Abstract: The invention provides a process for producing an aluminium-based matrix melt, having boride particles dispersed therein, which is castable, and yet when cast produces a product having a surprisingly good combination of mechanical properties such as stiffness, strength, and elongation at failure. In the process, precursors for boride particles are reacted within an aluminium-based melt to produce boride ceramic particles such as titanium diboride, the process being carried out under conditions such that the melt remains fluid.

Abstract: The invention provides a method of making a titanium carbide metal matrix alloy, by firing a particulate reaction mixture comprising carbon, titanium and matrix material, under conditions such that the titanium and carbon react exothermically to form a dispersion of fine particles comprising titanium carbide (preferably less than 10 microns) in a predominantly metal matrix. The titanium and matrix are preferably added as a titanium alloy such as ferrotitanium, e.g. eutectic ferrotitanium. The reaction conditions are preferably selected so that during the reaction a molten zone moves through the body of the reaction mixture; the resulting hard particles are of globular form; and their average size is uniform throughout the resulting dispersion.

Abstract: The invention provides a method of making a titanium boride metal matrix alloy, by firing a particulate reaction mixture comprising titanium, matrix material and a source of boron (e.g. boron carbide), under conditions such that the titanium and boron react exothermically to form a dispersion of fine particles (preferably greater than 1 micron and less than 10 microns in size) comprising titanium boride (plus titanium carbide where the source of boron is boron carbide) in a predominantly metal matrix. The titanium and matrix are preferably added as a titanium alloy such as ferrotitanium (e.g. eutectic ferrotitanium) or titanium-aluminium. The reaction conditions are preferably selected so that during the reaction a molten zone moves through the body of the reaction mixture, and the average size of the resulting hard particles is uniform throughout the resulting dispersion.