CA2678554A1 - Composite materials comprising a hard ceramic phase and a cu-ni-mn infiltration alloy - Google Patents
Composite materials comprising a hard ceramic phase and a cu-ni-mn infiltration alloy Download PDFInfo
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- CA2678554A1 CA2678554A1 CA002678554A CA2678554A CA2678554A1 CA 2678554 A1 CA2678554 A1 CA 2678554A1 CA 002678554 A CA002678554 A CA 002678554A CA 2678554 A CA2678554 A CA 2678554A CA 2678554 A1 CA2678554 A1 CA 2678554A1
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- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 91
- 239000000956 alloy Substances 0.000 title claims abstract description 91
- 239000002131 composite material Substances 0.000 title claims abstract description 77
- 230000008595 infiltration Effects 0.000 title claims abstract description 69
- 238000001764 infiltration Methods 0.000 title claims abstract description 69
- 239000000919 ceramic Substances 0.000 title claims abstract description 36
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 13
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 12
- 229910052718 tin Inorganic materials 0.000 claims abstract description 10
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 8
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000010949 copper Substances 0.000 claims description 29
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 28
- 239000011572 manganese Substances 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 19
- 239000011701 zinc Substances 0.000 claims description 13
- 229910052802 copper Inorganic materials 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- 239000010959 steel Substances 0.000 claims description 8
- 239000012535 impurity Substances 0.000 claims description 7
- 238000003878 thermal aging Methods 0.000 claims description 7
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 4
- 150000004767 nitrides Chemical class 0.000 claims description 4
- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 claims description 3
- QIJNJJZPYXGIQM-UHFFFAOYSA-N 1lambda4,2lambda4-dimolybdacyclopropa-1,2,3-triene Chemical compound [Mo]=C=[Mo] QIJNJJZPYXGIQM-UHFFFAOYSA-N 0.000 claims description 3
- 229910039444 MoC Inorganic materials 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910026551 ZrC Inorganic materials 0.000 claims description 3
- OTCHGXYCWNXDOA-UHFFFAOYSA-N [C].[Zr] Chemical compound [C].[Zr] OTCHGXYCWNXDOA-UHFFFAOYSA-N 0.000 claims description 3
- 230000032683 aging Effects 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 claims description 3
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 claims description 3
- 229910003468 tantalcarbide Inorganic materials 0.000 claims description 3
- 229910003470 tongbaite Inorganic materials 0.000 claims description 3
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 2
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052796 boron Inorganic materials 0.000 claims description 2
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000011651 chromium Substances 0.000 claims description 2
- 229910017052 cobalt Inorganic materials 0.000 claims description 2
- 239000010941 cobalt Substances 0.000 claims description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 2
- WHJFNYXPKGDKBB-UHFFFAOYSA-N hafnium;methane Chemical compound C.[Hf] WHJFNYXPKGDKBB-UHFFFAOYSA-N 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 239000011733 molybdenum Substances 0.000 claims description 2
- 229910052710 silicon Inorganic materials 0.000 claims description 2
- 239000010703 silicon Substances 0.000 claims description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 2
- 239000010937 tungsten Substances 0.000 claims description 2
- 229910003286 Ni-Mn Inorganic materials 0.000 abstract description 22
- 239000000203 mixture Substances 0.000 abstract description 9
- 239000000843 powder Substances 0.000 description 18
- 150000001247 metal acetylides Chemical class 0.000 description 7
- 239000011135 tin Substances 0.000 description 7
- 238000007596 consolidation process Methods 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 239000010432 diamond Substances 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 229910018605 Ni—Zn Inorganic materials 0.000 description 3
- -1 borides Chemical class 0.000 description 3
- 239000006104 solid solution Substances 0.000 description 3
- 229910001203 Alloy 20 Inorganic materials 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 2
- 229910033181 TiB2 Inorganic materials 0.000 description 2
- 229910000905 alloy phase Inorganic materials 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 230000003628 erosive effect Effects 0.000 description 2
- 239000002244 precipitate Substances 0.000 description 2
- 238000004881 precipitation hardening Methods 0.000 description 2
- 239000003870 refractory metal Substances 0.000 description 2
- 229910016897 MnNi Inorganic materials 0.000 description 1
- 229910018100 Ni-Sn Inorganic materials 0.000 description 1
- 229910018532 Ni—Sn Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical group [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/06—Alloys based on copper with nickel or cobalt as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/05—Alloys based on copper with manganese as the next major constituent
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
- Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- Y10T428/12049—Nonmetal component
- Y10T428/12056—Entirely inorganic
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Ceramic Products (AREA)
Abstract
Composite materials comprising a hard ceramic phase (16) and an infiltration alloy (20) are disclosed. The hard ceramic phase (16) may comprise a carbide such as tungsten carbide and/or cast carbide. The infiltration alloy (20) is a heat treatable Cu-based alloy comprising Ni and Mn. The infiltration alloy (20) may be substantially free of Sn and Zn. The composite material is heat treated in order to improve its mechanical properties. For example, the composition of the Cu-Ni-Mn infiltration alloy (20) may be selected such that its hardness, wear resistance, toughness and/or transverse rupture strength are improved after the composite material is solutionized, cooled and thermally aged.
Description
COMPOSITE MATERIALS COMPRISING
A HARD CERAMIC PHASE AND A CU-NI-MN INFILTRATION ALLOY
FIELD OF THE INVENTION
[0001] The present ilivention relates to composite materials comprising a hard ceramic phase infiltrated with a metal alloy, and more particularly relates to the use of a Cu-Ni-Mn infiltration alloy which is susceptible to heat treatment and demonstrates improved properties.
BACKGROUND INFORMATION
A HARD CERAMIC PHASE AND A CU-NI-MN INFILTRATION ALLOY
FIELD OF THE INVENTION
[0001] The present ilivention relates to composite materials comprising a hard ceramic phase infiltrated with a metal alloy, and more particularly relates to the use of a Cu-Ni-Mn infiltration alloy which is susceptible to heat treatment and demonstrates improved properties.
BACKGROUND INFORMATION
[0002] Infltration alloys are used with hard ceramics such as WC or cast carbides in drilling bit applications. To make such composite materials, a mold is filled with a mixture of ceramic powder and infiltration alloy powder, heated above the liquidus temperature of the infiltration alloy, and cooled to obtain a composite material. Examples of cutting tools comprising such composite materials are disclosed in U.S. Patent Nos.
5,589,268, 5,733,649 and 5,733,664 which are incorporated herein by reference.
5,589,268, 5,733,649 and 5,733,664 which are incorporated herein by reference.
[0003] A conventional infiltration alloy comprises copper, manganese, nickel and tin.
When such a Cu-Mn-Ni-Sn alloy is used in composite materials that are brazed to steel shanks of drill bits, a twist-off type of failure tends to occur at the interface between the composite material and the steel shank.
When such a Cu-Mn-Ni-Sn alloy is used in composite materials that are brazed to steel shanks of drill bits, a twist-off type of failure tends to occur at the interface between the composite material and the steel shank.
[0004] Another conventional infiltration alloy comprises copper, manganese, nickel and zinc. The use of such a Cu-Mn-Ni-Zn infiltration alloy may reduce or elinlinate the above-noted twist off failure, but may also cause a drop in erosion resistance.
[0005] There is a need for a composite niaterial comprisillg an infiltration alloy with improved erosion resistance and toughness.
SUMMARY OF TIIE INVENTION
SUMMARY OF TIIE INVENTION
[0006] The present invention provides composite materials cotnprising a hard ceramic phase and a Cu-based infiltration alloy. The hard ceramic phase may comprise carbides, borides, nitrides and oxides. Suitable carbides include tungsten carbide, tantalum carbide, niobium carbide, molybdenum carbide, chromium carbide, vanadium carbide, zirconium carbide, hafnium carbide, titanium carbide and cast carbides. Borides such as titanium diboride and other refractory metal borides may be used.
[0007] The Cu-based infiltration alloy is a heat treatable alloy which comprises Ni and Mn. In certain embodiments, the infiltration alloy is substantially free of Sn and Zn. The composite material may be heat treated in order to improve its mechanical properties. For example, the composition of the infiltration alloy may be selected such that its hardness, wear resistance, toughness and/or transverse rupture strength is improved after the composite material has been solutionized and aged at elevated temperatures. The composite materials are suitable for use in cutting tools and the like.
[0008] An aspect of the present invention is to provide a composite material comprising a hard ceramic phase, and a heat treated metal phase comprising a Cu-based infiltration alloy comprising Ni and Mn.
[0009] Another aspect of the present invention is to provide a method of making composite material comprising infiltrating an alloy into hard ceramic particles, wherein the infiltration alloy is a heat treatable alloy consisting essentially of Cu, Ni and Mn.
[0010] A fi.u=ther aspect of the present invention is to provide a method of heat treating a composite material comprising providing a composite material including a hard ceramic phase and an infiltration alloy comprising Cu, Ni and Mn, and heat treating the composite material.
[0011] These and other aspects of the present invention will be more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Fig. 1 is an isometric view of a cutting bit including a composite material of the present invention.
[0013] Fig. 2 schematically illustrates a fixture for consolidating composite materials in accordance with an embodiment of the present invention.
[0014] Fig. 3 is a flow diagram illustrating a method of forming and heat treating a composite material comprising a hard ceramic phase and a Cu-Ni-Mn infiltration alloy in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
DETAILED DESCRIPTION
[0015] A composite material comprising a hard ceramic phase and a Cu-based infiltration alloy is provided. The infiltration alloy is a Cu-Ni-Mn alloy that can be heat treated to improve the properties of the composite inaterial. The heat treated Cu-Ni-Mn alloy may be substantially free of Sn and Zn. The composite material is usefi.il for applications such as cutting tools.
[0016] Fig. 1 is an isometric view of a cutting bit 5 including a etttting head 6 made of a composite material of the present invention comprising a hard ceramic phase and a heat treated Cu-Ni-Mn infiltration alloy. Discrete diamond elen7ents 7 may be bonded at the forward surface of the cutting head 6.
[0017] Suitable hard ceramic materials for use in accordance with the present invention include carbides, borides, nitrides and oxides. Suitable carbides for use as the hard ceramic phase include tungsten carbide, tantalum carbide, niobium carbide, molybdenum carbide, chromium carbide, vanadium carbide, zirconium carbide, hafizium carbide, titanium carbide and cast carbides. Suitable borides include titanium diboride and other refractory metal borides. Tungsten carbide may be particularly suitable as the hard ceramic phase, for example, in the form of sintered cemented macrocrystalline tungsten carbide particles.
[0018] In accordance with an embodiment of the present invention, the infiltration alloy is a heat treatable Cu-Ni-Mn alloy. As used herein, the term "heat treatable" means an alloy or composite containing the alloy which exhibit at least one improved mechanical property such as increased hardness, wear resistance, toughness and/or transverse rupture strength after the alloy or composite has been solutionized, cooled and thermally aged.
During the solutionizing step, solute atoms are dissolved to form a single-phase solid solution. During the cooling step, the solutionized material is rapidly cooled or quenched, e.g., to room temperature, to form a supersaturated solid solution. During the thermal aging step, the supersaturated solid solution is heated to an intermediate temperature, i.e., within a two-phase region, at which second-phase precipitates form as finely dispersed particles.
Lattice strains are established at the precipitate-matrix interfaces, which provide increased resistance to dislocation motion. The heat treatable Cu-Ni-Mn infiltration alloy thus exhibits precipitation hardening as a result of the heat treatment process.
During the solutionizing step, solute atoms are dissolved to form a single-phase solid solution. During the cooling step, the solutionized material is rapidly cooled or quenched, e.g., to room temperature, to form a supersaturated solid solution. During the thermal aging step, the supersaturated solid solution is heated to an intermediate temperature, i.e., within a two-phase region, at which second-phase precipitates form as finely dispersed particles.
Lattice strains are established at the precipitate-matrix interfaces, which provide increased resistance to dislocation motion. The heat treatable Cu-Ni-Mn infiltration alloy thus exhibits precipitation hardening as a result of the heat treatment process.
[0019] The amount of copper contained in the infiltration alloy typically ranges from about 30 to about 70 percent, for example, from about 55 to about 65 weight percent. As a particular example, the amount of copper may be about 60 weight percent.
[0020] The amount of Ni contained in the infiltration alloy typically ranges from about 15 to about 35 weight percent, for example, from about 18 to about 22 weight percent.
As a particular example, the Ni content may be about 20 weight percent.
As a particular example, the Ni content may be about 20 weight percent.
[0021] The amount of Mn contained in the infiltration alloy typically ranges from about 15 to about 35 weight percent, for example, from about 18 to about 22 weight percent.
As a particular example, the Mn may comprise about 20 weight percent of the infiltration alloy.
As a particular example, the Mn may comprise about 20 weight percent of the infiltration alloy.
[0022] The ratio of Ni to Mn may be controlled. For example, the atomic ratio of Ni:Mn may typically range from about 0.8:1 to about 1.2:1. In one embodiment, the atomic ratio of Ni:Mn may be 1:1. In another embodiment, the atomic ratio of Ni:Mn may be greater than 1:1, for example from about 1.01:1 to about 1.1:1 in order to increase the precipitation hardening effect.
[0023] In an embodiment of the present invention, the infiltration alloy is substantially free of Sn and Zn. As used herein, the term "substantially free of Sn and Zn"
means that Sn and Zn are not piuposefiilly added as alloying additions to the infiltration alloy, and are only present in the infiltration alloy up to trace amounts or as impurities.
means that Sn and Zn are not piuposefiilly added as alloying additions to the infiltration alloy, and are only present in the infiltration alloy up to trace amounts or as impurities.
[0024] The heat treated Cu-Ni-Mn infiltration alloy includes strengthening precipitates, e.g., in the form of an MnNi intermetallic material having a face centered tetragonal structure.
[0025] The relative amounts of the hard ceramic powder and Cu-Ni-Mn infiltration alloy powder may be selected in order to produce the desired ratio of ceramic phase and infiltration alloy phase in the final composite material. The hard ceramic phase is typically the most predominant phase of the composite material on a weight percentage basis. In one embodiment, the hard ceramic phase may comprise from about 60 to about 80 weight percent of the composite material, while the Cu-Ni-Mn infiltration alloy may comprise from about 20 to about 40 weight percent of the composite. As a particular example, the hard ceramic phase may comprise about 67 weight percent of the composite and the Cu-Ni-Mn infiltration alloy may comprise about 33 weight percent of the composite.
[0026] In addition to the above-noted hard ceramic and Cu-Ni-Mn infiltration alloy phases, the composite material may optionally include at least one additional phase. For example, the additional phase may comprise iron, 4600 steel, tungsten, cobalt, nickel, manganese, silicon, molybdenum, copper, zinc, chromium, boron, carbon, complex carbide eta phase materials, nitrides and/or carbonitrides. Eta phase materials are of the formula M6C
or M12C where M is a combination of carbide-forming metals such as Co, Fe, Ni and W, e.g., Co3W3C. Such optional additional phases may be present in the infiltration alloy in a total amount of up to about 5 weight percent.
or M12C where M is a combination of carbide-forming metals such as Co, Fe, Ni and W, e.g., Co3W3C. Such optional additional phases may be present in the infiltration alloy in a total amount of up to about 5 weight percent.
[0027] Fig. 2 schematically illustrates a fixture for consolidating composite materials of the present invention. The production assembly shown in Fig. 2 includes a carbon mold, generally designated as 11, having a bottom wall 12 and an upstanding wall 13.
The mold 11 defines a volume therein. The assembly filrther includes a top member 14, which fits over the opening of the mold 11. It should be understood that the use of the top number 14 is optional depending upon the degree of atmosphereic control one desires.
The mold 11 defines a volume therein. The assembly filrther includes a top member 14, which fits over the opening of the mold 11. It should be understood that the use of the top number 14 is optional depending upon the degree of atmosphereic control one desires.
[0028] A steel shank 17 is positioned within the mold before the powder is poured therein. A portion of the steel shank 17 is within the powder mixture 16 and another portion of the steel shank 17 is outside of the mixture 16. Shank 17 has threads 18 at one end thereof, and grooves 19 at the other end thereof.
[0029] Referring to the contents of the mold, a plurality of discrete diamonds 15 are positioned at selected positions within the mold so as to be at selected positions on the surface of the finished product. The ceramic matrix powder 16 is a carbide-based powder, which is poured into the mold 11 so as to be on top of the diamonds 15. Once the diamonds have been set and the ceramic matrix powder 16 poured into the mold, a Cu-Ni-Mn infiltration alloy 20 of the present invention is positioned on top of the powder mixture 16 in the mold 11. Then the top 14 is positioned over the mold, and the mold is placed into a ftirnace and heated to approximately 1,200 C so that the infiltration alloy 20 melts and infiltrates the powder mass. The result is an end product wherein the infiltration alloy bonds the ceramic powder together, the matrix holds the diamonds therein, and the composite is bonded to the steel shank.
[0030] Fig. 3 schematically illustrates a method of forming and heat treating a composite material comprising a hard ceramic phase and a Cu-Ni-Mn infiltration alloy in accordance with an embodiment of the present invention. Hard ceramic powder is mixed with a Cu-Ni-Mn infiltration alloy powder and consolidated. Consolidation may be performed in a mold by heating the powder mixture above the liquidous temperature of the Cu-Ni-Mn infiltration alloy. During the consolidation step, temperatures of from about 1,100 to 1,200 C are typically used, for example, a consolidation temperature of about 1,200 C may be suitable. The consolidation temperature is held for a sufficient period of time to allow melting of the Cu-Ni-Mn iiifiltration alloy powder and bonding of the hard ceramic powder, such that a dense composite material is formed. The consolidation temperature may typically be held for a duration of from less than 1 miiiute to more than 5 hours. As a particular example, the consolidation temperature may be held for about 30 minutes.
[0031] The consolidated composite material may be cooled, e.g., to room temperature, followed by solutionizing at elevated temperatures, e.g., from about 500 to about 1,000 C, typically from about 750 to about 900 C. As a particular example, the solutionizing temperature may be about 850 C. Solutionizing at such elevated temperatures may typically be performed from 0.5 to 3 hours, for example, about 2 hours.
[0032] After the sohrtioiiizing step, the composite may be cooled to ambient temperature at a relatively fast cooling rate by any suitable means such as air cooling. The solutionized and cooled composite material may then be thermally aged at a tenlperature and time sufficient to increase at least one mechanical property of the composite.
For example, aging temperatures may range from about 100 to about 450 C, typically from about 300 to about 450 C. As a particular example, a thermal aging temperature of about 430 C may be used. Typical thermal aging times may be from 0.5 to 72 hours, for example, about 5 hours.
After the thermal aging step, the composite may be cooled by any suitable means such as air cooling.
For example, aging temperatures may range from about 100 to about 450 C, typically from about 300 to about 450 C. As a particular example, a thermal aging temperature of about 430 C may be used. Typical thermal aging times may be from 0.5 to 72 hours, for example, about 5 hours.
After the thermal aging step, the composite may be cooled by any suitable means such as air cooling.
[0033] Infiltration alloys listed in Table 1 were prepared. Alloy A is a Cu-Ni-Mn infiltration alloy in accordance with an embodiment of the present invention.
Alloy B is a Cu-Mn-Ni-Zn alloy provided for comparison purposes.
Table 1 Infiltration Alloy Compositions Allo Description Content (wt. %) Cu Ni Mn Sn Zn A Cu-Ni-Mn Alloy 60 20 20 0 0 B Cu-Mn-Ni-Zn Alloy 53 15 24 0 8 [0034] Alloys in Table 1 were made in the form of roughly '/4 inch shots (Alloy A) or `/z inch cubes (Alloy B). Graphite molds were used to make infiltrated test specimens containing either an alloy or a mixture of 33% alloy and 67% P90 WC matrix powder comprising 67% macrocrystalline WC (-80 + 325 mesh) and 31 % of cast carbide (-mesh).
Alloy B is a Cu-Mn-Ni-Zn alloy provided for comparison purposes.
Table 1 Infiltration Alloy Compositions Allo Description Content (wt. %) Cu Ni Mn Sn Zn A Cu-Ni-Mn Alloy 60 20 20 0 0 B Cu-Mn-Ni-Zn Alloy 53 15 24 0 8 [0034] Alloys in Table 1 were made in the form of roughly '/4 inch shots (Alloy A) or `/z inch cubes (Alloy B). Graphite molds were used to make infiltrated test specimens containing either an alloy or a mixture of 33% alloy and 67% P90 WC matrix powder comprising 67% macrocrystalline WC (-80 + 325 mesh) and 31 % of cast carbide (-mesh).
[0035] The test specimens were made by heating the filled molds to 1,200 C
under argon or hydrogen, holding at the temperature for 30 minutes, and cooling to room temperature. The specimens were used to determine impact toughness, B611 wear number, and transverse rupture strength (TRS). In the case of the Cu-Ni-Mn Alloy A, the following heat treatment was used on a number of specimens to assess the effectiveness of this treatment in improving the alloy properties: solutionize at 850 C; hold for 2 hours; air cool;
age at 430 C for 8 to 72 hours; and air cool. Results of the tests are listed in Table 2.
Table 2 Properties of Tungsten Carbide and Infiltration Alloy Composites A A
Alloy (As Cast) (Heat Treated) B
Hardness (HV) 120 410 140 (100% Alloy) Impact Toughness 1.0 2.5 2.6 (ft-lb) B61 1 wea-= Number 0.67 0.98 0.65 TRS (ksi) 98 110 90 [0036] As shown in Table 2, mechanical properties of the composites including Alloy A may be dramatically increased by heat treatment in comparison with the conventional composite infiltrated with Alloy B. In accordance with embodiments of the present invention, it is possible to heat treat a Cu-Ni-Mn infiltration alloy to siu=pass properties such as wear resistance and TRS of conventional Cu-based infiltration alloys.
Drilling bits made with the present spinodal infiltration alloys can be readily heat treated to obtain optimum combinatioiis of service properties.
100371 Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the iilvention as defined in the appended claims.
under argon or hydrogen, holding at the temperature for 30 minutes, and cooling to room temperature. The specimens were used to determine impact toughness, B611 wear number, and transverse rupture strength (TRS). In the case of the Cu-Ni-Mn Alloy A, the following heat treatment was used on a number of specimens to assess the effectiveness of this treatment in improving the alloy properties: solutionize at 850 C; hold for 2 hours; air cool;
age at 430 C for 8 to 72 hours; and air cool. Results of the tests are listed in Table 2.
Table 2 Properties of Tungsten Carbide and Infiltration Alloy Composites A A
Alloy (As Cast) (Heat Treated) B
Hardness (HV) 120 410 140 (100% Alloy) Impact Toughness 1.0 2.5 2.6 (ft-lb) B61 1 wea-= Number 0.67 0.98 0.65 TRS (ksi) 98 110 90 [0036] As shown in Table 2, mechanical properties of the composites including Alloy A may be dramatically increased by heat treatment in comparison with the conventional composite infiltrated with Alloy B. In accordance with embodiments of the present invention, it is possible to heat treat a Cu-Ni-Mn infiltration alloy to siu=pass properties such as wear resistance and TRS of conventional Cu-based infiltration alloys.
Drilling bits made with the present spinodal infiltration alloys can be readily heat treated to obtain optimum combinatioiis of service properties.
100371 Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the iilvention as defined in the appended claims.
Claims (29)
1. A composite material comprising:
a hard ceramic phase; and a metal phase comprising a heat treated Cu-based infiltration alloy comprising Ni and Mn.
a hard ceramic phase; and a metal phase comprising a heat treated Cu-based infiltration alloy comprising Ni and Mn.
2. The composite material of Claim 1, wherein the heat treated Cu-based infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities.
3. The composite material of Claim 1, wherein the heat treated Cu-based infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities.
4. The composite material of Claim 1, wherein the heat treated Cu-based infiltration alloy is substantially free of Sn.
5. The composite material of Claim 1, wherein the heat treated Cu-based infiltration alloy is substantially free of Zn.
6. The composite material of Claim 1, wherein the heat treated Cu-based infiltration alloy is substantially free of Sn and Zn.
7. The composite material of Claim 1, wherein the hard ceramic phase comprises from about 60 to about 80 weight percent of the composite material, and the infiltration alloy comprises from about 20 to about 40 weight percent of the composite material.
8. The composite material of Claim 1, wherein the hard ceramic phase comprises at least one carbide selected from tungsten carbide, titanium carbide, tantalum carbide, niobium carbide, molybdenum carbide, chromium carbide, vanadium carbide, zirconium carbide and hafnium carbide.
9. The composite material of Claim 8, wherein the carbide comprises WC.
10. The composite material of Claim 1, further comprising at least one additional phase.
11. The composite material of Claim 10, wherein the at least one additional phase comprises iron, 4600 steel, tungsten, cobalt, nickel, manganese, silicon, molybdenum, copper, zinc, chromium, boron, carbon, nitrides and/or carbonitrides.
12. The composite material of Claim 1, further comprising Co.
13. The composite material of Claim 1, wherein the composite material has been subjected to thermal aging at a temperature of from about 100 to about 450°C for a time of from about 0.5 to about 72 hours.
14. A method of making a composite material comprising infiltrating an alloy into hard ceramic particles, wherein the infiltration alloy consists essentially of Cu, Ni and Mn.
15. The method of Claim 14, wherein the infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities.
16. The method of Claim 14, wherein the infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities.
17. The method of Claim 14, wherein the infiltration alloy is substantially free of Sn and Zn.
18. The method of Claim 14, wherein the hard ceramic particles comprise from about 60 to about 80 weight percent of the composite material, and the infiltration alloy comprises from about 20 to about 40 weight percent of the composite material.
19. The method of Claim 14, wherein the hard ceramic particles comprise WC.
20. The method of Claim 14, further comprising heat treating the composite material.
21. The method of Claim 20, wherein the heat treating includes thermal aging at a temperature of from about 100 to about 450°C for a time of from about 0.5 to about 72 hours.
22. A method of heat treating a composite material comprising:
providing a composite material including a hard ceramic phase and an infiltration alloy comprising Cu, Ni and Mn; and heat treating the composite.
providing a composite material including a hard ceramic phase and an infiltration alloy comprising Cu, Ni and Mn; and heat treating the composite.
23. The method of Claim 22, wherein the heat treating includes thermal aging at a temperature of from about 100 to about 450°C for a time of from about 0.5 to about 72 hours.
24. The method of Claim 23, wherein the heat treating comprises solutionizing the composite material at an elevated temperature and cooling the solutionized composite prior to the step of thermally aging the composite.
25. The method of Claim 24, wherein the solutionizing step is performed at a temperature of from about 500 to about 1,000°C for a time of from about 0.5 to about 3 hours.
26. The method of Claim 24, wherein the solutionized composite is cooled to room temperature prior to the step of thermally aging the composite.
27. The method of Claim 24, wherein the heat treated Cu-based infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities.
28. The method of Claim 22, wherein the heat treated Cu-based infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities.
29. The method of Claim 28, wherein the infiltration alloy is substantially free of Sn and Zn.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US11/709,515 US20080206585A1 (en) | 2007-02-22 | 2007-02-22 | Composite materials comprising a hard ceramic phase and a Cu-Ni-Mn infiltration alloy |
US11/709,515 | 2007-02-22 | ||
PCT/US2008/054373 WO2008103704A1 (en) | 2007-02-22 | 2008-02-20 | Composite materials comprising a hard ceramic phase and a cu-ni-mn infiltration alloy |
Publications (1)
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CA2678554A1 true CA2678554A1 (en) | 2008-08-28 |
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CA002678554A Abandoned CA2678554A1 (en) | 2007-02-22 | 2008-02-20 | Composite materials comprising a hard ceramic phase and a cu-ni-mn infiltration alloy |
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US (1) | US20080206585A1 (en) |
EP (1) | EP2113034A4 (en) |
CN (1) | CN101631883B (en) |
AU (1) | AU2008218682A1 (en) |
CA (1) | CA2678554A1 (en) |
WO (1) | WO2008103704A1 (en) |
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US9056799B2 (en) | 2010-11-24 | 2015-06-16 | Kennametal Inc. | Matrix powder system and composite materials and articles made therefrom |
JP6483442B2 (en) * | 2011-12-05 | 2019-03-13 | エックス−ボディ インコーポレイテッド | PDGF receptor beta-binding polypeptide |
CN102433481B (en) * | 2011-12-16 | 2013-06-05 | 黑龙江省科学院高技术研究院 | Preparation method of AlN-particle-reinforced copper composite heat sink material and thereof |
CN104119095B (en) * | 2013-04-27 | 2016-04-27 | 比亚迪股份有限公司 | A kind of sintering metal composite product and preparation method thereof |
CN105522137B (en) * | 2014-10-24 | 2018-09-11 | 比亚迪股份有限公司 | A kind of cermet complex and preparation method thereof |
US10071464B2 (en) | 2015-01-16 | 2018-09-11 | Kennametal Inc. | Flowable composite particle and an infiltrated article and method for making the same |
CN105568037B (en) * | 2016-01-14 | 2017-11-17 | 北京科技大学 | A kind of chromium plating diamond particles disperse the preparation method of Cu-base composites |
CN105624462A (en) * | 2016-04-10 | 2016-06-01 | 吴成继 | Dental drill |
CN107400816B (en) * | 2017-08-10 | 2019-03-12 | 西迪技术股份有限公司 | A kind of Cu-base composites and preparation method thereof |
EP3697555A4 (en) * | 2017-10-19 | 2021-05-12 | Global Tungsten & Powders Corp. | High strength and erosion resistant powder blends |
CN109763019B (en) * | 2019-03-25 | 2020-06-23 | 中南大学 | High-strength high-elasticity copper-nickel-manganese alloy and preparation method thereof |
CN109763008B (en) * | 2019-03-25 | 2020-06-30 | 中南大学 | High-strength high-elasticity niobium-containing copper alloy and preparation method thereof |
CN110791674B (en) * | 2019-11-13 | 2021-03-30 | 哈尔滨工业大学 | Preparation method of refractory carbide particle reinforced tungsten copper infiltrated composite material |
JP7194145B2 (en) * | 2020-04-01 | 2022-12-21 | Koa株式会社 | Alloys for resistors and use of alloys for resistors in resistors |
CN115786796A (en) * | 2022-11-10 | 2023-03-14 | 昆明理工大学 | Medium-entropy copper alloy and preparation method thereof |
CN116065052B (en) * | 2023-03-28 | 2023-06-09 | 中南大学 | Copper-based binary composite material containing hafnium nitride |
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- 2007-02-22 US US11/709,515 patent/US20080206585A1/en not_active Abandoned
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- 2008-02-20 EP EP08730220A patent/EP2113034A4/en not_active Withdrawn
- 2008-02-20 CA CA002678554A patent/CA2678554A1/en not_active Abandoned
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AU2008218682A1 (en) | 2008-08-28 |
EP2113034A4 (en) | 2010-07-21 |
US20080206585A1 (en) | 2008-08-28 |
WO2008103704A1 (en) | 2008-08-28 |
CN101631883B (en) | 2012-03-28 |
EP2113034A1 (en) | 2009-11-04 |
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