Abstract: A process for optimizing grain refining response of intermetallic TiAl.sub.3 or ZrAl.sub.3 in aluminum welding consumables comprising the steps of processing the intermetallic particles to first form a flake morphology in a master alloy solid, then as a component of the production of an ingot from an aluminum melt, to thermally fracture the flakes, then obtain dissolution of the interface material to increase distribution of the fractured particles and then, by mechanical working, to further fracture and distribute the intermetallic particles. The process is continued during the welding operation by using specific welding parameters during the welding with the consumable such that the intermetallic particles can withstand the weld pool environment in order that they maintain the characteristics and properties which will result in the creation of a small grain size in the weldment.