The aim of this study was to demonstrate the advantages and the method of application of the SHS process in the manufacture of (NiAl/Ni₃Al)/TiB₂ composites. A comparison was made between sinters manufactured by FAST/SPS using two different routes to process the substrates, which formed the composite matrix. The evaluation criteria were based on measurements of selected physical, mechanical, and tribological properties, and on microstructure examinations. The evaluation has indicated a preferable method for the manufacture of composites, where the SHS reaction takes place during compaction of the powder mixture. This produces a sinter characterized not only by the high degree of sintering, and high values of the Young’s modulus and HV1 hardness, but also by the satisfactory resistance to tribological wear. Additionally, the use of this process saves energy and reduces product-making cost, owing to a less expensive technique of making individual substrates.

As part of the tests, a two-phase NiAl/Ni₃Al alloy and a composite based on this alloy with 4 vol% addition of TiB₂ were produced by the reactive FAST/SPS (Field Assisted Sintering Technology/Spark Plasma Sintering) sintering method. The sintering process was carried out at 1273 K for 30 s under an argon atmosphere. The effect of reactive SPS on the density, microstructure, and mechanical and tribological properties of a dual-phase Ni-Al intermetallic compound and Ni-Al-TiB₂ composite was investigated. Products obtained were characterized by a high degree of sintering (over 99% of the theoretical density). The microstructure of sinters was characterized by a large diversity, mainly in regard to the structure of the dual-phase alloy (matrix). Compression tests showed satisfactory plastic properties of the manufactured materials, especially at high temperature (1073 K). For both materials at room temperature, the compressive strength was over 3 GPa. The stress–strain curves were observed to assume a different course for the matrix material and composite material, including differences in the maximum plastic flow stress depending on the test temperature. The brittle-to-ductile transition temperature was determined to be above 873 K. The research has revealed differences in the physical, mechanical and tribological properties of the produced sinters. However, the differences favourable for the composite were mostly the result of the addition of TiB₂ ceramic particles uniformly distributed on grain boundaries.

In this study, four composites with different ZrB₂ content were made by the Spark Plasma Sintering (SPS/FAST) technique. The sintering process was carried out at 1373 K for 5 min under an argon atmosphere. The effect of ZrB₂ reinforcing phase content on the density, microstructure, and mechanical and tribological properties of composites was investigated. The results were compared with experimental data obtained for 316L austenitic stainless steel without the reinforcing phase. The results showed that the ZrB₂ content significantly affected the tested properties. With the increasing content of the ZrB₂ reinforcing phase, there was an increase in the Young’s modulus and hardness and an improvement in the abrasive wear resistance of sintered composites. In all composites, new fine precipitates were formed and distributed in the steel matrix and along the grain boundaries. Microstructural analysis (Scanning Electron Microscopy (SEM), Wavelength Dispersive Spectroscopy (WDS)) has revealed that the fine precipitates chromium contained chromium as well as boron.

The effect of zirconium diboride (ZrB₂) and titanium diboride (TiB₂) on the microstructure as well as the physical, mechanical, and tribological properties of composites based on 316 L steel is presented. Each reinforcing phase was added to the base alloy in the amount of 5 wt% and 10 wt%. The composites were fabricated by the SPS process (Spark Plasma Sintering). The results show that the weight fraction of the reinforcing phase affects the physical, mechanical, and tribological properties of the sintered composites. The sintered materials were characterized by a very high level of density. The addition of TiB₂ has proved to be effective in increasing the hardness and compressive strength of the composites. The hardness of the composites with the addition of 10% TiB₂ increased by 100% compared to the hardness of sintered 316L steel. It was found that introducing ZrB₂ to the steel matrix significantly improved the wear resistance of the composites. The results showed that compared to 316L steel with the wear rate of 519 × 10⁻⁶ mm³/Nm, the wear rate of the composites containing 10% ZrB₂ decreased more than twice, i.e., to 243 × 10⁻⁶ mm³/Nm.

This study aimed to investigate the physical, mechanical, corrosion, and tribological properties of Cu-based composites with varying zirconium diboride content. The composites were successfully consolidated using spark plasma sintering (SPS) at temperatures of 850 °C and 950 °C and a pressure of 35 MPa. The effect of the ZrB₂ content and the sintering temperature on the properties of the Cu-based composites was investigated. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and X-ray diffraction were used to analyse microstructure evolution in copper matrix composites. Microhardness tests were used to evaluate mechanical properties. Wear behaviour was evaluated using a ball-on-disc method. Corrosion properties were estimated on electrochemical tests, such as potentiodynamic polarisation. The results demonstrated an enhancement in the density and porosity of the composites as the sintering temperature increased. A uniform dispersion of ZrB₂ was observed in the copper matrix for all composites. With an increase in the content of the ZrB₂ reinforcement phase, there was an increase in microhardness and an improvement in the wear resistance of the sintered composites. A reduction in densification and corrosion resistance of Cu-based composites was observed with increasing ZrB₂ content.