Classifications

• • 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
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/05—Mixtures of metal powder with non-metallic powder
  • C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
• • 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
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/0475—Impregnated alloys
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• • 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
  • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
  • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
  • C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
• • 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

Definitions

• the invention pertains to a hard composite comprising a metal matrix and one or more discrete hard elements held therein wherein the hard composite can be useful as a cutter or a wear member. More particularly, the invention pertains to a diamond composite comprising a matrix composed of carbide-based particulates bonded together by an infiltrant metal with one or more discrete diamond-based elements held therein. It should be understood that the diamond-based element could comprise a discrete-diamond composite or polycrystalline diamond composite having a substrate with a layer of polycrystalline diamond thereon.
• Some types of tungsten carbide that are appropriate for use in matrix tools include a macrocrystalline tungsten carbide, a crushed sintered cemented macrocrystalline tungsten carbide having a binder metal, and a crushed cast tungsten carbide.
• this material is essentially stoichiometric WC which is, for the most part, in the form of single crystals.
• Some large crystals of macrocrystalline tungsten carbide are bicrystals.
• U.S. Patent No. 3,379,503 to McKenna for a PROCESS FOR PREPARING TUNGSTEN MONOCARBIDE assigned to the assignee of the present patent application, discloses a method of making macrocrystalline tungsten carbide.
• U.S. Patent No. 4,834,963 to Terry et al. for MACROCRYSTALLINE TUNGSTEN MONOCARBIDE POWDER AND PROCESS FOR PRODUCING assigned to the assignee of the present patent application, also discloses a method of making macrocrystalline tungsten carbide.
• this material comprises small particles of tungsten carbide bonded together in a metal matrix.
• the crushed sintered cemented macrocrystalline tungsten carbide with a binder is made by mixing together WC particles, Co or Ni powder and a lubricant. This mixture is pelletized, sintered, cooled, and then crushed. The pelletization does not use pressure, but instead, during the mixing of the WC particles and cobalt, the blades of the mixer cause the mixture of WC and cobalt (or nickel) to ball up into pellets.
• tungsten forms two carbides; namely, WC and W 2 C. There can be a continuous range of compositions therebetween.
• An eutectic mixture is about 4.5 weight percent carbon.
• Cast tungsten carbide commercially used as a matrix powder typically has a hypoeutectic carbon content of about 4 weight percent.
• Cast tungsten carbide is typically frozen from the molten state and comminuted to the desired particle size.
• hard composites comprised of a matrix and discrete hard elements held therein.
• one example of the carbide-based component contains about 67.10 weight percent macrocrystalline tungsten carbide having the following size distribution: between 18.0 and 22.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -80 +120 mesh (the mesh size is made according to ASTM Standard E-ll- 70, and corresponds to greater than 125 micrometers and less than or equal to 177 micrometers), between 25.0 to 30.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -120 +170 mesh (greater than 88 micrometers and less than or equal to 125 micrometers), between 29.0 weight percent and 33.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -170 +230 mesh (greater than 63 micrometers and less than or equal to 88 micrometers), between 18.0 weight percent and 22.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -230 +325 mesh (greater than 44 micrometer
• the matrix further contains about 30.90 weight percent crushed cast tungsten carbide particles having a size of -325 mesh (less than or equal to 44 micrometers) , 1.00 weight percent iron that has an average particle diameter of between 3 micrometers and 5 micrometers, and 1.00 weight percent grade 4600 steel having a particle size of -325 mesh (less than or equal to 44 micrometers) .
• the 4600 grade steel has the following nominal composition (weight percent): 1.57 weight percent nickel; 0.38 weight percent manganese; 0.32 weight percent silicon; 0.29 weight percent molybdenum 0.06 weight percent carbon; and balance iron.
• the carbide-based component comprises about 65 weight percent of macrocrystalline tungsten carbide having a particle size of -80 +325 mesh (greater than 44 micrometers an less than or equal to 177 micrometers), 27.6 weight percent tungsten carbide rod milled to an average particle size of 4 to 6 micrometers with superfines removed, 2.8 weight percent tungsten having a particle size of -325 mesh (less than or equal to 44 micrometers), 2.8 weight percent 4600 grade steel having a particle size of -140 mesh (less than or equa to 105 micrometers), and 1.8 weight percent of iron having a particle size of -325 mesh (less than or equa to 44 micrometers) .
• Another example of a carbide-based particulate component comprises 68 weight percent macrocrystalline tungsten carbide having a size of -80 +325 mesh (greater than 44 micrometers and less than o equal to 177 micrometers) ; 15 weight percent of macrocrystalline tungsten carbide having a size of -32 mesh (less than or equal to 44 micrometers) ; 15 weight percent of crushed cast tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; and 2 weight percent nickel having a size of -325 mesh (less than or equal to 44 micrometers) .
• This nickel is INCO type 123 from International Nickel Company and is a singular spike covered regular shaped powder.
• the chemical analysis and physical characteristics available from commercial literature reveal the following: The chemical analysis shows a composition of: 0.1 max. carbon, 0.15 max. oxygen, 0.001 max. sulfur, 0.01 max. iron, and balance nickel.
• the averag particle size is 3-7 micrometers (Fisher Subsieve
• a carbide-based particulate component comprises 64 weight percent macrocrystalline tungsten carbide having a size of -80 +325 mesh (greater than 44 micrometers and less than or equal to 177 micrometers) ; 14 weight percent of macrocrystalline tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; 14 weight percent of crushed cast tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; and 8 weight percent nickel having a size of -200 mesh (less than or equal to 74 micrometers) .
• Still another example of a particulate component comprises a 67.0 weight percent crushed cast tungsten carbide having a particle size distribution as follows: between 18.0 and 22.0 weight percent of the crushed cast tungsten carbide particles have a size of -80 +120 mesh (greater than 125 micrometers and less than or equal to 177 micrometers), between 25.0 to 30.0 weight percent of the crushed cast tungsten carbide particles have a size of -120 +170 mesh
• the component further has 31.0 weight percent crushed cast tungsten carbide having a particle size of -325 mesh (less than or equal to 44 micrometers), 1.0 weight percent iron having a particle size of -325 mesh (less than or equal to 44 micrometers), and 1.0 weight percent 4600 steel having a particle size of -325 mesh (less than or equal to 44 micrometers) .
• a suitable infiltrant comprises 63-67 weight percent copper, 14-16 weight percent nickel, and 19-21 weight percent zinc. This material has a specific gravity of 8.5 g/cc and has a melting point of 1100 °F. This infiltrant is used in l/32nd inch by 5/16ths inch granules. This alloy is identified as MACROFIL 65 by applicants' assignee, and this designation will be used in this application.
• a suitable infiltrant has a nominal composition of 52.7 weight percent copper, 24.0 weight percent manganese, 15.0 weight percent nickel, 8.0 weight percent zinc, .15 weight percent boron, and .15 weight percent silicon with traces of lead, tin and iron.
• This infiltrant is sold by Belmont Metals Inc., 330 Belmont Avenue, Brooklyn, New York 11207 under the name designation "VIRGIN binder 4537D" in 1 inch by 1/2 inch by 1/2 inch chunks.
• This alloy is identified as MACROFIL 53 by applicants' assignee, and this designation will be used in this application. While these earlier matrices for a hard composite have performed in a satisfactory fashion, it would be desirable to provide an improved matrix for a hard composite having improved properties.
• It is an object of the invention to provide an improved matrix powder for a hard composite comprising one or more discrete hard elements held in a matrix composed of carbide-based particulates bonded together by an infiltrant metal wherein the matrix has improved overall properties. It is contemplated that the hard composite could be used in cutting and drilling applications, and that the matrix powder and infiltrant without the hard element could be used in wear applications.
• It is another object of the invention to provide an improved hard composite comprising a plurality of discrete hard elements, such a diamond or polycrystalline diamond composite elements, held in a matrix composed of carbide-based particulates bonded together by an infiltrant metal that has improved impact strength.
• It is still another object of the invention to provide an improved hard composite comprising a plurality of discrete hard elements, such as diamond or polycrystalline diamond composite elements, held in a matrix composed of carbide-based particulates bonded together by an infiltrant metal that has improved transverse rupture strength.
• It is an object of the invention to provide an improved hard composite comprising a plurality of discrete hard elements, such as diamond or polycrystalline diamond composite elements, held in a matrix composed of carbide-based particulates bonded together by an infiltrant metal that has improved hardness.
• It is another object of the invention to provide an improved hard composite comprising a plurality of discrete hard elements, such as diamond or polycrystalline diamond composite elements, held in a matrix composed of carbide-based particulates bonded together by an infiltrant metal that has improved erosion resistance properties.
• the invention is a matrix powder for formation along with an infiltrant into a matrix.
• the matrix powder comprises crushed sintered cemented tungsten carbide particles having a particle size of -80+400 mesh (greater than 37 micrometers and less than or equal to 177 micrometers) .
• the composition of the crushed sintered cemented tungsten carbide comprises between about 5 weight percent and about 20 weight percent binder metal and between about 80 weight percent and about 95 weight percent tungsten carbide.
• the invention is a diamond composite member which includes a support and a diamond composite affixed to the support.
• the diamond composite comprises a matrix which includes a mass of particles held together by an infiltrant.
• the mass of particles is formed by heating a powder mixtur in the presence of an infiltrant.
• the powder mixture comprises crushed sintered cemented tungsten carbide particles having a particle size of -80+400 mesh (greater than 37 micrometers and less than or equal to 177 micrometers) .
• the composition of the crushed sintered cemented tungsten carbide comprises between about 5 weight percent and about 20 weight percent binder metal and between about 80 weight percent and about 95 weight percent tungsten carbide.
• FIG. 1 there is illustrated a schematic of the assembly used to manufacture a product using the diamond as part of the present invention.
• the typical product is a drill head.
• the drill head has a shank.
• Cutter elements such as the discrete diamonds are bonded to the bit head with the metal matrix.
• the production assembly includes a carbon, such as graphite, mold, generally designated as 10, having a bottom wall 12 and an upstanding wall 14.
• the mold 10 defines a volume therein.
• the assembly further includes a top member 16 which fits over the opening of the mold 10. It should be understood that the use of the top number 16 is optional depending upon the degree of atmospheric control one desires.
• a steel shank 24 is positioned within the mold before the powder is poured therein. A portion of the steel shank 24 is within the powder mixture 22 and another portion of the steel shank 24 is outside of the mixture 22. Shank 24 has threads 25 at one end thereof, and grooves 25A at the other end thereof.
• the matrix powder 22 is a carbide-based powder which is poured into the mold 10 so as to be adjacent to the diamonds 20.
• the composition of the matrix powder 22 will be set forth hereinafter.
• infiltrant alloy 26 is positioned adjacent to the powder mixture 22 in the mold 10. Then the top 16 is positioned over the mold, and the mold is placed into a furnace and heated to approximately 2200 °F (1177 °C) so that the infiltrant 26 melts and infiltrates the powder mass. The result is an end product wherein the infiltrant bonds the powder together, the matrix holds the diamonds therein, and the composite is bonded to the steel shank.
• the assembly includes a carbon, such as graphite, mold, generally designated as 30, having a bottom wall 32 and an upstanding wall 34.
• the mold 30 defines a volume therein.
• the assembly further includes a top member 36 which fits over the opening of the mold 30. It should be understood that the use of the top member 36 is optional depending upon the degree of atmospheric control one desires.
• a steel shank 42 is positioned within the mold before the powder mixture is poured therein. A portion of the steel shank 42 is within the powder mixture 40 and another portion of the steel shank 42 is outside of the mixture. The shank 42 has grooves 43 at the end that is within the powder mixture.
• the matrix powder 40 is a carbide- based powder which is poured into the mold 30 so as to be adjacent to the carbon (graphite) blanks 38.
• the composition of the matrix powder 40 will be set forth hereinafter.
• Infiltrant alloy 44 is positioned adjacent to the powder mixture in the mold. Then the top 36 is positioned over the mold, and the mold is placed into a furnace and heated to approximately 2200 °F (1177 °C) so that the infiltrant melts and infiltrates the powder mass. The result is an intermediate product wherein the infiltrant bonds the powder together, also bonding the powder mass to the steel shank, and the carbon
• the carbon (graphite) blanks are removed from bonded mass and a diamond composite insert, having a shape like that of the carbon (graphite) blank, is brazed into the recess to form the end product.
• the diamond composite drill head has a layer of discrete diamonds along the side.
• FIG. 3 there is illustrated therein a portion of a tool, generally designated as
• the tool 50 has a forwardly facing surface to which are bonded discrete diamond elements 52.
• Comparative Example A comprises a powder matrix mixture having a composition and size distribution as follows: about 67.10 weight percent macrocrystalline tungsten carbide having the following size distribution: between 18.0 and 22.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -80 +120 mesh (greater than 125 micrometers and less than or equal to 177 micrometers) between 25.0 to 30.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -120 +170 mesh (greater than 88 micrometers and less than or equal to 125 micrometers), between 29.0 weight percent and 33.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -170 +230 mesh (greater than 63 micrometers and less than or equal to 88 micrometers), between 18.0 weight percent and 22.0 weight percent of the macrocrystalline tungsten carbide particles have a size of -230 +325 mesh (greater than 44 micrometers and less than or equal to 63 micrometers), and up to 5.0 weight percent
• the matrix further contains about 30.9 weight percent crushed cast tungsten carbide particles having a size of -325 mesh (less than or equal to 44 micrometers), 1.00 weight percent iron and has an average particle diameter of between 3 micrometers and 5 micrometers, and 1.00 weight percent grade 4600 steel having a particle size of -325 mesh (less than or equal to 44 micrometers) .
• the 4600 grade steel has the following nominal composition (weight percent): 1.57 weight percent nickel; 0.38 weight percent manganese; 0.32 weight percent silicon; 0.29 weight percent molybdenum; 0.06 weight percent carbon; and balance iron.
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above.
• This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Comparative Example B comprises a powder matrix mixture having a composition and size distribution as follows: about 68 weight percent macrocrystalline tungsten carbide having a size of -80 +325 mesh (greater than 44 micrometers and less than or equal to 177 micrometers) ; 15 weight percent of macrocrystalline tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; 15 weight percent of crushed cast tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; and 2 weight percent nickel having a size of -325 mesh (less than or equal to 44 micrometers) .
• This nickel is INCO type 123 from International Nickel Company and is a singular spike covered regular shaped powder.
• the chemical analysis and physical characteristics available from commercial literature reveal the following: The chemical analysis shows a composition of: 0.1 max. carbon, 0.15 max. oxygen, 0.001 max. sulfur, 0.01 max. iron, and balance nickel.
• the average particle size is 3-7 micrometers (Fisher Subsieve
• the apparent density is 1.8-2.7 grams/cc, and the specific surface area is 0.34-0.44 m 2 /g.
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above. This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Comparative Example C comprises a powder matrix mixture having a composition and size distribution as follows: about 67.0 weight percent crushed cast tungsten carbide having a particle size distribution as follows: between 18.0 and 22.0 weight percent of the crushed cast tungsten carbide particles have a size of -80 +120 mesh (greater than 125 micrometers and less than or equal to 177 micrometers) , between 25.0 to 30.0 weight percent of the crushed cast tungsten carbide particles have a size of -120 +170 mesh (greater than 88 micrometers and less than or equal to 125 micrometers), between 29.0 weight percent and 33.0 weight percent of the crushed cast tungsten carbide particles have a size of -170 +230 mesh (greater than 63 micrometers and less than or equal to 88 micrometers), between 18.0 weight percent and 22.0 weight percent of the crushed cast tungsten carbide particles have a size of -230 +325 mesh
• the component further has 31.0 weight percent crushed cast tungsten carbide having a particle size of -325 mesh (less than or equal to 44 micrometers), 1.0 weight percent iron having a particle size of -325 mesh (less than or equal to 44 micrometers), and 1.0 weight percent 4600 steel having a particle size of -325 mesh (less than or equal to 44 micrometers) .
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above. This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Comparative Example D comprises a powder matrix mixture having a composition and size distribution as follows: about 64 weight percent macrocrystalline tungsten carbide having a size of -80 +325 mesh (greater than 44 micrometers and less than or equal to 177 micrometers) ; 14 weight percent of macrocrystalline tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; 14 weight percent of crushed cast tungsten carbide having a size of -325 mesh (less than or equal to 44 micrometers) ; and 8 weight percent nickel having a size of -200 mesh (less than or equal to 74 micrometers) .
• This nickel is INCO type 123 from International Nickel Company and is a singular spike covered regular shaped powder.
• the chemical analysis and physical characteristics available from commercial literature reveal the following: The chemical analysis shows a composition of: 0.1 max. carbon, 0.15 max. oxygen, 0.001 max. sulfur, 0.01 max. iron, and balance nickel.
• the average particle size is 3-7 micrometers (Fisher Subsieve Size), the apparent density is 1.8-2.7 grams/cc, and the specific surface area is 0.34-0.44 m 2 /g.
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above. This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Example No. 1 comprises a powder matrix mixture having a composition and size distribution as follows: 100 weight percent of crushed sintered cemented macrocrystalline tungsten carbide particles having a particle size of -140 +325 mesh (greater than 44 micrometers and less than or equal to 105 micrometers) .
• the composition of the cemented macrocrystalline tungsten carbide comprises 13 weight percent cobalt and 87 weight percent macrocrystalline tungsten carbide wherein the macrocrystalline tungsten carbide has an average particle size between about 5 micrometers and about 25 micrometers.
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above.
• This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Example No. 2 comprises a powder mixture comprising the following: 100 weight percent of crushed sintered cemented macrocrystalline tungsten carbide particles having a particle size of -140+270 mesh (greater than 63 micrometers and less than or equal to 105 micrometers) .
• the composition of the cemented macrocrystalline tungsten carbide comprises 6 weight percent cobalt and 94 weight percent macrocrystalline tungsten carbide wherein the tungsten carbide has an average particle size between about 5 micrometers and about 25 micrometers.
• the infiltrant was MACROFIL 53.
• the composition of the MACROFIL 53 is set forth above.
• This powder mixture was placed in a mold along with MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Example No. 3 comprises a powder mixture that has the following composition and particle size distribution:
• This powder mixture was placed in a mold along with the MACROFIL 53 infiltrant, and heated at about 2200 °F (1177 °C) until the infiltrant adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Example No. 4 comprises a powder mixture that has the following composition and particle size distribution: (a) about 33.50 weight percent of the mixture is macrocrystalline tungsten carbide particles with a particle size of -80+325 mesh (greater than 44 micrometers and less than or equal to 177 micrometers) ; (b) about 50.00 weight percent of the mixture is crushed sintered cemented macrocrystalline tungsten carbide particles of a size of -120 mesh (less than or equal to 125 micrometers) , and having the following composition: about 6 weight percent cobalt, a maximum of 1 weight percent iron, a maximum of 1.0 weight percent tantalum, a maximum of 1.0 weight percent titanium, a maximum of 0.5 weight percent niobium, a maximum of 0.5 weight percent of other impurities and the balance macrocrystalline tungsten carbide having an average particle size of between about 5 micrometers to about 25 micrometers;
• (e)about 0.50 weight percent of the mixture is iron having an average particle size of 3-5 micrometers.
• Example No. 5 comprises a powder mixture having the following composition and particle size distribution:
• Example No. 6 comprises a powder mixture having the following composition and particle size distribution:
• This powder mixture was placed in a mold along with a MACROFIL 53 infiltrant, and was heated at about 1177°C (2200 °F) until the infiltrant had adequately infiltrated the powder mass so as to bond it together. The mass was then allowed to cool.
• Example No. 7 comprises a powder mixture of 100 weight percent cemented macrocrystalline tungsten carbide having a composition of 10 weight percent nickel and 90 weight percent macrocrystalline tungsten carbide.
• the particle size distribution of the powder mixture comprises: 0.1 weight percent of the cemented macrocrystalline tungsten carbide having a particle size of -80+120 mesh (greater than 125 micrometers and less than or equal to 177 micrometers) ; 11.4 weight percent of the cemented macrocrystalline tungsten carbide having a particle size of -120+170 mesh (greater than 88 micrometers and less than or equal to 125 micrometers); 41.1 weight percent of the cemented macrocrystalline tungsten carbide having a particle size of -170+230 mesh (greater than 63 micrometers and less than or equal to 88 micrometers); 44.5 weight percent of the cemented macrocrystalline tungsten carbide having a particle size of -230+325 mesh (greater than 44 micrometers and less than or equal to 63 micrometers); and 2.9 weight percent
• Examples Nos. 8 and 9 are the same as Example No. 7.
• macrocrystalline tungsten carbide was mixed with 10 weight percent nickel and the powder mixture sintered for one hour at 1371 °C (2500°F) . The sintered material was then crushed into the particle sizes set forth in Examples Nos. 7 through 9.
• Tests for impact strength were conducted according to a procedure using an impact toughness machine.
• the machine had a hammer which when dropped created an impact loading force on a test specimen.
• the load required to break the specimen and the time it took to break the specimen were used to calculate the impact strength. This test was conducted using a
• Dynatap instrumented drop weight tower This test is a high strain rate three-point bend test which measures the amount of energy required to break a one-half inch diameter sample pin.
• Tests for the transverse rupture strength were conducted according to a procedure where a cylindrical pin of the infiltrated material was placed in a fixture. A load was then exerted on the pin until failure. The transverse rupture strength was then calculated based upon the actual load and the dimensions of the pin specimen. Tests for hardness were conducted according to the ASTM Standard B347-85
• Example No. 8 350.4/257.2
• Example No. 9 357.4/331.7
• Example C 322.3/329.0
• Example D 419.4/406.5
• the units for the weight loss are grams per fifty wheel revolutions.
• the testing consisted of subjecting coins made of the matrix material to a high pressure water plus sand abrasive stream for a set length of time and measuring the mass loss of the coin.
• the test parameters were set as follows: Water Pressure lOOOpsi
• Impingement Angle 20 degrees The test setup consisted of a large, high pressure water pump unit, a barrel of sand, a trigger- operated nozzle delivery system, and the hoses to connect all of these together.
• the procedure used for testing was to weigh the coin, place it into the blast fixture, blast it for one minute, then weight it again to measure the loss due to erosion.
• the scale used to weigh the coin was a Mettler balance with a resolution of 0.002 grams. The coin was cleaned and dried prior t every weighing. Two tests were done on each side of th coin.
• the sand and water flow rates were also monitored.
• the water flow rate averaged at about 2 gallons per minute throughout the entire test.
• the san flow rate averaged about 0.65 lbs./minute for the test with some noticeable increase as the testing progressed.
• the accuracy of the sand flow measurement was about ⁇ 0.05 lbs/minute.
• ASTM Standard G76 ASTM Standard G76, except that it uses a liquid jet instead of a gas jet.
• Example No. 3 0.12/0.16
• Example No. 4 0.13/0.10
• Example No. 8 0.05/0.04

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• 1996
  • 1996-01-30 CN CN96191735A patent/CN1172506A/zh active Pending
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