U.S. patent application number 13/487323 was filed with the patent office on 2012-09-20 for cemented carbide - metallic alloy composites.
This patent application is currently assigned to TDY INDUSTRIES, LLC. Invention is credited to Morris E. Chandler, Prakash K. Mirchandani, Eric W. Olsen.
Application Number | 20120237386 13/487323 |
Document ID | / |
Family ID | 41278446 |
Filed Date | 2012-09-20 |
United States Patent
Application |
20120237386 |
Kind Code |
A1 |
Mirchandani; Prakash K. ; et
al. |
September 20, 2012 |
CEMENTED CARBIDE - METALLIC ALLOY COMPOSITES
Abstract
A method of making a composite sintered powder metal article
includes providing a first powder comprising hard particles and a
powdered binder in a first region of a mold. Providing a second
powder comprising a metal or metal alloy powder in a second region
of the mold, wherein the second powder contacts the first powder
and comprises at least one of a metal powder and a metallic alloy
powder. The first powder and the second powder are consolidated in
the mold to provide a green compact. The green compact is sintered
to provide a composite sintered powder metal article comprising a
cemented hard particle region formed from the first powder and
metallurgically bonded to a metallic second region formed from the
second powder.
Inventors: |
Mirchandani; Prakash K.;
(Houston, TX) ; Chandler; Morris E.; (Santa Fe,
TX) ; Olsen; Eric W.; (Cypress, TX) |
Assignee: |
TDY INDUSTRIES, LLC
Pittsburgh
PA
|
Family ID: |
41278446 |
Appl. No.: |
13/487323 |
Filed: |
June 4, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12476738 |
Jun 2, 2009 |
8221517 |
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13487323 |
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61057885 |
Jun 2, 2008 |
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Current U.S.
Class: |
419/6 |
Current CPC
Class: |
B22F 2999/00 20130101;
B22F 2998/00 20130101; C22C 27/04 20130101; B22F 2998/00 20130101;
C22C 29/00 20130101; B22F 3/10 20130101; B22F 3/10 20130101; B22F
3/02 20130101; B22F 2998/10 20130101; C22C 29/08 20130101; B22F
2998/10 20130101; B22F 2999/00 20130101; B22F 2201/013 20130101;
B22F 2201/20 20130101; C22C 32/00 20130101 |
Class at
Publication: |
419/6 |
International
Class: |
B22F 7/02 20060101
B22F007/02 |
Claims
1. A method of making a composite sintered powder metal article,
comprising: providing a first powder in a first region of a mold,
the first powder comprising hard particles and a powdered binder;
providing a second powder in a second region of the mold, wherein
the second powder contacts the first powder and comprises at least
one of a metal powder and a metallic alloy powder selected from a
steel powder, a nickel powder, a nickel alloy powder, a molybdenum
powder, a molybdenum alloy powder, a titanium powder, a titanium
alloy powder, a cobalt powder, a cobalt alloy powder, a tungsten
powder, and a tungsten alloy powder; consolidating the first powder
and the second powder in the mold to provide a green compact; and
sintering the green compact to provide a composite sintered powder
metal article comprising a cemented hard particle region formed
from the first powder and metallurgically bonded to a metallic
second region formed from the second powder.
2. The method of claim 1, wherein a thermal conductivity of the
metallic second region is less than a thermal conductivity of the
cemented hard particle region.
3. The method of claim 2, wherein a thermal conductivity of the
metallic second region is less than 100 W/mK.
4. The method of claim 1, wherein a melting point of the metallic
second region is greater than 1200.degree. C.
5. The method of claim 1, wherein the metallic second region
comprises up to 50 percent by volume of one or more hard particles
selected from the group consisting of a carbide, a nitride, a
boride, a silicide, an oxide, and solid solutions thereof.
6. The method of claim 1, wherein the metallic second region
comprises up to 50 percent by volume of tungsten carbide
particles.
7. The method of claim 1, wherein the cemented hard particle region
comprises hard particles dispersed in a continuous binder
phase.
8. The method of claim 7, wherein the hard particles comprise one
or more hard particles selected from a carbide, a nitride, a
boride, a silicide, an oxide, and solid solutions thereof, and the
binder phase comprises at least one of cobalt, a cobalt alloy,
molybdenum, a molybdenum alloy, nickel, a nickel alloy, iron, and
an iron alloy.
9. The method of claim 7, wherein the hard particles comprise
carbide particles of at least one transition metal selected from
titanium, chromium, vanadium, zirconium, hafnium, tantalum,
molybdenum, niobium, and tungsten.
10. The method of claim 1, wherein the cemented hard particle
region comprises tungsten carbide particles.
11. The method of claim 10, wherein the tungsten carbide particles
have an average grain size of 0.3 to 10 .mu.m.
12. The method of claim 7, wherein the binder phase comprises
cobalt.
13. The method of claim 1, wherein the cemented hard particle
region comprises from 2 to 40 volume percent of a continuous binder
phase and from 60 to 98 volume percent of hard particles dispersed
in the continuous binder phase.
14. The method of claim 1, wherein the cemented hard particle
region comprises particles of a hybrid cemented carbide.
15. The method of claim 14, wherein the hybrid cemented carbide
particles comprise: a cemented carbide continuous phase; and a
cemented carbide dispersed phase dispersed in the cemented carbide
continuous phase; wherein the contiguity ratio of the cemented
carbide dispersed phase in the hybrid cemented carbide particles is
less than or equal to 0.48.
16. The method of claim 15, wherein the volume fraction of the
cemented carbide dispersed phase in the hybrid cemented carbide
particles is less than 50 volume percent and a contiguity ratio of
the cemented carbide dispersed phase in the hybrid cemented carbide
particles is less than or equal to 1.5 times the volume fraction of
the dispersed phase in the hybrid cemented carbide particles.
17. The method of claim 1, wherein metallic second region has a
thickness of at least 100 microns.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C.
.sctn.120 as a divisional application of co-pending U.S. patent
application Ser. No. 12/476,738, filed Jun. 2, 2009, which claims
priority to U.S. Provisional Patent Application Ser. No.
61/057,885, filed Jun. 2, 2008, now abandoned.
FIELD OF TECHNOLOGY
[0002] The present disclosure relates to improved articles
including cemented hard particles and methods of making such
articles.
BACKGROUND
[0003] Materials composed of cemented hard particles are
technologically and commercially important. Cemented hard particles
include a discontinuous dispersed phase of hard metallic (i.e.,
metal-containing) and/or ceramic particles embedded in a continuous
metallic binder phase. Many such materials possess unique
combinations of abrasion and wear resistance, strength, and
fracture toughness.
[0004] Terms used herein have the following meanings. "Strength" is
the stress at which a material ruptures or fails. "Fracture
toughness" is the ability of a material to absorb energy and deform
plastically before fracturing. "Toughness" is proportional to the
area under the stress-strain curve from the origin to the breaking
point. See McGraw Hill Dictionary of Scientific and Technical Terms
(5th ed. 1994). "Wear resistance" is the ability of a material to
withstand damage to its surface. "Wear" generally involves
progressive loss of material due to a relative motion between a
material and a contacting surface or substance. See Metals Handbook
Desk Edition (2d ed. 1998).
[0005] The dispersed hard particle phase typically includes grains
of, for example, one or more of a carbide, a nitride, a boride, a
silicide, an oxide, and solid solutions of any of these types of
compounds. Hard particles commonly used in cemented hard particle
materials are metal carbides such as tungsten carbide and, thus,
these materials are often referred to generically as "cemented
carbides." The continuous binder phase, which binds or "cements"
the hard particles together, generally includes, for example, at
least one of cobalt, cobalt alloy, nickel, nickel alloy, iron and
iron alloy. Additionally, alloying elements such as, for example,
chromium, molybdenum, ruthenium, boron, tungsten, tantalum,
titanium, and niobium may be included in the binder phase to
enhance particular properties. The various commercially available
cemented carbide grades differ in terms of at least one property
such as, for example, composition, grain size, or volume fractions
of the discontinuous and/or continuous phases.
[0006] For certain applications parts formed from cemented hard
particles may need to be attached to parts formed of different
materials such as, for example, steels, nonferrous metallic alloys,
and plastics. Techniques that have been used to attach such parts
include metallurgical techniques such as, for example, brazing,
welding, and soldering, and mechanical techniques such as, for
example, press or shrink fitting, application of epoxy and other
adhesives, and mating of mechanical features such as threaded
coupling and keyway arrangements.
[0007] Problems are encountered when attaching cemented hard
particle parts to parts formed of steels or nonferrous alloys using
conventional metallurgical or mechanical techniques. The difference
in coefficient of thermal expansion (CTE) between cemented carbide
materials and most steels (as well as most nonferrous alloys) is
significant. For example, the CTE of steel ranges from about
10.times.10.sup.-6 in/in/.degree. K. to 15.times.10.sup.-6
in/in/.degree. K., which is about twice the range of about
5.times.10.sup.-6 in/in/.degree. K. to 7.times.10.sup.-6
in/in/.degree. K. CTE for a cemented carbide. The CTE of certain
nonferrous alloys exceeds that of steel, resulting in an even more
significant CTE mismatch. If metallurgical bonding techniques such
as brazing or welding are employed to attach a cemented carbide
part to a steel part, for example, enormous stresses may develop at
the interface between the parts during cooling due to differences
in rates of part contraction. These stresses often result in the
development of cracks at and near the interface of the parts. These
defects weaken the bond between the cemented hard particle region
and the metal or metallic region, and also the attached regions of
the parts themselves.
[0008] In general, it is usually not practical to mechanically
attach cemented hard particle parts to steel or other metallic
parts using threads, keyways or other mechanical features because
the fracture toughness of cemented carbides is low relative to
steel and other metals and metallic alloys. Moreover, cemented
carbides, for example, are highly notch-sensitive and susceptible
to premature crack formation at sharp corners. Corners are
difficult to avoid including in parts when designing mechanical
features such as threads and keyways on the parts. Thus, the
cemented hard particle parts can prematurely fracture in the areas
incorporating the mechanical features.
[0009] The technique described in U.S. Pat. No. 5,359,772 to
Carlsson et al. attempts to overcome certain difficulties
encountered in forming composite articles having a cemented carbide
region attached to a metal region. Carlsson teaches a technique of
spin-casting iron onto pre-formed cemented carbide rings. Carlsson
asserts that the technique forms a "metallurgical bond" between the
iron and the cemented carbide. The composition of the cast iron in
Carlsson must be carefully controlled such that a portion of the
austenite forms bainite in order to relieve the stresses caused by
differential shrinkage between the cemented carbide and the cast
iron during cooling from the casting temperature. However, this
transition occurs during a heat treating step after the composite
is formed, to relieve stress that already exists. Thus, the bond
formed between the cast iron and the cemented carbide in the method
of Carlsson may already suffer from stress damage. Further, a
bonding technique as described in Carlsson has limited utility and
will only potentially be effective when using spin casting and cast
iron, and would not be effective with other metals or metal
alloys.
[0010] The difficulties associated with the attachment of cemented
hard particle parts to parts of dissimilar materials, and
particularly metallic parts, have posed substantial challenges to
design engineers and have limited the applications for cemented
hard particle parts. As such, there is a need for improved cemented
hard particle-metallic and related materials, methods, and
designs.
SUMMARY
[0011] One non-limiting embodiment according to the present
disclosure is directed to a composite sintered powder metal article
that includes a first region including cemented hard particles and
a second region including at least one of a metal and a metallic
alloy. The metal or metallic alloy is selected from a steel,
nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a
molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten
alloy. The first region is metallurgically bonded to the second
region, and the second region has a thickness greater than 100
microns.
[0012] Another non-limiting embodiment according to the present
disclosure is directed to a method of making a composite sintered
powder metal article. The method includes providing a first powder
in a first region of a mold, and providing a second powder in a
second region of the mold, wherein the second powder contacts the
first powder. The first powder includes hard particles and a
powdered binder. The second powder includes at least one of a metal
powder and a metallic alloy powder selected from a steel powder, a
nickel powder, a nickel alloy powder, a molybdenum powder, a
molybdenum alloy powder, a titanium powder, a titanium alloy
powder, a cobalt powder, a cobalt alloy powder, a tungsten powder,
and a tungsten alloy powder. The method further includes
consolidating the first powder and the second powder in the mold to
provide a green compact. The green compact is sintered to provide a
composite sintered powder metal article including a first region
metallurgically bonded to a second region. The first region
includes a cemented hard particle material formed on sintering the
first powder. The second region includes a metal or metallic alloy
formed on sintering the second powder.
BRIEF DESCRIPTION OF THE FIGURES
[0013] Features and advantages of the subject matter described
herein may be better understood by reference to the accompanying
figures in which:
[0014] FIG. 1A illustrates non-limiting embodiments of composite
sintered powder metal articles according to the present disclosure
including a cemented carbide region metallurgically bonded to a
nickel region, wherein the article depicted on the left includes
threads machined into the nickel region.
[0015] FIG. 1B is a photomicrograph of a cross-section of the
metallurgical bond region of one non-limiting embodiment of a
cemented carbide-nickel composite article according to the present
disclosure.
[0016] FIG. 2 illustrates one non-limiting embodiment of a
three-layer composite sintered powder metal article according to
the present disclosure, wherein the composite includes a cemented
carbide region, a nickel region, and a steel region.
[0017] FIG. 3 is a photomicrograph of a cross-section of a region
of a composite sintered powder metal article according to the
present disclosure, wherein the composite includes a cemented
carbide region and a tungsten alloy region, and wherein the figure
depicts the metallurgical bond region of the composite. The grains
visible in the tungsten alloy portion are grains of pure tungsten.
The grains visible in the cemented carbide region are grains of
cemented carbide.
DETAILED DESCRIPTION
[0018] In the present description of non-limiting embodiments and
in the claims, other than in the operating examples or where
otherwise indicated, all numbers expressing quantities or
characteristics of ingredients and products, processing conditions,
and the like are to be understood as being modified in all
instances by the term "about". Accordingly, unless indicated to the
contrary, any numerical parameters set forth in the following
description and the attached claims are approximations that may
vary depending upon the desired properties one seeks to obtain in
the subject matter described in the present disclosure. At the very
least, and not as an attempt to limit the application of the
doctrine of equivalents to the scope of the claims, each numerical
parameter should at least be construed in light of the number of
reported significant digits and by applying ordinary rounding
techniques.
[0019] Certain embodiments according to the present disclosure are
directed to composite sintered powder metal articles. A composite
article is an object that comprises at least two regions, each
region composed of a different material. Composite sintered powder
metal articles according to the present disclosure include at least
a first region, which includes cemented hard particles,
metallurgically bonded to a second region, which includes at least
one of a metal and a metallic alloy. Two non-limiting examples of
composite articles according to the present disclosure are shown in
FIG. 1A. Sintered powder metal article 100 includes a first region
in the form of a cemented carbide region 110 metallurgically bonded
to a second region in the form of a nickel region 112. Sintered
powder metal article 200 includes a first region in the form of a
cemented carbide region 210 metallurgically bonded to a second
region in the form of a threaded nickel region 212.
[0020] As it is known in the art sintered powder metal material is
produced by pressing and sintering masses of metallurgical powders.
In a conventional press-and-sinter process, a metallurgical powder
blend is placed in a void of a mold and compressed to form a "green
compact." The green compact is sintered, which densifies the
compact and metallurgically bonds together the individual powder
particles. In certain instances, the compact may be consolidated
during sintering to full or near-full theoretical density.
[0021] In composite articles according to the present disclosure,
the cemented hard particles of the first region are a composite
including a discontinuous phase of hard particles dispersed in a
continuous binder phase. The metal and/or metallic alloy included
in the second region is one or more selected from a steel, nickel,
a nickel alloy, titanium, a titanium alloy, molybdenum, a
molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten
alloy. The two regions are formed from metallurgical powders that
are pressed and sintered together. During sintering, a
metallurgical bond forms between the first and second regions, for
example, at the interface between the cemented hard particles in
the first region and the metal and/or metallic alloy in the second
region.
[0022] The present inventors determined that the metallurgical bond
that forms between the first region (including cemented hard
particles) and the second region (including at least one of a metal
and a metallic alloy) during sintering is surprisingly and
unexpectedly strong. In various embodiments produced according to
the present disclosure, the metallurgical bond between the first
and second regions is free from significant defects, including
cracks and brittle secondary phases. Such bond defects commonly are
present when conventional techniques are used to bond a cemented
hard particle material to a metal or metallic alloy. The
metallurgical bond formed according to the present disclosure forms
directly between the first and second regions at the
microstructural level and is significantly stronger than bonds
formed by prior art techniques used to bind together cemented
carbides and metal or metallic alloys, such as, for example, the
casting technique discussed in U.S. Pat. No. 5,359,772 to Carlsson.
The method of Carlsson involving casting a molten iron onto
cemented hard particles does not form a strong bond. Molten iron
reacts with cemented carbides by chemically reacting with the
tungsten carbide particles and forming a brittle phase commonly
referred to as eta-phase. The interface is thus weak and brittle.
The bond formed by the technique described in Carlsson is limited
to the relatively weak bond that can be formed between a relatively
low-melting molten cast iron and a pre-formed cemented carbide.
Further, this technique only applies to cast iron as it relies on
an austenite to bainite transition to relieve stress at the bond
area.
[0023] The metallurgical bond formed by the present press and
sinter technique using the materials recited herein avoids the
stresses and cracking experienced with other bonding techniques.
The strong bond formed according to the present disclosure
effectively counteracts stresses resulting from differences in
thermal expansion properties of the bonded materials, such that no
cracks form in the interface between the first and second regions
of the composite articles. This is believed to be at least
partially a result of the nature of the unexpectedly strong
metallurgical bond formed by the technique of the present
disclosure, and also is a result of the compatibility of the
materials discovered in the present technique. It has been
discovered that not all metals and metallic alloys can be sintered
to cemented hard particles such as cemented carbide.
[0024] In certain embodiments according to the present disclosure,
the first region comprising cemented hard particles has a thickness
greater than 100 microns. Also, in certain embodiments, the first
region has a thickness greater than that of a coating.
[0025] In certain embodiments according to the present disclosure,
the first and second regions each have a thickness greater than 100
microns. In certain other embodiments, each of the first and second
regions has a thickness greater than 0.1 centimeters. In still
other embodiments, the first and second regions each have a
thickness greater than 0.5 centimeters. Certain other embodiments
according to the present disclosure include first and second
regions having a thickness of greater than 1 centimeter. Still
other embodiments comprise first and second regions having a
thickness greater than 5 centimeters. Also, in certain embodiments
according to the present disclosure, at least the second region or
another region of the composite sintered powder metal article has a
thickness sufficient for the region to include mechanical
attachment features such as, for example, threads or keyways, so
that the composite article can be attached to another article via
the mechanical attachment features.
[0026] The embodiments described herein achieve an unexpectedly and
surprisingly strong metallurgical bond between the first region
(including cemented hard particles) and the second region
(including at least one of metal and a metallic alloy) of the
composite article. In certain embodiments according to the present
disclosure, the formation of the superior bond between the first
and second regions is combined with incorporating advantageous
mechanical features, such as threads or keyways, on the second
region of the composite to provide a strong and durable composite
article that may be used in a variety of applications or adapted
for connection to other articles for use in specialized
applications.
[0027] In other embodiments according to the present disclosure, a
metal or metallic alloy of the second region has a thermal
conductivity less than a thermal conductivity of the cemented hard
particle material of the first region, wherein both thermal
conductivities are evaluated at room temperature (20.degree. C.).
Without being limited to any specific theory, it is believed that
the metal or metallic alloy of the second region must have a
thermal conductivity that is less than a thermal conductivity of
the cemented hard particle material of the first region in order to
form a metallurgical bond between the first and second regions
having sufficient strength for certain demanding applications of
cemented hard particle materials. In certain embodiments, only
metals or metallic alloys having thermal conductivity less than a
cemented carbide may be used in the second region. In certain
embodiments, the second region or any metal or metallic alloy of
the second region has a thermal conductivity less than 100 W/mK. In
other embodiments, the second region or any metal or metallic alloy
of the second region may have a thermal conductivity less than 90
W/mK.
[0028] In certain other embodiments according to the present
disclosure, the metal or metallic alloy of the second region of the
composite article has a melting point greater than 1200.degree. C.
Without being limited to any specific theory, it is believed that
the metal or metallic alloy of the second region must have a
melting point greater than 1200.degree. C. so as to form a
metallurgical bond with the cemented hard particle material of the
first region with bond strength sufficient for certain demanding
applications of cemented hard particle materials. In other
embodiments, the metal or metallic alloy of the second region of
the composite article has a melting point greater than 1275.degree.
C. In some embodiments, the melting point of the metal or metallic
alloy of the second region is greater than a cast iron.
[0029] According to the present disclosure, the cemented hard
particle material included in the first region must include at
least 60 percent by volume dispersed hard particles. If the
cemented hard particle material includes less than 60 percent by
volume of hard particles, the cemented hard particle material will
lack the required combination of abrasion and wear resistance,
strength, and fracture toughness needed for applications in which
cemented hard particle materials are used. See Kenneth J. A.
Brookes, Handbook of Hardmetals and Hard Materials (International
Carbide Data, 1992). Accordingly, as used herein, "cemented hard
particles" and "cemented hard particle material" refer to a
composite material comprising a discontinuous phase of hard
particles dispersed in a continuous binder material, and wherein
the composite material includes at least 60 volume percent of the
hard particle discontinuous phase.
[0030] In certain embodiments of the composite article according to
the present disclosure, the metal or metallic alloy of the second
region may include from 0 up to 50 volume percent of hard particles
(based on the volume of the metal or metallic alloy). The presence
of certain concentrations of such particles in the metal or
metallic alloy may enhance wear resistance of the metal or alloy
relative to the same material lacking such hard particles, but
without significantly adversely affecting machinability of the
metal or metallic alloy. Obviously, the presence of up to 50 volume
percent of such particles in the metallic alloy does not result in
a cemented hard particle material, as defined herein, for at least
the reason that the hard particle volume fraction is significantly
less than in a cemented hard particle material. In addition, it has
been discovered that in certain composite articles according to the
present disclosure, the presence of hard particles in the metal or
metallic alloy of the second region may modify the shrinkage
characteristics of the region so as to more closely approximate the
shrinkage characteristics of the first region. In this way, the CTE
of the second region may be adjusted to better ensure compatibility
with the CTE of the first region to prevent formation of stresses
in the metallurgical bond region that could result in cracking.
[0031] Thus, in certain embodiments according to the present
disclosure, the metal or metallic alloy of the second region of the
composite article includes from 0 up to 50 percent by volume, and
preferably no more than 20 to 30 percent by volume hard particles
dispersed in the metal or metallic alloy. The minimum amount of
hard particles in the metal or metallic alloy region that would
affect the wear resistance and/or shrinkage properties of the metal
or metallic alloy is believed to be about 2 to 5 percent by volume.
Thus, in certain embodiments according to the present disclosure,
the metal or metallic alloy of the second region of the composite
article includes from 2 to 50 percent by volume, and preferably
from 2 to 30 percent by volume hard particles dispersed in the
metal or metallic alloy. Other embodiments may include from 5 to 50
percent hard particles, or from 5 to 30 percent by volume hard
particles dispersed in the metal or metallic alloy. Still other
embodiments may comprise from 2 to 20, or from 5 to 20 percent by
volume hard particles dispersed in the metal or metallic alloy.
Certain other embodiments may comprise from 20 to 30 percent by
volume hard particles by volume dispersed in the metal or metallic
alloy.
[0032] The hard particles included in the first region and,
optionally, the second region may be selected from, for example,
the group consisting of a carbide, a nitride, a boride, a silicide,
an oxide, and mixtures and solid solutions thereof. In one
embodiment, the metal or metallic alloy of the second region
includes up to 50 percent by volume of dispersed tungsten carbide
particles.
[0033] In certain embodiments according to the present disclosure,
the dispersed hard particle phase of the cemented hard particle
material of the first region may include one or more hard particles
selected from a carbide, a nitride, a boride, a silicide, an oxide,
and solid solutions thereof. In certain embodiments, the hard
particles may include carbide particles of at least one transition
metal selected from titanium, chromium, vanadium, zirconium,
hafnium, tantalum, molybdenum, niobium, and tungsten. In still
other embodiments, the continuous binder phase of the cemented hard
particle material of the first region includes at least one of
cobalt, a cobalt alloy, nickel, a nickel alloy, iron, and an iron
alloy. The binder also may include, for example, one or more
elements selected from tungsten, chromium, titanium, tantalum,
vanadium, molybdenum, niobium, zirconium, hafnium, and carbon, up
to the solubility limits of these elements in the binder.
Additionally, the binder may include up to 5 weight percent of one
or more elements selected from copper, manganese, silver, aluminum,
and ruthenium. One skilled in the art will recognize that any or
all of the constituents of the cemented hard particle material may
be introduced into the metallurgical powder from which the cemented
hard particle material is formed in elemental form, as compounds,
and/or as master alloys.
[0034] The properties of cemented hard particle materials, such as
cemented carbides, depend on parameters including the average hard
particle grain size and the weight fraction or volume fraction of
the hard particles and/or binder. In general, the hardness and wear
resistance increases as the grain size decreases and/or the binder
content decreases. On the other hand, fracture toughness increases
as the grain size increases and/or the binder content increases.
Thus, there is a trade-off between wear resistance and fracture
toughness when selecting a cemented hard particle material grade
for any application. As wear resistance increases, fracture
toughness typically decreases, and vice versa.
[0035] Certain other embodiments of the articles of the present
disclosure include hard particles comprising carbide particles of
at least one transition metal selected from titanium, chromium,
vanadium, zirconium, hafnium, tantalum, molybdenum, niobium, and
tungsten. In certain other embodiments, the hard particles include
tungsten carbide particles. In still other embodiments, the
tungsten carbide particles may have an average grain size of from
0.3 to 10 .mu.m.
[0036] The hard particles of the cemented hard particle material in
the first region preferably comprise from about 60 to about 98
volume percent of the total volume of the cemented hard particle
material. The hard particles are dispersed within a matrix of a
binder that preferably constitutes from about 2 to about 40 volume
percent of the total volume of the cemented hard particle
material.
[0037] Embodiments of the composite articles according to the
present disclosure may also include hybrid cemented carbides such
as, for example, any of the hybrid cemented carbides described in
copending U.S. patent application Ser. No. 10/735,379, the entire
disclosure of which is hereby incorporated herein by reference. For
example, an article according to the present disclosure may
comprise at least a first region including a hybrid cemented
carbide metallurgically bonded to a second region comprising one of
a metal and a metallic alloy. Certain other articles may comprise
at least a first region including cemented hard particles, a second
region including at least one of a metal and a metallic alloy,
wherein the first and third regions are metallurgically bonded to
the second region, and a third region including a hybrid cemented
carbide material.
[0038] Generally, a hybrid cemented carbide is a material
comprising particles of at least one cemented carbide grade
dispersed throughout a second cemented carbide continuous phase,
thereby forming a microscopic composite of cemented carbides. The
hybrid cemented carbides of application Ser. No. 10/735,379 have
low dispersed phase particle contiguity ratios and improved
properties relative to certain other hybrid cemented carbides.
Preferably, the contiguity ratio of the dispersed phase of a hybrid
cemented carbide included in embodiments according to the present
disclosure is less than or equal to 0.48. Also, a hybrid cemented
carbide included in the embodiments according to the present
disclosure preferably comprises a dispersed phase having a hardness
greater than a hardness of the continuous phase of the hybrid
cemented carbide. For example, in certain embodiments of hybrid
cemented carbides included in one or more regions of the composite
articles according to the present disclosure, the hardness of the
dispersed phase in the hybrid cemented carbide is preferably
greater than or equal to 88 Rockwell A Hardness (HRA) and less than
or equal to 95 HRA, and the hardness of the continuous phase in the
hybrid carbide is greater than or equal to 78 HRA and less than or
equal to 91 HRA.
[0039] Additional embodiments of the articles according to the
present disclosure may include hybrid cemented carbide in one or
more regions of the articles wherein a volume fraction of the
dispersed cemented carbide phase is less than 50 volume percent of
the hybrid cemented carbide, and wherein the contiguity ratio of
the dispersed cemented carbide phase is less than or equal to 1.5
times the volume fraction of the dispersed cemented carbide phase
in the hybrid cemented carbide.
[0040] Certain embodiments of articles according to the present
disclosure include a second region comprising at least one of a
metal and a metallic alloy wherein the region includes at least one
mechanical attachment feature or other mechanical feature. A
mechanical attachment feature, as used herein, enables certain
articles according to the present disclosure to be connected to
certain other articles and function as part of a larger device.
Mechanical attachment features may include, for example, threads,
slots, keyways, teeth or cogs, steps, bevels, bores, pins, and
arms. It has not previously been possible to successfully include
such mechanical attachment features on articles formed solely from
cemented hard particles for certain demanding applications because
of the limited tensile strength and notch sensitivity of cemented
hard particle materials. Prior art articles have included a metal
or metallic alloy region including one or more mechanical
attachment features that were coupled to a cemented hard particle
region by means other than co-pressing and sintering. Such prior
art articles suffered from a relatively weak bond between the metal
or metallic alloy region and the cemented hard particle region,
severely limiting the possible applications of the articles.
[0041] The process for manufacturing cemented hard particle parts
typically comprises blending or mixing powdered ingredients
including hard particles and a powdered binder to form a
metallurgical powder blend. The metallurgical powder blend may be
consolidated or pressed to form a green compact. The green compact
is then sintered to form the article or a portion of the article.
According to one process, the metallurgical powder blend is
consolidated by mechanically or isostatically compressing to form
the green compact, typically at pressures between 10,000 and 60,000
psi. In certain cases, the green compact may be pre-sintered at a
temperature between about 400.degree. C. and 1200.degree. C. to
form a "brown" compact. The green or brown compact is subsequently
sintered to autogenously bond together the metallurgical powder
particles and further densify the compact. In certain embodiments
the powder compact may be sintered in vacuum or in hydrogen. In
certain embodiments the compact is over pressure sintered at
300-2000 psi and at a temperature of 1350-1500.degree. C.
Subsequent to sintering, the article may be appropriately machined
to form the desired shape or other features of the particular
geometry of the article.
[0042] Embodiments of the present disclosure include methods of
making a composite sintered powder metal composite article. One
such method includes placing a first metallurgical powder into a
first region of a void of a mold, wherein the first powder includes
hard particles and a powdered binder. A second metallurgical powder
blend is placed into a second region of the void of the mold. The
second powder may include at least one of a metal powder and a
metal alloy powder selected from the group consisting of a steel
powder, a nickel powder, a nickel alloy powder, a molybdenum
powder, a molybdenum alloy powder, a titanium powder, a titanium
alloy powder, a cobalt powder, a cobalt alloy powder, a tungsten
powder, and a tungsten alloy powder. The second powder may contact
the first powder, or initially may be separated from the first
powder in the mold by a separating means. Depending on the number
of cemented hard particle and metal or metal alloy regions desired
in the composite article, the mold may be partitioned into
additional regions in which additional metallurgical powder blends
may be disposed. For example, the mold may be segregated into
regions by placing one or more physical partitions in the void of
the mold to define the several regions and/or by merely filling
regions of the mold with different powders without providing
partitions between adjacent powders. The metallurgical powders are
chosen to achieve the desired properties of the corresponding
regions of the article as described herein. The materials used in
the embodiments of the methods of this disclosure may comprise any
of the materials discussed herein, but in powdered form, such that
they can be pressed and sintered. Once the powders are loaded into
the mold, any partitions are removed and the powders within the
mold are then consolidated to form a green compact. The powders may
be consolidated, for example, by mechanical or isostatic
compression. The green compact may then be sintered to provide a
composite sintered powder metal article including a cemented hard
particle region formed from the first powder and metallurgically
bonded to a second region formed from the second metal or metallic
alloy powder. For example, sintering may be performed at a
temperature suitable to autogenously bond the powder particles and
suitably densify the article, such as at temperatures up to
1500.degree. C.
[0043] The conventional methods of preparing a sintered powder
metal article may be used to provide sintered articles of various
shapes and including various geometric features. Such conventional
methods will be readily known to those having ordinary skill in the
art. Those persons, after considering the present disclosure, may
readily adapt the conventional methods to produce composites
articles according to the present disclosure.
[0044] A further embodiment of a method according to the present
disclosure comprises consolidating a first metallurgical powder in
a mold forming a first green compact and placing the first green
compact in a second mold, wherein the first green compact fills a
portion of the second mold. The second mold may be at least
partially filled with a second metallurgical powder. The second
metallurgical powder and the first green compact may be
consolidated to form a second green compact. Finally, the second
green compact is sintered to further densify the compact and to
form a metallurgical bond between the region of the first
metallurgical powder and the region of the second metallurgical
powder. If necessary, the first green compact may be presintered up
to a temperature of about 1200.degree. C. to provide additional
strength to the first green compact. Such embodiments of methods
according to the present disclosure provide increased flexibility
in design of the different regions of the composite article, for
particular applications. The first green compact may be designed in
any desired shape from any desired powder metal material according
to the embodiments herein. In addition, the process may be repeated
as many times as desired, preferably prior to sintering. For
example, after consolidating to form the second green compact, the
second green compact may be placed in a third mold with a third
metallurgical powder and consolidated to form a third green
compact. By such a repetitive process, more complex shapes may be
formed. Articles including multiple clearly defined regions of
differing properties may be formed. For example, a composite
article of the present disclosure may include cemented hard
particle materials where increased wear resistance properties, for
example, are desired, and a metal or metallic alloy in article
regions at which it is desired to provide mechanical attachment
features.
[0045] Certain embodiments of the methods according to the present
disclosure are directed to composite sintered powder metal
articles. As used herein, a composite article is an object that
comprises at least two regions, each region composed of a different
material. Composite sintered powder metal articles according to the
present disclosure include at least a first region, which includes
cemented hard particles, metallurgically bonded to a second region,
which includes at least one of a metal and a metallic alloy. Two
non-limiting examples of composite articles according to the
present disclosure are shown in FIG. 1A. Sintered powder metal
article 100 includes a first region in the form of cemented carbide
region 110 metallurgically bonded to a nickel region 112. Sintered
powder metal article 200 includes a first region in the form of a
cemented carbide region 210 metallurgically bonded to a second
region in the form of a threaded nickel region 212.
[0046] In composite articles according to the present disclosure,
the cemented hard particles of the first region are a composite
including a discontinuous phase of hard particles dispersed in a
continuous binder phase. The metal and/or metallic alloy included
in the second region is one or more selected from a steel, nickel,
a nickel alloy, titanium, a titanium alloy, molybdenum, a
molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten
alloy. The two regions are formed from metallurgical powders that
are pressed and sintered together. During sintering, a
metallurgical bond forms between the first and second regions, for
example, at the interface between the cemented hard particles in
the first region and the metal or metallic alloy in the second
region.
[0047] In the embodiments of the methods of the present disclosure,
the present inventors determined that the metallurgical bond that
forms between the first region (including cemented hard particles)
and the second region (including at least one of a metal and a
metallic alloy) during sintering is surprisingly and unexpectedly
strong. In various embodiments produced according to the present
disclosure, the metallurgical bond between the first and second
regions is free from significant defects, including cracks. Such
bond defects commonly are present when conventional techniques are
used to bond a cemented hard particle material to a metal or
metallic alloy. The metallurgical bond formed according to the
present disclosure forms directly between the first and second
regions at the microstructural level and is significantly stronger
than bonds formed by prior art techniques used to bind together
cemented carbides and metal or metallic alloys, such as the casting
technique discussed in U.S. Pat. No. 5,359,772 to Carlsson, which
is described above. The metallurgical bond formed by the press and
sinter technique using the materials recited herein avoids the
stresses and cracking experienced with other bonding techniques.
This is believed to be at least partially a result of the nature of
the strong metallurgical bond formed by the technique of the
present disclosure, and also is a result of the compatibility of
the materials used in the present technique. It has been discovered
that not all metals and metallic alloys can be sintered to cemented
hard particles such as cemented carbide. Also, the strong bond
formed according to the present disclosure effectively counteracts
stresses resulting from differences in thermal expansion properties
of the bonded materials, such that no cracks form in the interface
between the first and second regions of the composite articles.
[0048] In certain embodiments of the methods according to the
present disclosure, the first region comprising cemented hard
particles has a thickness greater than 100 microns. Also, in
certain embodiments, the first region has a thickness greater than
that of a coating.
[0049] The embodiments of the methods described herein achieve an
unexpectedly and surprisingly strong metallurgical bond between the
first region (including cemented hard particles) and the second
region (including at least one of metal and a metallic alloy) of
the composite article. In certain embodiments of the methods
according to the present disclosure, the formation of the superior
bond between the first and second regions is combined with the step
of incorporating advantageous mechanical features, such as threads
or keyways, on the second region of the composite to provide a
strong and durable composite article that may be used in a variety
of applications or adapted for connection to other articles for use
in specialized applications.
[0050] In certain embodiments of the methods according to the
present disclosure, the first and second regions each have a
thickness greater than 100 microns. In certain other embodiments,
each of the first and second regions has a thickness greater than
0.1 centimeters. In still other embodiments, the first and second
regions each have a thickness greater than 0.5 centimeters. Certain
other embodiments according to the present disclosure include first
and second regions having a thickness of greater than 1 centimeter.
Still other embodiments comprise first and second regions having a
thickness greater than 5 centimeters. Also, in certain embodiments
of the methods according to the present disclosure, at least the
second region or another region of the composite sintered powder
metal article has a thickness sufficient for the region to include
mechanical attachment features such as, for example, threads or
keyways, so that the composite article can be attached to another
article via the mechanical attachment features.
[0051] In other embodiments according to the methods of the present
disclosure, a metal or metallic alloy of the second region has a
thermal conductivity less than a thermal conductivity of the
cemented hard particle material of the first region, wherein both
thermal conductivities are evaluated at room temperature
(20.degree. C.). Without being limited to any specific theory, it
is believed that the metal or metallic alloy of the second region
must have a thermal conductivity that is less than a thermal
conductivity of the cemented hard particle material of the first
region in order to form a metallurgical bond between the first and
second regions having sufficient strength for certain demanding
applications of cemented hard particle materials. In certain
embodiments, only metals or metallic alloys having thermal
conductivity less than a cemented carbide may be used in the second
region. In certain embodiments, the second region or any metal or
metallic alloy of the second region has a thermal conductivity less
than 100 W/mK. In other embodiments, the second region or any metal
or metallic alloy of the second region may have a thermal
conductivity less than 90 W/mK.
[0052] In certain other embodiments of the methods according to the
present disclosure, the metal or metallic alloy of the second
region of the composite article has a melting point greater than
1200.degree. C. Without being limited to any specific theory, it is
believed that the metal or metallic alloy of the second region must
have a melting point greater than 1200.degree. C. so as to form a
metallurgical bond with the cemented hard particle material of the
first region with bond strength sufficient for certain demanding
applications of cemented hard particle materials. In other
embodiments, the metal or metallic alloy of the second region of
the composite article has a melting point greater than 1275.degree.
C. In some embodiments, the melting point of the metal or metallic
alloy of the second region is greater than a cast iron.
[0053] According to the present disclosure, the cemented hard
particle material included in the first region must include at
least 60 percent by volume dispersed hard particles. If the
cemented hard particle material includes less than 60 percent by
volume of hard particles, the cemented hard particle material will
lack the required combination of abrasion and wear resistance,
strength, and fracture toughness needed for applications in which
cemented hard particle materials are used. Accordingly, as used
herein, "cemented hard particles" and "cemented hard particle
material" refer to a composite material comprising a discontinuous
phase of hard particles dispersed in a continuous binder material,
and wherein the composite material includes at least 60 volume
percent of the hard particle discontinuous phase.
[0054] In certain embodiments of the methods of making the
composite articles according to the present disclosure, the metal
or metallic alloy of the second region may include from 0 up to 50
volume percent of hard particles (based on the volume of the metal
or metallic alloy). The presence of certain concentrations of such
particles in the metal or metallic alloy may enhance wear
resistance of the metal or alloy relative to the same material
lacking such hard particles, but without significantly adversely
affecting machinability of the metal or metallic alloy. Obviously,
the presence of up to 50 volume percent of such particles in the
metallic alloy does not result in a cemented hard particle
material, as defined herein, for at least the reason that the hard
particle volume fraction is significantly less than in a cemented
hard particle material. In addition, it has been discovered that in
certain composite articles according to the present disclosure, the
presence of hard particles in the metal or metallic alloy of the
second region may modify the shrinkage characteristics of the
region so as to more closely approximate the shrinkage
characteristics of the first region. In this way, the CTE of the
second region may be adjusted to better ensure compatibility with
the CTE of the first region to prevent formation of stresses in the
metallurgical bond region that could result in cracking.
[0055] Thus, in certain embodiments of the methods according to the
present disclosure, the metal or metallic alloy of the second
region of the composite article includes from 0 up to 50 percent by
volume, and preferably no more than 20 to 30 percent by volume,
hard particles dispersed in the metal or metallic alloy. The
minimum amount of hard particles in the metal or metallic alloy
region that would affect the wear resistance and/or shrinkage
properties of the metal or metallic alloy is believed to be about 2
to 5 percent by volume. Thus, in certain embodiments according to
the present disclosure, the metallic alloy of the second region of
the composite article includes from 2 to 50 percent by volume, and
preferably from 2 to 30 percent by volume hard particles dispersed
in the metal or metallic alloy. Other embodiments may include from
5 to 50 percent hard particles, or from 5 to 30 percent by volume
hard particles dispersed in the metal or metallic alloy. Still
other embodiments may comprise from 2 to 20, or from 5 to 20
percent by volume hard particles dispersed in the metal or metallic
alloy. Certain other embodiments may comprise from 20 to 30 percent
by volume hard particles dispersed in the metal or metallic
alloy.
[0056] The hard particles included in the first region and,
optionally, the second region may be selected from, for example,
the group consisting of a carbide, a nitride, a boride, a silicide,
an oxide, and mixtures and solid solutions thereof. In one
embodiment, the metal or metallic alloy of the second region
includes up to 50 percent by volume of dispersed tungsten carbide
particles.
[0057] In certain embodiments of the methods according to the
present disclosure, the dispersed hard particle phase of the
cemented hard particle material of the first region may include one
or more hard particles selected from a carbide, a nitride, a
boride, a silicide, an oxide, and solid solutions thereof. In
certain embodiments, the hard particles may include carbide
particles of at least one transition metal selected from titanium,
chromium, vanadium, zirconium, hafnium, tantalum, molybdenum,
niobium, and tungsten. In still other embodiments, the continuous
binder phase of the cemented hard particle material of the first
region includes at least one of cobalt, a cobalt alloy, nickel, a
nickel alloy, iron, and an iron alloy. The binder also may include,
for example, one or more elements selected from tungsten, chromium,
titanium, tantalum, vanadium, molybdenum, niobium, zirconium,
hafnium, and carbon, up to the solubility limits of these elements
in the binder. Additionally, the binder may include up to 5 weight
percent of one of more elements selected from copper, manganese,
silver, aluminum, and ruthenium. One skilled in the art will
recognize that any or all of the constituents of the cemented hard
particle material may be introduced into the metallurgical powder
from which the cemented hard particle material is formed in
elemental form, as compounds, and/or as master alloys.
[0058] The properties of cemented hard particle materials, such as
cemented carbides, depend on parameters including the average hard
particle grain size and the weight fraction or volume fraction of
the hard particles and/or binder. In general, the hardness and wear
resistance increases as the grain size decreases and/or the binder
content decreases. On the other hand, fracture toughness increases
as the grain size increases and/or the binder content increases.
Thus, there is a trade-off between wear resistance and fracture
toughness when selecting a cemented hard particle material grade
for any application. As wear resistance increases, fracture
toughness typically decreases, and vice versa.
[0059] Certain other embodiments of the methods to make the
articles of the present disclosure include hard particles
comprising carbide particles of at least one transition metal
selected from titanium, chromium, vanadium, zirconium, hafnium,
tantalum, molybdenum, niobium, and tungsten. In certain other
embodiments, the hard particles include tungsten carbide particles.
In still other embodiments, the tungsten carbide particles may have
an average grain size of from 0.3 to 10 .mu.m.
[0060] The hard particles of the cemented hard particle material in
the first region preferably comprise from about 60 to about 98
volume percent of the total volume of the cemented hard particle
material. The hard particles are dispersed within a matrix of a
binder that preferably constitutes from about 2 to about 40 volume
percent of the total volume of the cemented hard particle
material.
[0061] Embodiments of the methods to make the composite articles
according to the present disclosure may also include hybrid
cemented carbides such as, for example, any of the hybrid cemented
carbides described in copending U.S. patent application Ser. No.
10/735,379, the entire disclosure of which is hereby incorporated
herein by reference. For example, an article according to the
present disclosure may comprise at least a first region including
hybrid cemented carbide metallurgically bonded to a second region
comprising one of a metal and a metallic alloy. Certain other
articles may comprise at least a first region including cemented
hard particles, a second region including at least one of a metal
and a metallic alloy, and a third region including a hybrid
cemented carbide material, wherein the first and third regions are
metallurgically bonded to the second region.
[0062] Generally, a hybrid cemented carbide is a material
comprising particles of at least one cemented carbide grade
dispersed throughout a second cemented carbide continuous phase,
thereby forming a microscopic composite of cemented carbides. The
hybrid cemented of application Ser. No. 10/735,379 have low
dispersed phase particle contiguity ratios and improved properties
relative to certain other hybrid cemented carbides. Preferably, the
contiguity ratio of the dispersed phase of a hybrid cemented
carbide included in embodiments according to the present disclosure
is less than or equal to 0.48. Also, a hybrid cemented carbide
included in the embodiments according to the present disclosure
preferably comprises a dispersed phase having a hardness greater
than a hardness of the continuous phase of the hybrid cemented
carbide. For example, in certain embodiments of hybrid cemented
carbides included in one or more regions of the composite articles
according to the present disclosure, the hardness of the dispersed
phase in the hybrid cemented carbide is preferably greater than or
equal to 88 Rockwell A Hardness (HRA) and less than or equal to 95
HRA, and the hardness of the continuous phase in the hybrid carbide
is greater than or equal to 78 HRA and less than or equal to 91
HRA.
[0063] Additional embodiments of the methods to make the articles
according to the present disclosure may include hybrid cemented
carbide in one or more regions of the articles wherein a volume
fraction of the dispersed cemented carbide phase is less than 50
volume percent of the hybrid cemented carbide, and wherein the
contiguity ratio of the dispersed cemented carbide phase is less
than or equal to 1.5 times the volume fraction of the dispersed
cemented carbide phase in the hybrid cemented carbide.
[0064] Certain embodiments of the methods to make the articles
according to the present disclosure include forming a mechanical
attachment feature or other mechanical feature on at least the
second region comprising at least one of a metal and a metallic
alloy. A mechanical attachment feature, as used herein, enables
certain articles according to the present disclosure to be
connected to certain other articles and function as part of a
larger device. Mechanical attachment features may include, for
example, threads, slots, keyways, teeth or cogs, steps, bevels,
bores, pins, and arms. It has not previously been possible to
successfully include such mechanical attachment features on
articles formed solely from cemented hard particles for certain
demanding applications because of the limited tensile strength and
notch sensitivity of cemented hard particle materials. Prior art
articles have included a metal or metallic alloy region including
one or more mechanical attachment features that were attached by
means other than co-pressing and sintering to a cemented hard
particle region. Such prior art articles suffered from a relatively
weak bond between the metal or metallic alloy region and the
cemented hard particle region, severely limiting the possible
applications of the articles.
EXAMPLE 1
[0065] FIG. 1A shows cemented carbide-metallic composite articles
100, 200 consisting of a cemented carbide portion 110, 210
metallurgically bonded to a nickel portion 112, 212 that were
fabricated using the following method according to the present
disclosure. A layer of cemented carbide powder (available
commercially as FL30.TM. powder, from ATI Firth Sterling, Madison,
Ala., USA) consisting of 70% tungsten carbide, 18% cobalt, and 12%
nickel was placed in a mold in contact with a layer of nickel
powder (available commercially as Inco Type 123 high purity nickel
from Inco Special Products, Wyckoff, N.J., USA) and co-pressed to
form a single green compact consisting of two distinct layers of
consolidated powder materials. The pressing (or consolidation) was
performed in a 100 ton hydraulic press employing a pressing
pressure of approximately 20,000 psi. The resulting green compact
was a cylinder approximately 1.5 inches in diameter and
approximately 2 inches long. The cemented carbide layer was
approximately 0.7 inches long, and the nickel layer was
approximately 1.3 inches long. Following pressing, the composite
compact was sintered in a vacuum furnace at 1380.degree. C. During
sintering the compact's linear shrinkage was approximately 18%
along any direction. The composite sintered articles were ground on
the outside diameter, and threads were machined in the nickel
portion 212 of one of the articles. FIG. 1B is a photomicrograph
showing the microstructure of articles 100 and 200 at the interface
of the cemented carbide material 300 and nickel material 301. FIG.
1B clearly shows the cemented carbide and nickel portions
metallurgically bonded together at interface region 302. No cracks
were apparent in the interface region.
EXAMPLE 2
[0066] FIG. 2 shows a cemented carbide-metallic alloy composite
article 400 that was fabricated by powder metal pressing and
sintering techniques according to the present disclosure and
included three separate layers. The first layer 401 consisted of
cemented carbide formed from FL30.TM. (see above). The second layer
402 consisted of nickel formed from nickel powder, and the third
layer 403 consisted of steel formed from a steel powder. The method
employed for fabricating the composite was essentially identical to
the method employed in Example 1 except that three layers of
powders were co-pressed together to form the green compact, instead
of two layers. The three layers appeared uniformly metallurgically
bonded together to form the composite article. No cracks were
apparent on the exterior of the sintered article in the vicinity of
the interface between the cemented carbide and nickel regions.
EXAMPLE 3
[0067] A composite article consisting of a cemented carbide portion
and a tungsten alloy portion was fabricated according to the
present disclosure using the following method. A layer of cemented
carbide powder (FL30.TM. powder) was disposed in a mold in contact
with a layer of tungsten alloy powder (consisting of 70% tungsten,
24% nickel, and 6% copper) and co-pressed to form a single
composite green compact consisting of two distinct layers of
consolidated powders. The pressing (or consolidation) was performed
in a 100 ton hydraulic press employing a pressing pressure of
approximately 20,000 psi. The green compact was a cylinder
approximately 1.5 inches in diameter and approximately 2 inches
long. The cemented carbide layer was approximately 1.0 inches long
and the tungsten alloy layer was also approximately 1.0 inches
long. Following pressing, the composite compact was sintered at
1400.degree. C. in hydrogen, which minimizes or eliminates
oxidation when sintering tungsten alloys. During sintering, the
compact's linear shrinkage was approximately 18% along any
direction. FIG. 3 illustrates the microstructure which clearly
shows the cemented carbide 502 and tungsten alloy 500 portions
metallurgically bonded together at the interface 501. No cracking
was apparent in the interface region.
[0068] Although the foregoing description has necessarily presented
only a limited number of embodiments, those of ordinary skill in
the relevant art will appreciate that various changes in the
subject matter and other details of the examples that have been
described and illustrated herein may be made by those skilled in
the art, and all such modifications will remain within the
principle and scope of the present disclosure as expressed herein
and in the appended claims. For example, although the present
disclosure has necessarily only presented a limited number of
embodiments of rotary burrs constructed according to the present
disclosure, it will be understood that the present disclosure and
associated claims are not so limited. Those having ordinary skill
will readily identify additional rotary burr designs and may design
and build additional rotary burrs along the lines and within the
spirit of the necessarily limited number of embodiments discussed
herein. It is understood, therefore, that the present invention is
not limited to the particular embodiments disclosed or incorporated
herein, but is intended to cover modifications that are within the
principle and scope of the invention, as defined by the claims. It
will also be appreciated by those skilled in the art that changes
could be made to the embodiments above without departing from the
broad inventive concept thereof.
* * * * *