. The results show that the driving force for the cross-layer diffusion of the reinforcement can ...