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Volume 109
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Plasma dynamic synthesis of hybrid carbide-reinforced aluminium matrix composites
Dmitriy Nikitin a, Ivan Shanenkov a *, Artur Nassyrbayev a, Alexander Tsimmerman a, Yuliya Shanenkova a, Egor Kashkarov a, Junzhi Li b, Wei Han c *
a National Research Tomsk Polytechnic University, Tomsk, 634050, Russia
b School of Materials Science and Engineering, Key Laboratory of Materials Design and Quantum Simulation, Changchun University, Changchun, 130022, China
c College of Physics, International Center of Future Science, Jilin University, Changchun, 130012, China
10.1016/j.partic.2025.12.024
Volume 109, February 2026, Pages 247-257
Received 15 November 2025, Revised 27 December 2025, Accepted 30 December 2025, Available online 8 January 2026, Version of Record 14 January 2026.
E-mail: shanenkovii@tpu.ru; whan@jlu.edu.cn
Highlights

• Hybrid Al matrix composites with several carbides are formed in a pulsed arc discharge plasma.

• Plasma impact provides polymodal size particle distribution of as-prepared HAMCs.

• Features of as-prepared HAMCs enable high densities (up to 99.5 %) after the SPS process.

• Bulk HAMCs demonstrate enhanced mechanical (134 HV) and comparable thermal properties.


Abstract

The development of hybrid aluminum matrix composites (HAMCs) reinforced with superhard carbides is a crucial scientific direction, which still faces challenges related to the inhomogeneous distribution of reinforcing component and the formation of undesirable interphase compounds. This study was aimed to develop a universal in-situ approach for plasma dynamic synthesis of HAMCs with enhanced structural, mechanical, and functional properties. Dispersed powders of HAMCs reinforced with WC, SiC, and B4C were produced by high-speed spraying of a multicomponent thermal plasma jet, followed by spark plasma sintering (SPS) to fabricate bulk materials. The developed plasma processing technology provides complete alignment of the HAMCs components and form a composite structure with a polymodal particle size distribution, where the aluminum matrix is primarily presented with porous microsized particles filled in by ceramic component. These features of composite powders affect high mechanical properties of bulk sintered samples with density values of up to 99 % and microhardness values of up to 134 HV, which exceed those of known analogs and pure aluminum. A combination of high mechanical, thermal and electrical properties confirms the functionality of synthesized materials and highlights the potential of applying in-situ approach based on plasma processes for producing advanced HAMCs with improved performance characteristics.

Graphical abstract
Keywords
Aluminium matrix composites; Hybrid composites; Carbides; Arc discharge; Thermal plasma
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