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ABSTRACT Elemental aluminum and powders with compositions of Al-1.74(4 wt.%), 32, 50 and at.% Cu, repectively, were mechanically alloyed in a Spex 8000 mixer mill using a ball-to- powder weight ratio of 10:1. The alloying process has been investigated by X-ray diffraction and differential scanning calorimetry, and the microstructure has been characterized by scanning and transmission electronmicroscopy. A solid solution of Cu in Al was formed in the composition of Al-4 wt.% Cu after 3 h of mechanical alloying process. Mechanical alloying of blended elemental Al-32 at.% Cu powders resulted in the formation of Al2Cu phaseand Al4Cu9 phase after 3 h of process. Annealing of the as-milled powders increased the relative amount of the Al2Cu phase over the Al4Cu9 phase. The Al4Cu9 intermediate phase could be directly synthesized using mechanical alloying. As for the AlCu phase, it could not be obtained directly from the mechanical alloying process. Annealing treatment on the as-milled Al50Cu50 powders is required to transform them into the AlCu phase.
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