Method of producing rapidly solidified aluminum-transition metal-silicon alloys

A method for producing aluminum alloy, comprising the steps of:

• (a) a carbothermically reducing an aluminous material containing oxides of Al, Si, and transition metals to provide a reduced material;
• (b) producing with said reduced material an alloy consisting essentially of the formula Al.sub.bal TM.sub.d Si.sub.e, wherein "TM" is at least one element selected from the group consisting of Fe Co, Ti, V, Ni, Zr, Cu, Mg and Mn, "d" ranges from about 2-20 wt %, "e" ranges from about 2.1-20 wt % and the balance is aluminum and incidental impurities;
• (c) placing said alloy in the molten state;
• and
• (d) rapidly solidifying said alloy at a quench rate of at least about 10.sup.6 K/sec to produce a rapidly solidified alloy in which the microstructure is at least about 50% composed of a microeutectic and/or microcellular structure.