Synthesis of Al–TiC and Al–WC Nanocomposites by Electrical Spark Dispersion and Investigation of their Properties

Abstract

Аluminum matrix nanocomposites reinforced with titanium carbide (TiC) or tungsten carbide (WC) exhibit high strength, excellent wear resistance, and superior thermal stability. These materials are widely used in the automotive, transportation, and defense industries for manufacturing critical components operating under extreme mechanical and thermal loads. Objectives: The aim of this study was to develop a technology for producing Al–TiC and Al–WC aluminum matrix nanocomposites by the electrical spark dispersion (ESD) method and to investigate their phase composition, crystal structure, morphology, elemental composition, and the formation characteristics of reinforcing carbide phases in order to evaluate their potential as high-strength, wear-resistant structural materials. Aluminum matrix nanocomposite powders were synthesized by electrical spark dispersion. The resulting powders exhibited average particle sizes ranging from 5 to 100 nm, depending on the carbide system and processing conditions. Phase analysis performed by X-ray diffraction (XRD) confirmed the presence of α-Al together with the corresponding carbide phases (TiC and WC), without significant formation of undesirable secondary phases. A small amount of aluminum oxide was detected, which was attributed to surface oxidation during processing. Crystallite sizes calculated using the Scherrer equation ranged from 15 to 60 nm. Slight distortions of the crystal lattice were observed and were associated with interfacial stresses between the aluminum matrix and the reinforcing carbide particles. Among the investigated materials, the Al–TiC nanocomposite exhibited the most homogeneous microstructure, whereas the Al–WC system demonstrated higher density and greater carbide-phase stability due to the thermodynamic characteristics of the W–C system. The obtained results demonstrate that electrical spark dispersion is a rapid, energy-efficient, and scalable technique for producing carbide-reinforced aluminum matrix nanocomposites with controlled phase composition and nanostructure. The synthesized materials show considerable potential for the development of advanced structural materials intended for operation under severe mechanical loading, intensive wear, and elevated temperatures.