Al-B master alloys have been produced by liquid state reaction between aluminium and boron oxide in liquid aluminium. Taguchi design method has been employed to examine the effects of four process parameters of holding temperature, holding time, cooling rate and matrix type on the extent of boron dissolved and size distribution of the resulting AlB2 intermetallic flake structure. In the experiments, melting, casting, solidification, metallography, optical microscope, scanning electron microscope (SEM) and wet chemical analysis techniques have been used. Results showed that maximum 2.14 wt.% boron has been dissolved in the aluminium through direct addition of boron oxide (B2O3). It is concluded that the cooling rate is the most effective factor on the size of AlB2 particles. (C) 2013 Elsevier B.V. All rights reserved.