Abstract <p>The present work proposes a unified strategy for the production of aluminum powders and aluminum matrix composites in a high-speed arc discharge plasma jet. During the acceleration of the plasma jet in a coaxial magnetoplasma accelerator, the material of the metal electrode system is obtained by an electrical erosion, allowing the production of aluminum powders with a polymodal particle size distribution. In addition, it is possible to introduce reinforcing particles into the metal matrix in the form of boron carbide, which is placed into a plasma structure formation channel. As a result, composite powder materials were obtained with a mass concentration of solid carbide from 6.0 to 14.4 wt % uniformly distributed in the aluminum matrix. Preliminary plasma chemical treatment of the metal matrix and the reinforcing component produces positive effects for the subsequent sintering of the composites. High levels of densification (up to 99%) and mechanical properties (140–215 HV) of bulk samples compared to standard materials (40–47 HV) were achieved. The proposed method of in-situ joining of metal matrix (aluminum) and reinforcing ceramic component (superhard carbide) allows us to avoid the disadvantages of the more common ex-situ approach (high porosity, recrystallisation, non-uniform particle distribution and agglomeration) and to improve the final properties of both pure metal products and metal matrix composites.</p>