A process of making a carbon alloy from other carbonaceous materials is provided. A particulate of partially pyrolyzed carbon (PPC) base is formed on heating a carbon-containing feed material and a nucleating agent in the form of an interactive filler. The nucleating agent is adhered together to the PPC particles by application of heat. The material is molded into a shape, voids in the material are collapsed and the resulting carbon alloy is cooled.