Functionally gradient composites were spray formed via vacuum plasma spray deposition using tungsten cylindrical substrates. Materials deposited included tungsten-hafnium alloys and M-2 tool steel. Some deposits included micro-laminate layering with hafiiium alloys sprayed within the tungsten-hafnium matrix. Vacuum plasma deposition was shown to provide a viable means of producing functionally gradient composites from tungsten base materials. This was determined both by microstructural characterization of deposit structures and by measuring the compressive properties of the materials. Compression testing of the W-Hf matrix composites demonstrated compression strength of 1,552 MPa (225 ksi). Compression strengths of the tungsten/steel composite averaged 1,068 MPa (155 ksi). Failure of the W-Hf samples occurred via fracture of the tungsten/hafnium matrix whereas the tungsten/steel composites failed within the wrought tungsten core.

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