Reduced-temperature processing and consolidation of ultra-refractory Ta4HfC5

TaC, HfC, and WC powders were subjected to high-energy milling and hot pressing to produce Ta4HfC5, a composite of Ta4HfC5 + 30 vol.% WC, and a composite of Ta4HfC5 + 50 vol.% WC. Sub-micron powders were examined after four different milling intervals prior to hot pressing. XRD was used to verify proper phase formation. SEM, relative density, and hardness measurements were used to examine the resulting phases. Hot pressed compacts of Ta4HfC5 showed densification as high as 98.6% along with Vickers hardness values of 21.4 GPa. Similarly, Ta4HfC5 + 30 vol.% WC exhibited 99% densification with a Vickers hardness of 22.5 GPa. These levels of densification were achieved at 1500 °C, which is lower than any previously reported sintering temperature for Ta4HfC5. Microhardness values measured in this study were higher than those previously reported for Ta4HfC5. The WC additions to Ta4HfC5 were found to improve densification and increase microhardness.