Properties and Microstructure Evaluation in NiAl-xWC (x = 0 − 90 wt.%) Intermetallic-Based Composites Prepared by Mechanical Alloying

In this work, NiAl-xWC (x = 0 − 90 wt.% WC) intermetallic-based composites were successfully synthesized by mechanical alloying (MA) and a hot-pressing approach. As initial powders, a mixture of nickel, aluminum and tungsten carbide was used. The phase changes in analyzed systems after mechanical alloying and hot pressing were evaluated by an X-ray diffraction method. Scanning electron microscopy and hardness test examination were used for evaluating microstructure and properties for all fabricated systems from the initial powder to the final sinter stage. The basic sinter properties were evaluated to estimate their relative densities. Synthesized and fabricated NiAl-xWC composites showed an interesting relationship between the structure of the constituting phases, analyzed by planimetric and structural methods and sintering temperature. The analyzed relationship proves that the structural order reconstructed by sintering strongly depends on the initial formulation and its decomposition after MA processing. The results confirm that it is possible to obtain an intermetallic NiAl phase after 10 h of MA. For processed powder mixtures, the results showed that increased WC content intensifies fragmentation and structural disintegration. The final structure of the sinters fabricated in lower (800 °C) and higher temperature regimes (1100 °C), consisted of recrystallized NiAl and WC phases. The macro hardness of sinters obtained at 1100 °C increased from 409 HV (NiAl) to 1800 HV (NiAl + 90% WC). Obtained results reveal a new applicable perspective in the field of intermetallic-based composites and remain highly anticipated for possible application in severe-wear or high-temperature conditions.