Effect of W and C addition on the microstructure and phase composition of W–ZrC composites prepared by using Zr2Cu alloy and variant

W–ZrC composites were successfully fabricated by reacting amounts of Zr2Cu alloy with powder mixtures ofvarying composition including stoichiometric WC, WC with additional/W (WC/W), and WC with additional/C(WC/C). The use of WC/C powders to reactively form W–ZrC composites with increased ZrC phase content is anew approach that shows potential for ultra-high temperature applications where higher ZrC content, relative toW, is preferred such as land and aeroengines, aerospace thermal protection, and nuclear. The focus of this workwas to stabilize diffusion between W and ZrC during formation, limit interfacial phases, and increase the ZrCcontent. This was done by varying reactant powder compositions while understanding the final phase compositionand microstructure. The composites were prepared by heating the powder mixtures to 1400 ◦C for 8 h in afurnace with 96% Ar - 4% H2 gas atmosphere. The W–ZrC sample prepared using WC/C powders gave the W–ZrCcomposite with the highest ZrC phase compared to W and showed promise for phase stabilization. Additionally,there was no W2C, or residual WC identified in the final composite indicating complete conversion from WC toZrC when adding additional carbon to the WC powder. WC/C sample had the highest hardness due to theincreased ZrC phase content. This research addresses the critical comparison of carbon addition on the W–ZrCcomposites and produced composite with high ZrC content, limited interfacial phases and interlockingmicrostructure.