Aluminium matrix tungsten aluminide and tungsten reinforced composites by solid-state diffusion mechanism.

In-situ processing of tungsten aluminide and tungsten reinforced aluminium matrix composites from elemental tungsten (W) and aluminium (Al) was investigated by thermal analysis and pulsed current processing (PCP). The formation mechanism of tungsten aluminides in 80 at.% Al-20 at.% W system was controlled by atomic diffusion. The particle size of W and Al in the starting powder mixture regulated the phase formation and microstructure. PCP of micron sized elemental Al and W resulted in formation of particulate reinforcements, W, AlW and AlW, dispersed in Al matrix. W particles were surrounded by a ~3 μm thick dual-layer structure of AlW and AlW. The hardness of Al matrix, containing AlW reinforcements, was increased by 50% compared to pure Al, from 0.3 GPa to 0.45 GPa and W reinforcements showed a hardness of 4.35 GPa. On PCP of 80 at.% Al-20 at.% W mixture with particle size of W and Al ~70 nm, resulted in formation of AlW as major phase along with small fractions of AlW and unreacted W phase. This suggested strongly that the particle size of the starting elemental Al and W could be the controlling parameter in processing and tailoring of phase evolution, microstructure of particulate reinforced Al matrix composite.