The early stages of phase formation during mechanical alloying of Ti/A
l powder blends were investigated using x-ray diffraction and transmis
sion electron microscopy. After the initial formation of an hcp solid
solution by the diffusion of Al into Ti, the first phase nucleated at
the Ti/Al interface is a (partially) L1(2)-ordered fcc phase with a cr
ystallite size of about 10-30 nm. This observation is ascribed to the
kinetics of phase formation and the energetic destabilization of the e
quilibrium intermetallic compounds during milling due to chemical and
structural disordering. A mechanism of phase formation during mechanic
al alloying is proposed, and comparisons are made with the thermal ann
ealing behavior of Ti/Al multilayered thin films.