EP2347025B1 - Process for manufacturing a part comprising a block of dense material constituted of hard particles and of binder phase having a gradient of properties, and resulting part - Google Patents

Process for manufacturing a part comprising a block of dense material constituted of hard particles and of binder phase having a gradient of properties, and resulting part Download PDF

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Publication number
EP2347025B1
EP2347025B1 EP09755981A EP09755981A EP2347025B1 EP 2347025 B1 EP2347025 B1 EP 2347025B1 EP 09755981 A EP09755981 A EP 09755981A EP 09755981 A EP09755981 A EP 09755981A EP 2347025 B1 EP2347025 B1 EP 2347025B1
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Prior art keywords
block
binder phase
dense
temperature
dense material
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German (de)
French (fr)
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EP2347025A1 (en
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Christophe Colin
Elodie Lefort
Alfazazi Dourfaye
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Varel Europe SAS
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Varel Europe SAS
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    • 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
    • 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

Definitions

  • a part comprising a block of dense material consisting of hard particles dispersed in a binder phase by a thermo-chemical treatment, the part having a property gradient.
  • Many parts in particular drill bit cutters or machining tools, consist of blocks of hardened carbide type material consisting of carbide particles dispersed in a metal binder phase. These materials, which are extremely hard, and therefore resistant to wear, can also be fragile. Also, in order to reinforce their toughness, they are subjected to treatments intended to introduce within them a ductile phase composition gradient with or without the formation of new phases whose hardness is different from the initial hardness of the block which results either in blocks whose outer surface, or at least a part thereof, is extremely hard and the inner part is more tenacious, either to blocks whose outer surface or at least a part is more tenacious and the inner part is harder .
  • non-dense cemented carbide blocks having a porosity gradient can be produced by powder metallurgy and infiltrated by a binder phase to improve their ductility to the core.
  • This method is poorly suited in particular to the WC-Co type system, because it leads to the partial destruction of the pre-existing carbide skeleton infiltration, and therefore does not achieve the desired properties for a cutter.
  • cemented carbides with a composition gradient by natural phase solid sintering of a multilayer component, each of the layers having a different composition.
  • this method does not completely densify the material and must be followed by an expensive treatment of hot isostatic compaction.
  • the preparation of the cemented carbide gradient composition is complex since it requires the realization of a succession of elementary layers that fit into each other.
  • this method has the disadvantage of not generating a continuous composition gradient.
  • cemented carbide blocks having a binder phase composition gradient over millimeter distances by enriching these cemented carbides by imbibition from the outside to from a liquid phase capable of penetrating (or migrating) into the cemented carbide.
  • This imbibition phenomenon corresponds to the migration of external liquid composition close to that of the solid / liquid system considered perfectly dense under the sole driving force of the migration pressure generated by a local imbalance of the volume fraction of the binder phase and / or the size and morphology of the solid grains.
  • This phenomenon concerns any system consisting of condensed phases (solid and liquid) which has an ability to adapt the shape of its solid grains by the absorption of liquid thus making it energetically more stable, that is to say which has a maturing Ostwald with modification of the shape of the hard particles without necessarily causing a magnification of these particles by the phenomenon of dissolution and re-precipitation.
  • the inventors have found that it is possible to generate binding phase concentration gradients over millimeter distances inside dense cemented carbide blocks, on the sole condition of depositing a suitable coating on all or part of the surface of the dense cemented carbide block and subject to a suitable heat treatment whose temperature must be at least equal to the temperature allowing the transition to the liquid state of the binder phase (solidus of the cemented carbide considered).
  • the material constituting the coating destabilizes (or dissociates) and one or more chemical elements constituting it, diffuse and react or not with the block material, thus generating a binder phase gradient in the block and / or the formation of phases whose hardness is different from the initial hardness of the block over greater or lesser distances, depending on the duration of the heat treatment applied.
  • the parameters of the heat treatment can be determined by those skilled in the art in particular depending on the shape of the desired gradient.
  • the subject of the invention is a method for manufacturing a part comprising a block of dense material consisting of hard particles of the same or different nature dispersed in a binder phase, the material having a solidus temperature T s from of which the binder phase is liquid, characterized in that at least a portion of the surface of the dense material block is deposited with an active coating consisting of a material possibly capable of reacting chemically with the dense material but not providing any additional binder phase, when the assembly is carried beyond a minimum reaction temperature T r , and in that the block coated with the active coating is subjected to a heat treatment comprising heating and then holding for a time t m at a holding temperature T m greater than or equal to the minimum reaction temperature T r , followed by cooling to room temperature.
  • This method leads to variations of the binder phase inside the block over millimeter distances which are done without external binder phase input and thus without leading to the overall enrichment of the block in additional binder phase.
  • the holding temperature T m is greater than or equal to the solidus temperature T s of the dense material.
  • the holding temperature T m is less than or equal to T s + 200 ° C.
  • the holding time t m is between 1 min and 10 min.
  • the active coating can be deposited only on a part of the surface of the block.
  • the active coating can be deposited on the entire surface of the block.
  • the dense material is for example a cemented carbide consisting of metal carbide particles dispersed in a metal matrix.
  • the cemented carbide may further contain natural or synthetic diamond particles up to 1 mm in diameter.
  • the cemented carbide is for example of the WC-M type, M being one or more metals taken from Co, Ni and Fe, the sum of the contents by weight of these metals in the binder phase being greater than 50%.
  • the coating material capable of reacting with the dense material of the block is for example composed of at least one of nitride, boride, carbide, oxide, hydride, carbonitride, borocarbide and graphite compounds. This material may consist of any mixture of these different compounds.
  • the coating may be deposited by a PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) method, or by a spraying, brushing, dipping or screen printing process.
  • PVD Physical Vapor Deposition
  • CVD Chemical Vapor Deposition
  • the block of dense material is for example a cutting or support block of a drill bit of a drilling tool or felling or machining of rocks or metals.
  • PDC Polycrystalline Diamond Compact
  • TSP Thermal Stable Polycrystalline diamond
  • the diamond plate can be attached to the block by soldering, after the treatment of the block.
  • This thermal process then has the advantage of very simply producing cemented carbide blocks having a property gradient suitable for use as a drill bit or cutting tool bit, or as a cutting bit support block. drilling tool or cutting tool.
  • the cutter for a rock size tool which comprises a block consisting of hard particles dispersed in a binder phase obtained by the process according to the invention may have a distance greater than 0.5 mm, better still greater than 1 mm, and better still higher at 3 mm, a continuous gradient of binder phase content, the difference in binder phase content between the richest zone and the less rich zone being greater than 1% by volume, better still greater than 2%, and better still, greater than 5%.
  • the cutting edge may comprise a PDC or TSP-type diamond insert having a thickness of between 0.4 mm and 5 mm.
  • the rock size tool may include at least one cutter or impregnated blade of a cemented carbide blend with natural or synthetic diamond particles (up to 1 mm in diameter).
  • blocks intended in particular to manufacture bits for drilling tools or more generally for cutting tools generally parallelepiped shape or cylindrical shape having dimensions of the order of a few millimeters or a few tens of millimeters .
  • These blocks obtained by powder metallurgy, consist of a dense material whose structure comprises on the one hand hard particles such as metal carbides, and in particular tungsten carbides, and on the other hand a binding phase consisting of mainly a metal or an alloy metallic.
  • this binder phase can form, at a suitable temperature, a eutectic whose melting temperature is lower both at the melting point of the carbides and at the melting point of the metal or of the metal alloy.
  • This metal or metal alloy which constitutes the binder phase is for example cobalt but may also be iron or nickel or a mixture of these metals, these elements represent at least 50% by weight of the binder phase.
  • This binder phase may also contain addition elements whose sum of the contents may reach at most 15% by weight but generally do not exceed 5%.
  • additive elements may be copper to improve electrical conductivity or silicon which has a surfactant effect with respect to the system consisting of carbides and the binder phase.
  • the alloying elements may also be of carbide-forming elements for forming carbides or mixed carbides of type M x C y other than tungsten carbide. These elements include manganese, chromium, molybdenum, vanadium, niobium, tantalum, titanium, zirconium and afnium.
  • the binder phase may comprise additive elements that change the shape and / or inhibit the magnification of hard particles and that those skilled in the art know.
  • the chemical composition of these materials includes unavoidable impurities that result from the processes of making.
  • the block 1 made of dense material is coated with a layer 2 of thickness generally between approximately 50 ⁇ m and 2 mm, made of a material capable of chemically reacting with the binder phase and / or the carbide phase of the dense material.
  • This coating is carried out by spraying, PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) deposit if this coating material is supplied in gaseous form, or by brush, dip or dipping. silkscreen if the coating material is brought in liquid form.
  • the holding temperature T m must be greater than or equal to the minimum reaction temperature T r which is the temperature above which the outer coating or one of its elements begins to react (in particular formation of solid phases) or diffuse without reacting (no formation of solid phases but can lead locally to a change in the composition of the binding phase of the dense block) significantly within the block.
  • This reaction temperature T r must be greater than or equal to the solidus temperature T s of the cemented carbide which constitutes the block.
  • This solidus temperature is the minimum temperature at which the binder phase of the cemented carbide is in the liquid state. This condition is desirable so that the coating or one of its constituent elements can rapidly diffuse and then react or not depending on the coating considered with the constituents (solid grains or liquid phase) of the block being treated.
  • the reaction temperature T r is greater than or equal to the destabilization or dissociation temperature T d of the compound which is not necessarily greater than the solidus temperature T s of the cemented carbide.
  • the reaction temperatures T r , of destabilization T d and the solidus temperature T s depend on the nature of the material of which the coating consists and of the material of which the block is made. Those skilled in the art know how to determine these temperatures.
  • reaction temperature Tr which has just been defined is greater than or equal to the solidus temperature Ts so that the diffusion takes place in the binder phase in the liquid state in order to obtain a sufficient diffusion rate.
  • the holding temperature T m must not be too high. Preferably, it should remain below T s + 200 ° C and better, below T s + 100 ° C, and better still, below T s + 50 ° C.
  • the holding time t m must be adapted to the shape and amplitude of the desired gradient and is deduced from the experiment. It is usually of the order of a few minutes.
  • the coating material capable of destabilizing or dissociating and / or reacting with the material constituting the dense block to be treated is, for example, a metalloid nitride or metal nitride such as boron nitride, aluminum nitride, titanium nitride, or a boride such as titanium boride, a metalloid carbide or metal such as boron carbide, titanium carbide, or a hydride such as titanium hydride or graphite or an oxide refractory such as alumina or a carbonitride or borocarbide metal or a mixture of such materials.
  • a metalloid nitride or metal nitride such as boron nitride, aluminum nitride, titanium nitride, or a boride such as titanium boride, a metalloid carbide or metal such as boron carbide, titanium carbide, or a hydride such as titanium hydride or graphite or an oxide
  • the materials used to make the coating of the block to be treated must be active or in some cases reactive above the solidus temperature T s , but it is preferable that they remain stable, that is to say, do not dissociate, below this temperature.
  • the property gradient obtained may result from a relative hardening of the surface of the block relative to the core, or on the contrary, a softening.
  • the heat treatment comprises, as shown in figure 4 , a rise in temperature up to the holding temperature T m , then a hold for a holding time t m at this temperature and cooling to room temperature.
  • the holding time t m and the holding temperature T m are adapted according to the dimensions of the block to be treated and the property gradient that is to be obtained.
  • the heat treatment can be carried out in a resistance furnace, or an induction furnace, or a microwave oven, under a protective atmosphere or under empty.
  • the protective atmosphere is for example argon or a mixture of argon and hydrogen but generally any neutral atmosphere such as argon, nitrogen, hydrogenated argon, hydrogenated nitrogen, hydrogen or possibly a primary or secondary vacuum.
  • the block thus treated has a composition, in particular a binder phase content, which varies from outside to inside.
  • the figure shows iso-concentration Ci curves in the binder phase, the outermost zone 10 being the poorest in the binder phase and therefore the hardest, and the intermediate zone 11 having an intermediate concentration and the the richest zone 12 binder phase being the least hard and therefore the most tenacious.
  • the variation in the binder phase content takes place over several millimeters.
  • the extent of the area affected by the variation of the binder phase content depends both on the maximum holding temperature T m , the holding time t m and the thickness of the coating material.
  • T m the maximum holding temperature
  • t m the holding time
  • the thickness of the coating material At equal thickness of the coating layer, the higher the temperature T m is and the longer the time t m is, the more the affected area is extended; that is, the deeper the block is affected.
  • the block as just described is covered on all sides with an active material. But, the active material can be deposited only on a part of the outer surface of the block and thus can lead to hardening or softening that areas of the block located under the coating and therefore have respectively a softened area or hardened core that can extend to the outer surface of the block that is not coated.
  • the variation in hardness that can reach several hundred Vickers can be over distances greater than 0.5mm, and can extend throughout the block.
  • the first block, spotted 10 at the figure 5 was spray-coated with a layer 11 of boron nitride BN, covering the upper face and the side faces of the block, and then treated under vacuum.
  • the direction of migration of the binder phase is indicated by the arrow and by the increasing direction of the iso-concentrations (C1 ⁇ C2 ⁇ C3 ⁇ C4).
  • the second block, spotted 20 at the figure 7 was also coated with a layer 21 of boron nitride BN, but this was deposited on only one half of the block.
  • the block was treated under a hydrogenated argon atmosphere.
  • the binder phase concentration gradient obtained leads to a hardness amplitude of 120 HV, only the zone 22 beneath the coating being cured, the remainder 23 not being hardened.
  • the direction of migration of the binder phase is indicated by the arrow and the increasing direction of the iso-concentrations (C1 ⁇ C2 ⁇ C3).
  • the third block, spotted 30 at the figure 9 was coated with a layer 31 of aluminum oxide Al 2 O 3 deposited in the form of liquid paste with a brush on the upper face and on the side faces of the block and treated under vacuum.
  • the binder phase concentration gradient obtained is dome-shaped, but, contrary to what was obtained with the first block, the zone 32 close to the surface has been softened so that their hardness is 150 HV less than that of the core zone 33.
  • the direction of migration of the binder phase is indicated by the arrow and by the increasing direction of the insulation. concentrations (C1 ⁇ C2 ⁇ C3 ⁇ C4) whose meaning is opposite to the two previous cases.
  • the boron nitride makes it possible to harden the zone of the block close to the coating layer, whereas the alumina makes it possible to soften it.
  • the furnace atmosphere (vacuum or argon-hydrogenated) used to carry out the treatments has no effect on the result.
  • the blocks thus treated may constitute bits of drilling tool or cutting tool and may have dimensions of a few millimeters or even more since it is conceivable to produce cutting blades having dimensions of several centimeters and which can be hardened by this process.
  • a cutter for a rock cutting tool or tool for cutting refractory or machining metals consisting of a cemented carbide support block 20 made using the method according to the invention, the lateral surface of which is hard and the tenacious core (C1 ⁇ C2 ⁇ C3 ⁇ C4) and whose underside has not been coated before heat treatment and whose upper face after treatment has been reported a plate 21 of natural or synthetic diamond of greater thickness at 0.4 mm according to the HPHT (High Pressure - High Temperature) process of the PDC (Polycrystalline Diamond Compact) or TSP (Thermally Stable Polycrystalline diamond) type.
  • HPHT High Pressure - High Temperature
  • PDC Polycrystalline Diamond Compact
  • TSP Thermally Stable Polycrystalline diamond
  • the support block 20 treated according to the invention can be assembled after the HPHT process by soldering for example according to the process known under the name of "LS Bond” and described in US Pat. US 4,225,322 and US 5,111,895 without this operation leading to a drastic change in the binder phase concentration gradient in the block.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Description

Procédé pour fabriquer une pièce comprenant un bloc en matériau dense constitué de particules dures dispersées dans une phase liante par un traitement thermo-chimique, la pièce présentant un gradient de propriétés.Process for manufacturing a part comprising a block of dense material consisting of hard particles dispersed in a binder phase by a thermo-chemical treatment, the part having a property gradient.

De nombreuses pièces, notamment des taillants d'outils de forage ou d'outils d'usinage, sont constituées de blocs en matériau du type carbure cémenté constitués de particules de carbure dispersées dans une phase liante métallique. Ces matériaux qui sont extrêmement durs, et donc résistants à l'usure, peuvent également être fragiles. Aussi, afin de renforcer leur ténacité, on les soumet à des traitements destinés à introduire en leur sein un gradient de composition en phase ductile avec ou non la formation de nouvelles phases dont la dureté est différente de la dureté initiale du bloc qui aboutit soit à des blocs dont la surface extérieure, ou au moins une partie de cette surface, est extrêmement dure et la partie intérieure est plus tenace, soit à des blocs dont la surface extérieure ou au moins une partie est plus tenace et la partie intérieure est plus dure.Many parts, in particular drill bit cutters or machining tools, consist of blocks of hardened carbide type material consisting of carbide particles dispersed in a metal binder phase. These materials, which are extremely hard, and therefore resistant to wear, can also be fragile. Also, in order to reinforce their toughness, they are subjected to treatments intended to introduce within them a ductile phase composition gradient with or without the formation of new phases whose hardness is different from the initial hardness of the block which results either in blocks whose outer surface, or at least a part thereof, is extremely hard and the inner part is more tenacious, either to blocks whose outer surface or at least a part is more tenacious and the inner part is harder .

Pour cela, on peut fabriquer des blocs de carbure cémenté non dense ayant un gradient de porosité qu'on réalise par métallurgie des poudres et que l'on infiltre par une phase liante afin d'améliorer leur ductilité à coeur. Cette méthode est mal adaptée en particulier au système du type WC-Co, car elle conduit à la destruction partielle du squelette de carbure préexistant à l'infiltration, et de ce fait, ne permet pas d'obtenir les propriétés souhaitées pour un taillant.For this purpose, non-dense cemented carbide blocks having a porosity gradient can be produced by powder metallurgy and infiltrated by a binder phase to improve their ductility to the core. This method is poorly suited in particular to the WC-Co type system, because it leads to the partial destruction of the pre-existing carbide skeleton infiltration, and therefore does not achieve the desired properties for a cutter.

Il a également été proposé de réaliser des carbures cémentés à gradient de composition par frittage naturel en phase solide d'une pièce multicouches, chacune des couches ayant une composition différente. Toutefois, cette méthode ne permet pas de densifier complètement le matériau et doit être suivie d'un traitement coûteux de compaction isostatique à chaud. En outre, la préparation du carbure cémenté à gradient de composition est complexe puisqu'elle nécessite la réalisation d'une succession de couches élémentaires qui s'emboîtent les unes dans les autres. Enfin, ce procédé présente l'inconvénient de ne pas engendrer un gradient continu de composition.It has also been proposed to produce cemented carbides with a composition gradient by natural phase solid sintering of a multilayer component, each of the layers having a different composition. However, this method does not completely densify the material and must be followed by an expensive treatment of hot isostatic compaction. In addition, the preparation of the cemented carbide gradient composition is complex since it requires the realization of a succession of elementary layers that fit into each other. Finally, this method has the disadvantage of not generating a continuous composition gradient.

Il a également été proposé de réaliser de tels matériaux par frittage naturel en phase liquide, ce qui permet d'obtenir très rapidement, et en une seule étape, un matériau à gradient de composition complètement dense. Mais, ce procédé présente l'inconvénient d'atténuer assez fortement le gradient de composition en raison de la migration de liquide entre les couches de faible épaisseur sous l'effet combiné des phénomènes d'infiltration et d'imbibition. En outre, et contre toute attente, le gradient de composition reste discontinu lorsque la durée de maintien à l'état liquide reste inférieure à une durée critique au-delà de laquelle on constate une complète homogénéisation du carbure cémenté mais insuffisante pour densifier le matériau.It has also been proposed to produce such materials by natural sintering in the liquid phase, which makes it possible to obtain very quickly, and in a single step, a completely dense composition gradient material. However, this method has the drawback of attenuating the composition gradient rather strongly because of the migration of liquid between the thin layers under the combined effect of infiltration and imbibition phenomena. In addition, and against all odds, the composition gradient remains discontinuous when the duration of maintenance in the liquid state remains below a critical time beyond which there is a complete homogenization of the cemented carbide but insufficient to densify the material.

Par ailleurs, il a été proposé d'améliorer la tenue en service d'outils coupants en déposant à la surface du carbure cémenté des revêtements durs en nitrure, carbonitrure, oxyde ou borure. De telles méthodes ont été décrites par exemple dans les brevets US 4 548 786 ou US 4 610 931 . Mais ces méthodes présentent l'inconvénient d'améliorer uniquement la résistance à l'usure par abrasion du carbure cémenté, et ce, uniquement sur de faibles épaisseurs (quelques microns).Furthermore, it has been proposed to improve the service life of cutting tools by depositing on the surface of the cemented carbide hard nitride, carbonitride, oxide or boride coatings. Such methods have been described, for example, in patents US 4,548,786 or US 4,610,931 . However, these methods have the disadvantage of only improving the abrasion wear resistance of the cemented carbide, and this only on small thicknesses (a few microns).

Il a été également proposé d'améliorer à la fois la résistance à l'usure de la surface ainsi que la résistance aux chocs des carbures cémentés de type WC-Co en mettant une phase gazeuse riche en carbone au contact d'un carbure cémenté dense sous-stoechiométrique en carbone. Sous l'effet de la température le carbone de la phase gazeuse diffuse dans le carbure cémenté sous-stoechiométrique et réagit avec la phase η-Co3W3C, ce qui conduit à une libération de cobalt qui migre vers la surface extérieure du carbure cémenté c'est-à-dire en arrière du front de diffusion du carbone. Cette méthode décrite dans le brevet US 4 743 515 présente l'inconvénient de conduire à un gradient de phase liante riche en cobalt sur 1 ou 2 mm tout en conservant une fragilité du coeur de la pièce traitée.It has also been proposed to improve both the wear resistance of the surface and the impact resistance of WC-Co carbide carbides by putting a carbon-rich gas phase in contact with a dense cemented carbide. substoichiometric carbon. Under the effect of the temperature, the carbon of the gaseous phase diffuses into the sub-stoichiometric cemented carbide and reacts with the η-Co 3 W 3 C phase, which leads to a release of cobalt which migrates towards the outer surface of the carbide cemented that is to say behind the carbon diffusion front. This method described in the patent US 4,743,515 has the disadvantage of leading to a binding phase gradient rich in cobalt 1 or 2 mm while maintaining a fragility of the core of the treated part.

Afin de remédier aux différentes insuffisances des méthodes qui viennent d'être énoncées, il a été proposé de fabriquer des blocs de carbure cémenté ayant un gradient de composition en phase liante sur des distances millimétriques en enrichissant ces carbures cémentés par imbibition depuis l'extérieur à partir d'une phase liquide susceptible de pénétrer (ou migrer) dans le carbure cémenté. Ce phénomène d'imbibition correspond à la migration de liquide externe de composition proche de celui du système solide/liquide considéré parfaitement dense sous la seule force motrice de la pression de migration générée par un déséquilibre local de la fraction volumique de phase liante et/ou de la taille et morphologie des grains solides. Ce phénomène concerne tout système constitué de phases condensées (solides et liquide) qui possède une aptitude à adapter la forme de ses grains solides par l'absorption de liquide le rendant ainsi énergétiquement plus stable, c'est-à-dire qui présente un mûrissement d'Ostwald avec modification de la forme des particules dures sans nécessairement engendrer un grossissement de ces particules par le phénomène de dissolution et re-précipitation.In order to remedy the various shortcomings of the methods which have just been stated, it has been proposed to manufacture cemented carbide blocks having a binder phase composition gradient over millimeter distances by enriching these cemented carbides by imbibition from the outside to from a liquid phase capable of penetrating (or migrating) into the cemented carbide. This imbibition phenomenon corresponds to the migration of external liquid composition close to that of the solid / liquid system considered perfectly dense under the sole driving force of the migration pressure generated by a local imbalance of the volume fraction of the binder phase and / or the size and morphology of the solid grains. This phenomenon concerns any system consisting of condensed phases (solid and liquid) which has an ability to adapt the shape of its solid grains by the absorption of liquid thus making it energetically more stable, that is to say which has a maturing Ostwald with modification of the shape of the hard particles without necessarily causing a magnification of these particles by the phenomenon of dissolution and re-precipitation.

L'utilisation de ce procédé pour fabriquer des taillants pour outils de forage ou outils de coupe, nécessite de réaliser des assemblages préalables entre un bloc fritté dense destiné à être enrichi et une pastille de poudre compactée en matériau d'imbibition destinée à apporter la phase liante par le phénomène d'imbibition et de disposer l'ensemble dans un four pour effectuer le traitement thermique adéquat. Ce procédé présente l'inconvénient de faire appel à un matériau d'imbibition qu'il convient de dimensionner par rapport au gradient de composition désiré, ce qui complexifie le procédé et nécessite le plus souvent une rectification de la surface d'imbibition.The use of this method for making cutters for drilling tools or cutting tools, requires prior assemblies between a dense sintered block intended to be enriched and a compacted pellet of impregnated material for imparting the phase binder by the imbibition phenomenon and arrange the assembly in an oven to perform the appropriate heat treatment. This method has the disadvantage of using an imbibition material that should be sized relative to the desired composition gradient, which complicates the process and most often requires a rectification of the imbibition surface.

De façon très inattendue, les inventeurs ont constaté qu'il était possible d'engendrer des gradients de concentration en phase liante sur des distances millimétriques à l'intérieur de blocs en carbure cémenté dense à la seule condition de déposer un revêtement adapté sur toute ou partie de la surface du bloc dense en carbure cémenté et de le soumettre à un traitement thermique adéquat dont la température doit être au moins égale à la température permettant le passage à l'état liquide de la phase liante (solidus du carbure cémenté considéré).Very unexpectedly, the inventors have found that it is possible to generate binding phase concentration gradients over millimeter distances inside dense cemented carbide blocks, on the sole condition of depositing a suitable coating on all or part of the surface of the dense cemented carbide block and subject to a suitable heat treatment whose temperature must be at least equal to the temperature allowing the transition to the liquid state of the binder phase (solidus of the cemented carbide considered).

Le matériau constituant le revêtement se déstabilise (ou se dissocie) et un ou plusieurs éléments chimiques qui le constituent, diffusent et réagissent ou non avec le matériau du bloc, générant ainsi un gradient de phase liante dans le bloc et/ou la formation de phases dont la dureté est différente de la dureté initiale du bloc sur des distances plus ou moins importantes, fonction de la durée du traitement thermique appliqué. La forme du gradient ainsi généré dans le bloc : durcissement de la surface sous laquelle a été déposée le revêtement et adoucissement du coeur ou inversement adoucissement de la surface sous laquelle a été appliquée le revêtement et durcissement du coeur, dépend notamment de la nature et de l'épaisseur du revêtement utilisé, de la proportion de la surface revêtue et du traitement thermique. Les paramètres du traitement thermique peuvent être déterminés par l'homme du métier notamment en fonction de la forme du gradient souhaité.The material constituting the coating destabilizes (or dissociates) and one or more chemical elements constituting it, diffuse and react or not with the block material, thus generating a binder phase gradient in the block and / or the formation of phases whose hardness is different from the initial hardness of the block over greater or lesser distances, depending on the duration of the heat treatment applied. The shape of the gradient thus generated in the block: hardening of the surface under which the coating has been deposited and softening of the core or conversely softening of the surface under which the coating has been applied and hardening of the core, depends in particular on the nature and the thickness of the coating used, the proportion coated surface and heat treatment. The parameters of the heat treatment can be determined by those skilled in the art in particular depending on the shape of the desired gradient.

Compte tenu de ces observations, les matériaux susceptibles d'être déposés sur la surface d'un Cermet avant d'effectuer un traitement thermique peuvent être classés dans les catégories suivantes :

  • matériaux inactifs avec le bloc dense : il s'agit de matériaux n'engendrant pas de variation locale de phase liante à l'échelle macroscopique dans le bloc dense ;
  • matériaux actifs avec le bloc dense : il s'agit de matériaux engendrant une variation locale de phase liante à l'échelle macroscopique dans le bloc dense. Aussi, le terme « actif » est à considérer par rapport au procédé à savoir amenant à une variation locale de la phase liante dans le bloc dense.
Given these observations, the materials that may be deposited on the surface of a Cermet before heat treatment can be classified into the following categories:
  • inactive materials with dense block: these are materials that do not generate local binder phase variation at the macroscopic scale in the dense block;
  • active materials with the dense block: these are materials generating a local variation of binder phase at the macroscopic scale in the dense block. Also, the term "active" is to be considered in relation to the method namely to bring about a local variation of the binder phase in the dense block.

Parmi les matériaux actifs, on distingue :

  • ceux qui sont susceptibles d'apporter de la phase liante supplémentaire, et
  • ceux qui ne peuvent pas apporter de phase liante supplémentaire.
Among the active materials, there are:
  • those which are likely to bring additional binding phase, and
  • those who can not bring additional binding phase.

On distingue également :

  • les matériaux actifs et non réactifs (ou inertes chimiquement) avec le bloc dense : les éléments chimiques du matériau diffusent mais ne réagissent pas avec l'une des deux phases (solide ou liquide) du Cermet dense ne formant pas de phases solides ; et
  • les matériaux actifs et réactifs chimiquement avec le bloc dense : certains éléments chimiques du matériau diffusent et réagissent aux dépens de la phase solide ou liquide du Cermet dense formant au moins une phase solide.
We also distinguish:
  • the active and non-reactive (or chemically inert) materials with the dense block: the chemical elements of the material diffuse but do not react with one of the two phases (solid or liquid) of the dense Cermet not forming solid phases; and
  • the active materials chemically reactive with the dense block: certain chemical elements of the material diffuse and react at the expense of the solid or liquid phase of the dense Cermet forming at least one solid phase.

Aussi, l'invention a pour objet un procédé pour fabriquer une pièce comprenant un bloc en matériau dense constitué de particules dures, de même nature ou de nature différente, dispersées dans une phase liante, le matériau ayant une température de solidus Ts à partir de laquelle la phase liante est liquide, caractérisé en ce qu'on dépose sur au moins une partie de la surface du bloc en matériau dense, un revêtement actif constitué d'un matériau éventuellement susceptible de réagir chimiquement avec le matériau dense mais n'apportant pas de phase liante supplémentaire, lorsque l'ensemble est porté au-delà d'une température minimale de réaction Tr, et en ce qu'on soumet le bloc revêtu du revêtement actif à un traitement thermique comprenant un chauffage puis un maintien pendant un temps tm à une température de maintien Tm supérieure ou égale à la température minimale de réaction Tr, suivi d'un refroidissement jusqu'à la température ambiante. Ce procédé conduit à des variations de la phase liante à l'intérieur du bloc sur des distances millimétriques qui se font sans apport de phase liante externe et donc sans conduire à l'enrichissement global du bloc en phase liante supplémentaire.Also, the subject of the invention is a method for manufacturing a part comprising a block of dense material consisting of hard particles of the same or different nature dispersed in a binder phase, the material having a solidus temperature T s from of which the binder phase is liquid, characterized in that at least a portion of the surface of the dense material block is deposited with an active coating consisting of a material possibly capable of reacting chemically with the dense material but not providing any additional binder phase, when the assembly is carried beyond a minimum reaction temperature T r , and in that the block coated with the active coating is subjected to a heat treatment comprising heating and then holding for a time t m at a holding temperature T m greater than or equal to the minimum reaction temperature T r , followed by cooling to room temperature. This method leads to variations of the binder phase inside the block over millimeter distances which are done without external binder phase input and thus without leading to the overall enrichment of the block in additional binder phase.

De préférence, la température de maintien Tm est supérieure ou égale à la température de solidus Ts du matériau dense.Preferably, the holding temperature T m is greater than or equal to the solidus temperature T s of the dense material.

De préférence, la température de maintien Tm est inférieure ou égale à Ts + 200°C.Preferably, the holding temperature T m is less than or equal to T s + 200 ° C.

De préférence, le temps de maintien tm est compris entre 1 min et 10min.Preferably, the holding time t m is between 1 min and 10 min.

Le revêtement actif peut n'être déposé que sur une partie de la surface du bloc.The active coating can be deposited only on a part of the surface of the block.

Le revêtement actif peut être déposé sur toute la surface du bloc.The active coating can be deposited on the entire surface of the block.

Le matériau dense est par exemple un carbure cémenté constitué de particules de carbure métallique dispersées dans une matrice métallique.The dense material is for example a cemented carbide consisting of metal carbide particles dispersed in a metal matrix.

Le carbure cémenté peut, en outre, contenir des particules de diamant naturel ou synthétique de taille allant jusqu'à 1 mm de diamètre.The cemented carbide may further contain natural or synthetic diamond particles up to 1 mm in diameter.

Le carbure cémenté est par exemple du type WC-M, M étant un ou plusieurs métaux pris parmi Co, Ni et Fe, la somme des teneurs en poids de ces métaux dans la phase liante étant supérieure à 50%.The cemented carbide is for example of the WC-M type, M being one or more metals taken from Co, Ni and Fe, the sum of the contents by weight of these metals in the binder phase being greater than 50%.

Le matériau de revêtement susceptible de réagir avec le matériau dense du bloc est par exemple constitué d'au moins un composé pris parmi les composés du type nitrure, borure, carbure, oxyde, hydrure, carbonitrure, borocarbure, graphite. Ce matériau peut être constitué de tout mélange de ces différents composés.The coating material capable of reacting with the dense material of the block is for example composed of at least one of nitride, boride, carbide, oxide, hydride, carbonitride, borocarbide and graphite compounds. This material may consist of any mixture of these different compounds.

Le revêtement peut être déposé par un procédé du type PVD (Physical Vapor Deposition) ou CVD (Chemical Vapor Deposition), ou un procédé de pulvérisation ou au pinceau ou au trempé ou par sérigraphie.The coating may be deposited by a PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) method, or by a spraying, brushing, dipping or screen printing process.

Le bloc de matériau dense est par exemple un taillant ou un bloc support d'un taillant d'un outil de forage ou abattage ou usinage de roches ou de métaux.The block of dense material is for example a cutting or support block of a drill bit of a drilling tool or felling or machining of rocks or metals.

En outre, on peut déposer sur une face du bloc support une plaquette diamantée de type PDC (Polycrystalline Diamond Compact) ou TSP (Thermally Stable Polycrystalline diamond).In addition, it is possible to deposit on one face of the support block a PDC (Polycrystalline Diamond Compact) or TSP (Thermally Stable Polycrystalline diamond) type diamond insert.

La plaquette diamantée peut être rapportée sur le bloc par brasage, après le traitement du bloc.The diamond plate can be attached to the block by soldering, after the treatment of the block.

Ce procédé thermique présente alors l'avantage de réaliser de façon très simple des blocs en carbure cémenté présentant un gradient de propriétés adapté à une utilisation comme taillant d'outil de forage ou d'outil de coupe, ou comme bloc support de taillant d'outil de forage ou d'outil de coupe.This thermal process then has the advantage of very simply producing cemented carbide blocks having a property gradient suitable for use as a drill bit or cutting tool bit, or as a cutting bit support block. drilling tool or cutting tool.

Le taillant pour outil de taille des roches qui comprend un bloc constitué de particules dures dispersées dans une phase liante obtenu par le procédé selon l'invention peut présenter sur une distance supérieure à 0,5mm, mieux supérieure à 1 mm, et mieux encore supérieure à 3mm, un gradient continu de teneur en phase liante, l'écart de teneur en phase liante entre la zone la plus riche et la zone la moins riche étant supérieure à 1% en volume, mieux supérieure à 2%, et mieux encore, supérieure à 5%.The cutter for a rock size tool which comprises a block consisting of hard particles dispersed in a binder phase obtained by the process according to the invention may have a distance greater than 0.5 mm, better still greater than 1 mm, and better still higher at 3 mm, a continuous gradient of binder phase content, the difference in binder phase content between the richest zone and the less rich zone being greater than 1% by volume, better still greater than 2%, and better still, greater than 5%.

Le taillant peut comprendre une plaquette diamantée rapportée de type PDC ou TSP d'épaisseur pouvant être comprise entre 0,4mm et 5mm.The cutting edge may comprise a PDC or TSP-type diamond insert having a thickness of between 0.4 mm and 5 mm.

L'outil de taille des roches peut comprendre au moins un taillant ou une lame d'imprégné constitué d'un mélange de carbure cémenté avec des particules de diamant naturel ou synthétique (de taille pouvant aller jusqu'à 1 mm de diamètre).The rock size tool may include at least one cutter or impregnated blade of a cemented carbide blend with natural or synthetic diamond particles (up to 1 mm in diameter).

L'invention va maintenant être décrite de façon plus précise mais non limitative en regard des figures annexées, dans lesquelles :

  • La figure 1 représente une vue en coupe d'un bloc de carbure cémenté dense recouvert complètement d'un revêtement et le tout disposé dans un four de traitement thermique.
  • La figure 2 est une vue en coupe d'un bloc en carbure cémenté dense traité et qui montre la répartition de la concentration en phase liante à l'intérieur du bloc à partir de la surface extérieure vers l'intérieur du carbure cémenté et la formation ou non de phases solides de dureté différente de la dureté initiale du bloc.
  • La figure 3 est une vue schématique en coupe d'un taillant pour outils de forage constitué d'une plaquette diamantée d'épaisseur millimétrique déposée sur un bloc support en carbure cémenté dense traité selon l'invention et dont la surface inférieure n'avait pas été revêtue.
  • La figure 4 est un schéma représentant l'évolution de la température en fonction du temps pour un cycle thermique de traitement d'un bloc dense en carbure cémenté revêtu.
  • La figure 5 représente schématiquement en coupe un premier exemple de bloc en carbure cémenté revêtu de nitrure de bore sur sa face supérieure et sur ses faces latérales.
  • La figure 6 représente schématiquement la forme en dôme du gradient de concentration en phase liante obtenu à partir du bloc de la figure 5, dont la surface extérieure est plus pauvre en phase liante que le coeur après traitement.
  • La figure 7 et la figure 8 représentent un deuxième exemple de bloc et de gradient de concentration en phase liante obtenu, le bloc étant revêtu de nitrure de bore seulement sur une partie de sa face supérieure et de ses faces latérales.
  • La figure 9 et la figure 10 représentent un troisième exemple de bloc et de gradient de concentration en phase liante obtenu, le bloc étant revêtu d'alumine sur sa face supérieure et sur ses faces latérales et dont la surface extérieure est plus riche en phase liante que le coeur après traitement.
The invention will now be described in a more precise but nonlimiting manner with reference to the appended figures, in which:
  • The figure 1 is a sectional view of a dense cemented carbide block completely covered with a coating and all disposed in a heat treatment furnace.
  • The figure 2 is a sectional view of a treated hard cemented carbide block showing the distribution of the binder phase concentration within the block from the outer surface inwardly of the cemented carbide and the formation or otherwise of solid phases of hardness different from the initial hardness of the block.
  • The figure 3 is a schematic cross-sectional view of a bit for drill tools consisting of a millimeter-thick diamond wafer deposited on a cemented carbide support block treated in accordance with the invention and whose lower surface had not been coated.
  • The figure 4 is a diagram showing the evolution of the temperature as a function of time for a heat treatment cycle of a dense block of coated cemented carbide.
  • The figure 5 is a diagrammatic sectional view of a first example of a cemented carbide block coated with boron nitride on its upper face and on its lateral faces.
  • The figure 6 schematically represents the dome shape of the binder phase concentration gradient obtained from the block of the figure 5 whose outer surface is poorer in the binder phase than the heart after treatment.
  • The figure 7 and the figure 8 represent a second example of block and concentration gradient in the binder phase obtained, the block being coated with boron nitride only on part of its upper face and its lateral faces.
  • The figure 9 and the figure 10 represent a third example of a block and concentration gradient in binder phase obtained, the block being coated with alumina on its upper face and on its lateral faces and whose outer surface is richer in binder phase than the core after treatment.

Dans la suite, on considère des blocs destinés notamment à fabriquer des taillants pour outils de forage ou plus généralement pour des outils de coupe, de forme généralement parallélépipédique ou de forme cylindrique ayant des dimensions de l'ordre de quelques millimètres ou quelques dizaines de millimètres. Ces blocs, obtenus par métallurgie des poudres, sont constitués d'un matériau dense dont la structure comprend d'une part des particules dures telles que des carbures métalliques, et en particulier des carbures de tungstène, et d'autre part une phase liante constituée principalement d'un métal ou d'un alliage métallique. Au contact des carbures, cette phase liante peut former, à une température adaptée, un eutectique dont la température de fusion est inférieure à la fois à la température de fusion des carbures et à la température de fusion du métal ou de l'alliage métallique. Ce métal ou cet alliage métallique qui constitue la phase liante est par exemple du cobalt mais peut être également du fer ou du nickel ou un mélange de ces métaux, ces éléments représentent au moins 50% en poids de la phase liante.In the following, we consider blocks intended in particular to manufacture bits for drilling tools or more generally for cutting tools, generally parallelepiped shape or cylindrical shape having dimensions of the order of a few millimeters or a few tens of millimeters . These blocks, obtained by powder metallurgy, consist of a dense material whose structure comprises on the one hand hard particles such as metal carbides, and in particular tungsten carbides, and on the other hand a binding phase consisting of mainly a metal or an alloy metallic. In contact with the carbides, this binder phase can form, at a suitable temperature, a eutectic whose melting temperature is lower both at the melting point of the carbides and at the melting point of the metal or of the metal alloy. This metal or metal alloy which constitutes the binder phase is for example cobalt but may also be iron or nickel or a mixture of these metals, these elements represent at least 50% by weight of the binder phase.

Cette phase liante peut également contenir des éléments d'addition dont la somme des teneurs peut atteindre au plus 15 % en poids mais en générale ne dépasse pas 5 %. Ces éléments d'addition peuvent être du cuivre pour améliorer la conductivité électrique ou du silicium qui a un effet tensioactif par rapport au système constitué par les carbures et par la phase liante. Les éléments d'addition peuvent également être des éléments carburigènes permettant de former des carbures mixtes ou des carbures de type MxCy autres que le carbure de tungstène. Ces éléments sont notamment le manganèse, le chrome, le molybdène, le vanadium, le niobium, le tantale, le titane, le zirconium et l'afnium.This binder phase may also contain addition elements whose sum of the contents may reach at most 15% by weight but generally do not exceed 5%. These additive elements may be copper to improve electrical conductivity or silicon which has a surfactant effect with respect to the system consisting of carbides and the binder phase. The alloying elements may also be of carbide-forming elements for forming carbides or mixed carbides of type M x C y other than tungsten carbide. These elements include manganese, chromium, molybdenum, vanadium, niobium, tantalum, titanium, zirconium and afnium.

En outre, la phase liante peut comporter des éléments d'addition qui modifient la forme et/ou inhibent le grossissement des particules dures et que l'homme du métier connaît.In addition, the binder phase may comprise additive elements that change the shape and / or inhibit the magnification of hard particles and that those skilled in the art know.

Enfin, la composition chimique de ces matériaux comprend des impuretés inévitables qui résultent des procédés d'élaboration.Finally, the chemical composition of these materials includes unavoidable impurities that result from the processes of making.

Pour certaines applications, afin de renforcer la résistance à l'usure des taillants, on peut ajouter des particules de diamant naturel ou synthétique dont le diamètre peut atteindre 1 mm. Ces particules de diamant sont ajoutées au mélange de poudre qui sert à la fabrication du bloc par frittage connu sous le nom d'imprégné.For some applications, to increase the wear resistance of the cutters, one can add natural or synthetic diamond particles whose diameter can reach 1 mm. These diamond particles are added to the powder mixture which is used to make the block by sintering known as impregnated.

Conformément à l'invention, pour réaliser un bloc en carbure cémenté à gradient de propriétés, on revêt le bloc 1 en matériau dense d'une couche 2 d'épaisseur généralement comprise entre 50µm et 2mm environ, en un matériau susceptible de réagir chimiquement avec la phase liante et/ou la phase carbure du matériau dense. Ce revêtement est réalisé par pulvérisation, dépôt PVD (Physical Vapor Deposition) ou CVD (Chemical Vapor Deposition) si ce matériau de revêtement est apporté sous forme gazeuse, ou au pinceau, au trempé ou par sérigraphie si le matériau de revêtement est apporté sous forme liquide. On dispose alors l'ensemble sur la sole 3 d'un four 4 et on porte l'ensemble à une température de maintien Tm et on maintient l'ensemble à cette température pendant un temps tm de façon à assurer l'interaction du revêtement externe ou d'un de ses éléments constitutifs avec le matériau dense et engendrer la formation d'un gradient de propriétés à l'intérieur du bloc. Pour cela, la température de maintien Tm doit être supérieure ou égale à la température minimale de réaction Tr qui est la température au-dessus de laquelle le revêtement externe ou un de ses éléments commence à réagir (notamment formation de phases solides) ou diffuser sans réagir (pas de formation de phases solides mais pouvant conduire localement à un changement de la composition de la phase liante du bloc dense) de façon significative à l'intérieur du bloc. Cette température de réaction Tr doit être supérieure ou égale à la température de solidus Ts du carbure cémenté qui constitue le bloc. Cette température de solidus est la température minimale à laquelle la phase liante du carbure cémenté est à l'état liquide. Cette condition est souhaitable pour que le revêtement ou un de ses éléments constitutifs puisse rapidement diffuser puis réagir ou non selon le revêtement considéré avec les constituants (grains solides ou phase liquide) du bloc en cours de traitement. Si le revêtement est constitué d'un composé avec un métalloïde tel que le bore ou tout autre métalloïde ou un non-métal tel que le carbone, l'azote, l'oxygène ou tout autre non-métal, la température de réaction Tr est supérieure ou égale à la température de déstabilisation ou de dissociation Td du composé qui n'est pas nécessairement supérieure à la température de solidus Ts du carbure cémenté. Les températures de réaction Tr, de déstabilisation Td et la température de solidus Ts dépendent de la nature du matériau dont est constitué le revêtement et du matériau dont est constitué le bloc. L'homme du métier sait déterminer ces températures.According to the invention, in order to produce a cemented carbide block with a property gradient, the block 1 made of dense material is coated with a layer 2 of thickness generally between approximately 50 μm and 2 mm, made of a material capable of chemically reacting with the binder phase and / or the carbide phase of the dense material. This coating is carried out by spraying, PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) deposit if this coating material is supplied in gaseous form, or by brush, dip or dipping. silkscreen if the coating material is brought in liquid form. The set is then placed on the hearth 3 of a furnace 4 and the assembly is brought to a holding temperature T m and the assembly is kept at this temperature for a time t m so as to ensure the interaction of the external coating or one of its constituent elements with the dense material and generate the formation of a property gradient within the block. For this, the holding temperature T m must be greater than or equal to the minimum reaction temperature T r which is the temperature above which the outer coating or one of its elements begins to react (in particular formation of solid phases) or diffuse without reacting (no formation of solid phases but can lead locally to a change in the composition of the binding phase of the dense block) significantly within the block. This reaction temperature T r must be greater than or equal to the solidus temperature T s of the cemented carbide which constitutes the block. This solidus temperature is the minimum temperature at which the binder phase of the cemented carbide is in the liquid state. This condition is desirable so that the coating or one of its constituent elements can rapidly diffuse and then react or not depending on the coating considered with the constituents (solid grains or liquid phase) of the block being treated. If the coating consists of a compound with a metalloid such as boron or any other metalloid or a non-metal such as carbon, nitrogen, oxygen or any other non-metal, the reaction temperature T r is greater than or equal to the destabilization or dissociation temperature T d of the compound which is not necessarily greater than the solidus temperature T s of the cemented carbide. The reaction temperatures T r , of destabilization T d and the solidus temperature T s depend on the nature of the material of which the coating consists and of the material of which the block is made. Those skilled in the art know how to determine these temperatures.

Comme il est indiqué ci-dessus, la température de réaction Tr qui vient d'être définie, est supérieure ou égale à la température de solidus Ts pour que la diffusion se fasse dans la phase liante à l'état liquide afin d'obtenir une vitesse de diffusion suffisante.As indicated above, the reaction temperature Tr which has just been defined is greater than or equal to the solidus temperature Ts so that the diffusion takes place in the binder phase in the liquid state in order to obtain a sufficient diffusion rate.

Mais, l'homme du métier comprendra aisément que, lorsque la température de déstabilisation ou de dissociation Td est inférieure à la température de solidus Ts du carbure cémenté, un ou plusieurs constituants du matériau de revêtement peuvent commencer à diffuser dans la phase liante du bloc à l'état solide et, éventuellement, réagir.However, those skilled in the art will readily understand that when the destabilization or dissociation temperature Td is lower than the solidus temperature Ts of the cemented carbide, one or more constituents of the coating material can begin to diffuse into the binder phase of the block in the solid state and possibly react.

La température de maintien Tm ne doit pas être trop élevée. De préférence, elle doit rester en dessous de Ts +200°C et mieux, en dessous de Ts +100°C, et mieux encore, en dessous de Ts +50°C. Le temps de maintien tm doit être quant à lui, adapté à la forme et à l'amplitude du gradient souhaité et est déduit de l'expérience. Il est généralement de l'ordre de quelques minutes.The holding temperature T m must not be too high. Preferably, it should remain below T s + 200 ° C and better, below T s + 100 ° C, and better still, below T s + 50 ° C. The holding time t m must be adapted to the shape and amplitude of the desired gradient and is deduced from the experiment. It is usually of the order of a few minutes.

Le matériau de revêtement susceptible de se déstabiliser ou de se dissocier et/ou de réagir avec le matériau qui constitue le bloc dense à traiter est par exemple un nitrure de métalloïde ou de métal tel que le nitrure de bore, le nitrure d'aluminium, le nitrure de titane, ou un borure tel que le borure de titane, un carbure de métalloïde ou de métal tel que le carbure de bore, le carbure de titane, ou un hydrure tel que l'hydrure de titane ou du graphite ou un oxyde réfractaire tel que l'alumine ou un carbonitrure ou un borocarbure de métal ou un mélange de tels matériaux.The coating material capable of destabilizing or dissociating and / or reacting with the material constituting the dense block to be treated is, for example, a metalloid nitride or metal nitride such as boron nitride, aluminum nitride, titanium nitride, or a boride such as titanium boride, a metalloid carbide or metal such as boron carbide, titanium carbide, or a hydride such as titanium hydride or graphite or an oxide refractory such as alumina or a carbonitride or borocarbide metal or a mixture of such materials.

Comme on l'a indiqué ci-dessus, les matériaux utilisés pour réaliser le revêtement du bloc à traiter doivent être actifs voire dans certains cas réactifs au-dessus de la température de solidus Ts, mais il est préférable qu'ils restent stables, c'est-à-dire ne se dissocient pas, en dessous de cette température.As indicated above, the materials used to make the coating of the block to be treated must be active or in some cases reactive above the solidus temperature T s , but it is preferable that they remain stable, that is to say, do not dissociate, below this temperature.

On notera que, selon la nature du matériau de revêtement et celle du matériau constitutif du bloc, le gradient de propriétés obtenu peut résulter d'un durcissement relatif de la surface du bloc par rapport au coeur, ou au contraire, d'un adoucissement.It will be noted that, depending on the nature of the coating material and that of the constituent material of the block, the property gradient obtained may result from a relative hardening of the surface of the block relative to the core, or on the contrary, a softening.

Le traitement thermique comprend, comme cela est représenté à la figure 4, une montée en température jusqu'à la température de maintien Tm, puis un maintien pendant un temps de maintien tm à cette température et un refroidissement jusqu'à la température ambiante.The heat treatment comprises, as shown in figure 4 , a rise in temperature up to the holding temperature T m , then a hold for a holding time t m at this temperature and cooling to room temperature.

Le temps de maintien tm et la température de maintien Tm sont adaptés en fonction des dimensions du bloc à traiter et du gradient de propriétés qu'on veut obtenir.The holding time t m and the holding temperature T m are adapted according to the dimensions of the block to be treated and the property gradient that is to be obtained.

Le traitement thermique peut être effectué dans un four à résistance, ou un four à induction, ou un four à micro-onde, sous atmosphère protectrice ou sous vide. L'atmosphère protectrice est par exemple de l'argon ou un mélange d'argon et d'hydrogène mais en règle générale toute atmosphère neutre telle que argon, azote, argon hydrogéné, azote hydrogéné, hydrogène ou éventuellement un vide primaire ou secondaire.The heat treatment can be carried out in a resistance furnace, or an induction furnace, or a microwave oven, under a protective atmosphere or under empty. The protective atmosphere is for example argon or a mixture of argon and hydrogen but generally any neutral atmosphere such as argon, nitrogen, hydrogenated argon, hydrogenated nitrogen, hydrogen or possibly a primary or secondary vacuum.

Comme représenté à la figure 2, le bloc ainsi traité a une composition, en particulier une teneur en phase liante, qui varie depuis l'extérieur vers l'intérieur. Sur la figure, on a représenté des courbes d'iso-concentration Ci en phase liante, la zone la plus externe 10 étant la plus pauvre en phase liante et par conséquent la plus dure, et la zone intermédiaire 11 ayant une concentration intermédiaire et la zone 12 la plus riche en phase liante étant la moins dure et par conséquent la plus tenace. Comme représenté sur cette figure 2, on voit que la variation de teneur en phase liante se fait sur plusieurs millimètres. De ce fait, il apparaît que l'action d'un ou plusieurs éléments constitutifs de la couche externe déposée avec l'un des constituants du carbure cémenté peut induire des phénomènes de transfert (ou de migration) de la phase liante liquide depuis la zone externe vers la zone interne en appauvrissant la zone externe pour enrichir la zone interne.As represented in figure 2 the block thus treated has a composition, in particular a binder phase content, which varies from outside to inside. The figure shows iso-concentration Ci curves in the binder phase, the outermost zone 10 being the poorest in the binder phase and therefore the hardest, and the intermediate zone 11 having an intermediate concentration and the the richest zone 12 binder phase being the least hard and therefore the most tenacious. As represented on this figure 2 it can be seen that the variation in the binder phase content takes place over several millimeters. As a result, it appears that the action of one or more constituent elements of the outer layer deposited with one of the constituents of the cemented carbide can induce transfer (or migration) phenomena of the liquid binder phase from the zone external to the inner zone by depleting the outer zone to enrich the inner zone.

Bien évidemment, pour un carbure cémenté donné et un matériau de revêtement donné, l'étendue de la zone affectée par la variation de la teneur en phase liante dépend à la fois de la température maximale de maintien Tm, du temps de maintien tm et de l'épaisseur du matériau de revêtement. A épaisseur égale de la couche de revêtement, plus la température Tm est élevée et plus le temps tm est long, plus la zone affectée est étendue ; c'est-à-dire, plus le bloc est affecté en profondeur.Of course, for a given cemented carbide and a given coating material, the extent of the area affected by the variation of the binder phase content depends both on the maximum holding temperature T m , the holding time t m and the thickness of the coating material. At equal thickness of the coating layer, the higher the temperature T m is and the longer the time t m is, the more the affected area is extended; that is, the deeper the block is affected.

L'homme du métier sait adapter les conditions du traitement aux résultats qu'il souhaite obtenir. On notera également que le bloc tel qu'il vient d'être décrit est recouvert sur toutes ses faces d'un matériau actif. Mais, le matériau actif peut n'être déposé que sur une partie de la surface externe du bloc et de ce fait peut conduire au durcissement ou à l'adoucissement que des zones du bloc situées sous le revêtement et donc posséder respectivement une zone adoucie ou durcie à coeur qui peut s'étendre jusqu'à la surface externe du bloc qui n'est pas revêtue.The person skilled in the art knows how to adapt the conditions of the treatment to the results that he wishes to obtain. It will also be noted that the block as just described is covered on all sides with an active material. But, the active material can be deposited only on a part of the outer surface of the block and thus can lead to hardening or softening that areas of the block located under the coating and therefore have respectively a softened area or hardened core that can extend to the outer surface of the block that is not coated.

On notera que cette variation de la répartition de la phase liante à l'intérieur du bloc sur des distances millimétriques se fait sans apport de phase liante externe. Mais ce n'est pas pour autant que la teneur en phase liante globale du bloc qui a été traitée reste identique car de la phase liante a pu se combiner avec un ou plusieurs éléments du revêtement pour former une phase solide, appauvrissant ainsi la teneur en phase liante du bloc.It will be noted that this variation of the distribution of the binder phase inside the block over millimeter distances is without external binder phase. But this does not mean that the overall binding phase content of the The block that has been treated remains identical because of the binder phase could combine with one or more elements of the coating to form a solid phase, thereby depleting the binder phase content of the block.

La variation de dureté qui peut atteindre plusieurs centaines de Vickers peut se faire sur des distances supérieures à 0,5mm, et peut s'étendre dans tout le bloc.The variation in hardness that can reach several hundred Vickers can be over distances greater than 0.5mm, and can extend throughout the block.

A titre d'exemple, on a réalisé trois traitements de blocs constitués du même matériau, WC-Co contenant environ 13% en poids de Cobalt (HV2kg/10s = 1220), selon le même cycle thermique (Tm = 1350 °C, tm, = 5 min) avec deux revêtements différents (nitrure de bore, alumine) sous vide et sous argon hydrogéné.By way of example, three block treatments consisting of the same material, WC-Co containing approximately 13% by weight of Cobalt (HV 2kg / 10s = 1220), were carried out according to the same thermal cycle (T m = 1350 ° C. , t m , = 5 min) with two different coatings (boron nitride, alumina) under vacuum and under hydrogenated argon.

Le premier bloc, repéré 10 à la figure 5, a été revêtu par pulvérisation d'une couche 11 de nitrure de bore BN, recouvrant la face supérieure et les faces latérales du bloc, puis traité sous vide.The first block, spotted 10 at the figure 5 , was spray-coated with a layer 11 of boron nitride BN, covering the upper face and the side faces of the block, and then treated under vacuum.

Comme cela est représenté de façon schématique à la figure 6, le gradient de concentration en phase liante obtenu a la forme d'un dôme tel que la zone 12 située sous les surfaces revêtues a une dureté supérieure de 130 HV environ à celle de la zone 13 située au coeur du bloc. Le sens de migration de la phase liante est indiqué par la flèche et par le sens croissant des iso-concentrations (C1<C2<C3<C4).As shown schematically in the figure 6 the binder phase concentration gradient obtained in the form of a dome such that the zone 12 located under the coated surfaces has a hardness greater than about 130 HV to that of the zone 13 located in the heart of the block. The direction of migration of the binder phase is indicated by the arrow and by the increasing direction of the iso-concentrations (C1 <C2 <C3 <C4).

Le deuxième bloc, repéré 20 à la figure 7, a également été revêtu d'une couche 21 de nitrure de bore BN, mais celle-ci n'a été déposée que sur une moitié du bloc. En outre, le bloc a été traité sous une atmosphère d'argon hydrogéné.The second block, spotted 20 at the figure 7 was also coated with a layer 21 of boron nitride BN, but this was deposited on only one half of the block. In addition, the block was treated under a hydrogenated argon atmosphere.

Comme représenté à la figure 8, le gradient de concentration en phase liante obtenu conduit à une amplitude de dureté de 120 HV, seule la zone 22 située sous le revêtement étant durcie, le reste 23 ne l'étant pas. De nouveau, le sens de migration de la phase liante est indiqué par la flèche et par le sens croissant des iso-concentrations (C1 <C2<C3).As represented in figure 8 the binder phase concentration gradient obtained leads to a hardness amplitude of 120 HV, only the zone 22 beneath the coating being cured, the remainder 23 not being hardened. Again, the direction of migration of the binder phase is indicated by the arrow and the increasing direction of the iso-concentrations (C1 <C2 <C3).

Le troisième bloc, repéré 30 à la figure 9, a été revêtu d'une couche 31 d'oxyde d'aluminium Al2O3 déposée sous la forme de pâte liquide au pinceau sur la face supérieure et sur les faces latérales du bloc et traité sous vide. Comme représenté à la figure 10, le gradient de concentration en phase liante obtenu est en forme de dôme, mais, contrairement à ce qui a été obtenu avec le premier bloc, la zone 32 proche de la surface a été adoucie de sorte que leur dureté est inférieure de 150 HV à celle de la zone à coeur 33. Le sens de migration de la phase liante est indiqué par la flèche et par le sens croissant des iso-concentrations (C1 <C2<C3<C4) dont le sens est inverse par rapport aux deux cas précédents.The third block, spotted 30 at the figure 9 was coated with a layer 31 of aluminum oxide Al 2 O 3 deposited in the form of liquid paste with a brush on the upper face and on the side faces of the block and treated under vacuum. As represented in figure 10 the binder phase concentration gradient obtained is dome-shaped, but, contrary to what was obtained with the first block, the zone 32 close to the surface has been softened so that their hardness is 150 HV less than that of the core zone 33. The direction of migration of the binder phase is indicated by the arrow and by the increasing direction of the insulation. concentrations (C1 <C2 <C3 <C4) whose meaning is opposite to the two previous cases.

Ainsi, dans le cas du matériau WC-Co considéré, le nitrure de bore permet de durcir la zone du bloc proche de la couche de revêtement, alors que l'alumine permet de l'adoucir.Thus, in the case of the WC-Co material considered, the boron nitride makes it possible to harden the zone of the block close to the coating layer, whereas the alumina makes it possible to soften it.

En revanche, l'atmosphère du four (vide ou argon-hydrogéné) utilisée pour effectuer les traitements est sans incidence sur le résultat.On the other hand, the furnace atmosphere (vacuum or argon-hydrogenated) used to carry out the treatments has no effect on the result.

Comme on l'a indiqué précédemment, les blocs ainsi traités peuvent constituer des taillants d'outil de forage ou d'outil de coupe et peuvent avoir des dimensions de quelques millimètres ou même plus puisqu'on peut envisager de réaliser des lames de coupe ayant des dimensions de plusieurs centimètres et qui peuvent être durcies par ce procédé.As previously indicated, the blocks thus treated may constitute bits of drilling tool or cutting tool and may have dimensions of a few millimeters or even more since it is conceivable to produce cutting blades having dimensions of several centimeters and which can be hardened by this process.

On peut également, comme cela est représenté à la figure 3, réaliser un taillant pour outil de taille des roches ou outil de coupe des métaux réfractaires ou d'usinage, constitué d'un bloc support 20 en carbure cémenté réalisé à l'aide du procédé selon l'invention dont la surface latérale est dure et le coeur plus tenace (C1 <C2<C3<C4) et dont la face inférieure n'a pas été revêtue avant traitement thermique et dont sur la face supérieure après traitement a été rapportée une plaquette 21 de diamant naturel ou synthétique d'épaisseur supérieure à 0,4mm selon le procédé HPHT (Haute Pression - Haute Température) du type PDC (Polycrystalline Diamond Compact) ou du type TSP (Thermally Stable Polycrystalline diamond).We can also, as shown in figure 3 , making a cutter for a rock cutting tool or tool for cutting refractory or machining metals, consisting of a cemented carbide support block 20 made using the method according to the invention, the lateral surface of which is hard and the tenacious core (C1 <C2 <C3 <C4) and whose underside has not been coated before heat treatment and whose upper face after treatment has been reported a plate 21 of natural or synthetic diamond of greater thickness at 0.4 mm according to the HPHT (High Pressure - High Temperature) process of the PDC (Polycrystalline Diamond Compact) or TSP (Thermally Stable Polycrystalline diamond) type.

En particulier, le bloc support 20 traité selon l'invention peut être assemblé après le procédé HPHT par brasage par exemple selon le procédé connu sous le nom de « LS Bond » et décrit dans les brevets US 4,225,322 et US 5,111,895 sans que cette opération n'entraîne dans le bloc une modification drastique du gradient de concentration en phase liante.In particular, the support block 20 treated according to the invention can be assembled after the HPHT process by soldering for example according to the process known under the name of "LS Bond" and described in US Pat. US 4,225,322 and US 5,111,895 without this operation leading to a drastic change in the binder phase concentration gradient in the block.

D'autres taillants que l'homme du métier peut imaginer peuvent être réalisés par ce procédé. Ces taillants peuvent être incorporés dans des outils divers connus de l'homme du métier tels que des outils pour le broyage des roches, pour des têtes de forage ou bien des outils d'usinage.Other cutters that the person skilled in the art can imagine can be made by this method. These bits can be incorporated into tools various known to those skilled in the art such as tools for grinding rocks, for drilling heads or machining tools.

Claims (17)

  1. Method of manufacturing a part comprising a bloc (1) of dense material composed of hard particles of the same or different nature(s) dispersed in a binder phase, the material having a solidus temperature Ts starting from which the binder phase is liquid, characterised in that an active coating (2) composed of a material optionally capable of reacting chemically with the dense material when the whole is heated beyond a minimum reaction temperature Tr is deposited on at least a portion of the surface of the block of dense material (1); and in that the block (1) coated with the active coating (2) is subjected to a thermal treatment comprising heating and then maintaining for a time tm at a maintenance temperature Tm greater than or equal to the minimum reaction temperature Tr, followed by cooling to ambient temperature, this method leading to variations in the binder phase in the interior of the block over distances of millimetres which occur without introduction of external binder phase and so without leading to overall enrichment of the block with additional binder phase.
  2. Method according to claim 1, characterised in that the maintenance temperature Tm is greater than or equal to the solidus temperature Ts of the dense material.
  3. Method according to claim 2, characterised in that the maintenance temperature Tm is less than or equal to Ts + 200°C.
  4. Method according to any one of claims 1 to 3, characterised in that the maintenance time tm is between 1 min and 10 min inclusive.
  5. Method according to any one of claims 1 to 4, characterised in that the active coating is deposited over only a portion of the surface of the block.
  6. Method according to any one of claims 1 to 4, characterised in that the active coating is deposited over the entire surface of the block.
  7. Method according to any one of claims 1 to 6, characterised in that the dense material is a cemented carbide composed of metal carbide particles dispersed in a metal matrix.
  8. Method according to claim 7, characterised In that the cemented carbide additionally comprises particles of natural or synthetic diamond of a size up to 1 mm in diameter.
  9. Method according to claim 7 or claim 8, characterised in that the cemented carbide is of the WC-M type, M being one or more metals selected from Co, Ni and Fe, the sum of the contents, by weight, of those metals in the binder phase being greater than 50 %.
  10. Method according to any one of claims 1 to 9, characterised in that the coating material capable of reacting with the dense material of the block is composed of at least one compound selected from compounds of the nitride, boride, carbide, oxide, hydride, carbonitride, borocarbide and graphite type or any mixture of those different compounds.
  11. Method according to any one of claims 1 to 10, characterised in that the coating is deposited by a method of the PVD (Physical Vapour Deposition) or CVD (Chemical Vapour Deposition) type or a spraying method or by brush or by dipping or by screen printing.
  12. Method according to any one of claims 1 to 11, characterised in that the block of dense material is a cutter or a cutter-supporting block of a tool for drilling or mining or machining (rocks/metals).
  13. Method according to claim 12, characterised in that, in addition, a diamond insert of the PDC (Polycrystalline Diamond Compact) or TSP (Thermally Stable Polycrystalline diamond) type is deposited on a face of the supporting block
  14. Method according to claim 13, characterised in that the diamond insert is mounted on a face of the block after treatment of the block, by brazing.
  15. Method according to any one of claims 1 to 14, characterised in that the part is a cutter for subdividing rocks, comprising a block composed of hard particles dispersed in a binder phase which has, over a distance greater than 0.5 mm, a continuous gradient in the binder phase content, the difference in the binder phase content between the richest zone and the poorest zone being greater than 1 % by volume.
  16. Method according to claim 15, characterised in that the cutter comprises a mounted diamond insert of the PDC or TSP type having a thickness greater than 0.4 mm.
  17. Method according to claim 15 or claim 16, characterised in that the part is a rock-cutting tool comprising at least one cutter or blade
EP09755981A 2008-10-07 2009-10-07 Process for manufacturing a part comprising a block of dense material constituted of hard particles and of binder phase having a gradient of properties, and resulting part Active EP2347025B1 (en)

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PCT/FR2009/051910 WO2010040953A1 (en) 2008-10-07 2009-10-07 Process for manufacturing a part comprising a block of dense material constituted of hard particles and of binder phase having a gradient of properties, and resulting part.

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JP5622731B2 (en) 2014-11-12
JP2012505306A (en) 2012-03-01
CN102282278A (en) 2011-12-14
FR2936817B1 (en) 2013-07-19
US8602131B2 (en) 2013-12-10
WO2010040953A1 (en) 2010-04-15
FR2936817A1 (en) 2010-04-09
EP2347025A1 (en) 2011-07-27
US20110174550A1 (en) 2011-07-21

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