Metal matrix composite powders and process for producing same

A process for producing a composite powdered material consisting essentially of particles having a metal matrix phase selected from the group consisting of metals and metal alloys, and one or more relatively uniform discrete dispersed reinforcement phases in said matrix, said reinforcement phase or phases being of high strength or high hardness compounds selected from intermetallic compounds and metal compounds selected from the group consisting of metal borides, carbides, nitrides, oxides, carbonitrides, and mixtures thereof, said composite powdered particles being spheres of from about 25 to about 200 micrometers and wherein said reinforcement phase or phases have particles of a maximum size of less than about 10 micrometers, said process comprising:

• (a) entraining in a carrier gas a plurality of powders wherein at least one of said powders supplies a metal or metal alloy from which the matrix is to be formed, and wherein at least two of said powders supply the reactant constituents from which at least one of said reinforcement phases is to be formed;
• (b) feeding said powders through a high temperature zone to cause essentially complete melting and coalescence of said powders and to cause at least part of said reactant constituents to combine to form at least one of said reinforcement phases;
• and
• (c) resolidifying the resulting high temperature treated powder particles to form said composite powdered material.