RU2141001C1 - Matrix for solid composite compound - Google Patents

Abstract

FIELD: formation of matrixes. SUBSTANCE: matrix powder and impregnating material used in the capacity of worn- out element or used to hold at least one individual solid element are employed for formation of matrix. Matrix powder includes particles of crushed baked carburized wolfram carbide. Composite compound of crushed baked carburized wolfram carbide contains approximately 6 to 13 per cent by weight of binding metal and from 87 to 95 per cent by weight of wolfram carbide. Technical result of process consists in improved matrix powder for solid composite compound carrying assemblage of solid elements of diamond type or elements of polycrystalline diamond compounds held in matrix, improved impact and breaking strength, hardness and resistance to erosion. EFFECT: improved properties of matrix. 17 cl, 3 dwg

Description

 The invention relates to a solid composite joint comprising a metal matrix and one or more separated solid elements held therein, in which the solid composite joint may be useful as a cutting tool or a wear member. More specifically, the invention relates to a diamond composite compound containing a matrix composed of carbide-based particulates bonded together by means of an impregnating metal with one or more separate diamond-based elements held in the matrix. It should be understood that the diamond-based element could comprise a composite compound with individual diamonds or a polycrystalline diamond composite compound having a substrate with a layer of polycrystalline diamond on it. Some types of tungsten carbide that are suitable for use in matrix tools include macrocrystalline tungsten carbide, crushed sintered cemented macrocrystalline tungsten carbide having a binder metal, and crushed cast tungsten carbide.

 As for macrocrystalline tungsten carbide, this material is essentially stoichiometric WC (tungsten carbide), which exists mainly in the form of individual crystals. Some large crystals of macrocrystalline tungsten carbide are bicrystals. US Patent No. 3,379,503, filed by McKenna under the title "Process for the Preparation of Tungsten Monocarbide", defined as a prototype of the description of this patent, discloses a method for manufacturing macrocrystalline tungsten carbide. US Pat. No. 4,834,963, filed by Terry et al., Entitled "Macrocrystalline Tungsten Monocarbide Powder and Process for its Production", defined as a prototype of the description of this patent, also discloses a method for manufacturing macrocrystalline tungsten carbide.

 As for crushed sintered cemented macrocrystalline tungsten, this material contains small particles of tungsten carbide bonded together in a metal matrix. For such material as used in this patent specification, crushed sintered cemented macrocrystalline tungsten carbide with a binder (cobalt or nickel) is made by mixing together WC particles, Co or Ni powder and a lubricant (lubricant). This mixture is granulated, sintered, cooled and then crushed. Granulation does not use pressure, but instead, while mixing WC and cobalt particles, the mixer blades cause the mixture of WC and cobalt (or nickel) to roll into granules.

As for crushed cast tungsten carbide, tungsten forms two carbides, namely WC and W ₂ C. Between them there can be a continuous series of intermediate compositions. The eutectic mixture contains approximately 4.5 weight percent carbon. Cast tungsten carbide, which is used commercially as a matrix powder, typically has a pre-eutectic carbon content of about 4 weight percent. Cast tungsten carbide usually solidifies from the molten state and is crushed to the desired particle size.

 Solid composite compounds are known comprising a matrix and individual solid elements held therein. Typically, the matrix contains carbide-based particulates bound together by an impregnating metal and solid elements containing diamond-based materials.

 For carbide-based particles, one sample of a carbide-based component contains approximately 67.10 weight percent of macrocrystalline tungsten carbide having the following particle size distribution: from 18.0 to 22.0 weight percent of macrocrystalline tungsten carbide particles have a size of 80 + 120 mesh. (mesh size - is set in accordance with ASTM E-11-70 standard, and in this case corresponds to a size greater than 125 micrometers and less than or equal to 177 micrometers), from 25.0 to 30.0 weight percent of macrocrystalline tungsten carbide particles have a size of -120 + 170 mesh. (more than 88 micrometers and less than or equal to 125 micrometers), from 29.0 weight percent to 33.0 weight percent of macrocrystalline tungsten carbide particles have a size of 170 + 230 mesh. (more than 63 micrometers and less than or equal to 88 micrometers), from 18 weight percent to 22.0 weight percent of macrocrystalline particles of tungsten carbide have a size of 230 + 325 mesh. (more than 44 micrometers and less than or equal to 63 micrometers), and up to 5.0 weight percent of macrocrystalline particles of tungsten carbide have a size of 325 mesh. (less than or equal to 44 micrometers). The matrix further contains approximately 30.90 weight percent of crushed tungsten carbide particles having a size of 325 (less than or equal to 44 micrometers), 1.00 weight percent of iron having an average particle diameter of between 3 micrometers and 5 micrometers, and 1.00 weight percent of grade 4600 steel having a particle size of 325 (less than or equal to 44 micrometers).

 Grade 4600 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 the rest is iron.

 Another sample of a carbide-based component contains about 65 weight percent of macrocrystalline tungsten carbide having a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers), 27.6 weight percent of a tungsten carbide rod milled to an average particle size of 4 to 6 micrometers with fine particles removed, 2.8 weight percent of tungsten having a particle size of 325 mesh. (less than or equal to 44 micrometers), 2.8 weight percent of grade 4600 steel having a particle size of 140 mesh. (less than or equal to 105 micrometers), and 1.8 weight percent iron having a particle size of 325 (less than or equal to 44 micrometers).

Another sample of the carbide-based particulate component contains 68 weight percent of macrocrystalline tungsten carbide having a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers); 15 weight percent of macrocrystalline tungsten carbide having a particle 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. It has a size of 325 mesh. (less than or equal to 44 micrometers). This nickel is INCO type 123 from the International Nickel Company and is a one of a kind (special) powder coated with spikes (spikes) of the correct form. Chemical analysis and physical characteristics available from commercial literature reveal the following: chemical analysis shows the composition: a maximum of 0.1 carbon, a maximum of 0.15 oxygen, a maximum of 0.001 sulfur, a maximum of 0.01 iron, and the rest is nickel. The average particle size is 3 - 7 micrometers (the size of the holes of the "fishing sieve"), bulk density is 1.8 - 2.7 grams / cm ³ and the specific surface area is 0.34 - 0.44 m ² / g.

 Another sample of the carbide-based particulate component contains 64 weight percent of macrocrystalline tungsten carbide having a (particle) size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers); 14 weight percent macrocrystalline tungsten carbide having a size of 325 mesh. (less than or equal to 44 micrometers); 14 weight percent crushed cast tungsten carbide having a size of 325 mesh. (less than or equal to 44 micrometers); 8 weight percent nickel having a size of 200 mesh. (less than or equal to 74 micrometers).

 Another sample of the particulate component contains 67.0 weight percent of crushed tungsten carbide cast having the following particle size distribution: 18.0 to 22.0 weight percent of crushed tungsten carbide particles have a size of 80 + 120 mesh. (more than 125 micrometers and less than or equal to 177 micrometers), from 25.0 to 30.0 weight percent of particles of crushed cast tungsten carbide have a size of 120 + 170 mesh. (more than 88 micrometers and less than or equal to 125 micrometers), from 29.0 weight percent to 33.0 weight percent of particles of crushed cast tungsten carbide have a size of 170 + 230 mesh. (more than 63 micrometers and less than or equal to 88 micrometers), from 18.0 weight percent to 22.0 weight percent of particles of crushed cast tungsten carbide have a size of 230+ 325 mesh. (more than 44 micrometers and less than or equal to 63 micrometers), and up to 5.0 weight percent particles of crushed cast tungsten carbide have a size of 325 mesh. (less than or equal to 44 micrometers). The component further has 31.0 weight percent of 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 of 4600 steel having a particle size of 325 mesh. (less than or equal to 44 micrometers).

One sample of a suitable impregnating material contains 63 to 67 weight percent of copper, 14 to 16 weight percent of nickel and 19 to 21 weight percent of zinc. This material has a specific gravity of 8.5 grams / cm ³ and has a melting point of 866.5 K (593 ^° C, 1100 ^° F). This impregnating material is used in 0.08 cm x 0.8 cm (1/32 inch X 5/16 inch) granules. This alloy is identified by the representative (prototype) of the applicants as MACROFIL 65, and this designation will be used in the present description.

 Another example of a suitable impregnating material 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 (very small amounts) of lead, tin and iron . This impregnating material is sold by Belmont Metal Inc., Belmont (Avenue) 330, Brooklyn, NY 11207, under the name "VIRGIN binder (binder) 4537D" in the form of bars measuring 2.54 cm x 1.27 cm x 1 , 27 cm (1 inch x 1/2 inch x 1/2 inch). This alloy is identified by the representative (prototype) of the applicants as MACROFIL 53, and this designation will be used in the present description.

 Although these known matrices for a solid composite compound are used satisfactorily, it would be desirable to provide an improved matrix for a solid composite compound having improved properties. These properties include impact resistance (impact strength), transverse tensile strength (tensile strength), hardness, resistance to abrasion and erosion resistance. It would also be desirable to provide an improved solid composite compound that utilizes an improved matrix material. Further, it would still be desirable to provide a tool part (structural member) that includes a tool shaft with an improved solid composite joint attached to it, in which case the tool part could be used, for example, in connection with an oil well drill head.

SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved matrix powder for a solid composite compound containing one or more individual solid elements held in a matrix composed of carbide-based particulates bound together by an impregnating metal in which the matrix has generally improved properties. It is believed that a solid composite compound could be used in cutting and drilling applications, and that matrix powder and impregnating material without a solid element could be used in wear applications (tools).

 Another object of the present invention is to provide an improved solid composite compound containing a plurality of individual solid elements, such as diamond or polycrystalline diamond compound elements, held in a matrix composed of carbide-based particulates bonded together with an impregnating metal that would have improved impact resistance.

 Another objective of the present invention is to provide an improved solid composite compound containing many individual solid elements, such as diamond or elements of polycrystalline diamond compounds held in a matrix composed of carbide-based particles bound together by an impregnating metal, which would have improved tensile strength.

 It is an object of the present invention to provide an improved solid composite compound containing a plurality of solid elements, such as diamond or polycrystalline diamond compound elements held in a matrix composed of carbide-based particulates bound together by an impregnating metal that would have improved hardness.

 Another objective of the present invention is to provide an improved solid composite compound containing many individual solid elements, such as diamond or elements of polycrystalline diamond compounds held in a matrix composed of carbide-based particulates bound together by an impregnating metal that would have improved erosion resistance properties.

 In one embodiment, the invention is a matrix powder for forming into a matrix together with an impregnating material. The matrix powder contains particles of crushed sintered cemented macrocrystalline tungsten carbide having a size of 80 + 400 mesh. (more than 37 micrometers and less than or equal to 177 micrometers). The composition of the crushed sintered cemented macrocrystalline tungsten carbide contains from about 5 weight percent to 20 weight percent binder metal and from about 80 weight percent to 95 weight percent tungsten carbide.

 In another embodiment, the invention is a diamond component that includes a support and a diamond composite joint attached to the support. The diamond composite compound contains a matrix that includes a mass of particles held together by the impregnating material. The mass of particles is formed by heating the powder mixture in the presence of an impregnating material. The powder mixture contains particles of crushed sintered cemented tungsten carbide having a size of 80 + 400 mesh. (more than 37 micrometers and less than or equal to 177 micrometers). The composition of the crushed sintered cemented macrocrystalline tungsten carbide contains from about 5 weight percent to 20 weight percent binder metal and from about 80 weight percent to 95 weight percent tungsten carbide.

Brief Description of the Drawings
The invention is further explained in the description of specific variants of its embodiment with reference to the accompanying drawings, in which;
FIG. 1 is a schematic view of an assembly used to make an article comprising a tool bar with individual diamonds attached to it in one embodiment, and
FIG. 2 is a schematic view of an assembly used to manufacture an article comprising a tool shaft with (elements) a diamond-based composite compound attached to it in another embodiment, and
FIG. 3 is a perspective view of the tool drill head that the present invention covers.

Detailed Description of Specific Embodiments
FIG. 1 illustrates a schematic view of an assembly used to manufacture an article using diamond as part of the present invention. A typical product is a drill head. As will become apparent, the drill head has a shaft. Cutting elements, such as individual diamonds, are attached to the drill head by means of a metal matrix. Although the method by which the rod is attached to the drill cable (rope) may vary, one general method is to provide thread on the rod so that the rod is screwed into the threaded hole in the drill cable. Another way is to weld the shaft to the drill cable.

 The manufacturing assembly includes a carbon (coal) mold of the graphite type, generally indicated at 10, having a base wall 12 and a vertical wall 14. Form 10 defines the internal volume. The device further includes an upper part 16, which fits to the upper hole (opening) of the mold 10. It should be understood that the use of the upper part 16 is an addition depending on the desired degree of atmospheric pressure control.

 The steel rod 24 is placed inside the mold before powder is poured there. Part of the steel rod 24 is located inside the powder mixture 22, and the other part of the steel rod 24 is outside the mixture 22. The rod 24 has a thread 25 at one end and grooves 25A at the other end.

 Regarding the contents of the mold, there are many individual diamonds 20 placed in selected positions inside the mold so as to be in selected positions on the surface of the finished product. The matrix powder 22 is a carbide-based powder that is poured into the mold 10 so that it closely touches the diamonds 20. The composition of the matrix 22 powder will be described later.

Once the diamonds 20 are installed and the matrix powder 22 is poured into the mold, the impregnating alloy 26 is placed close to the powder mixture 22 in mold 10. Then, the lid 16 is placed on the mold and the mold is placed in the furnace and heated to about 1478 K (2200 ^° F, ( 1177 ^o C, more precisely 1204 ^o C) so that the impregnating material 26 is melted and infiltrated the powder mass. The result is an end product wherein the infiltrant links (strengthens) the powder together, the matrix holds the diamonds therein, and the composite compound is attached to a steel rod.

 FIG. 2 illustrates a schematic view of an assembly used to manufacture a second type of article using a diamond-based composite material as part of the present invention. The assembly includes a carbon mold of graphite type, generally indicated at 30, having a wall 32 and a vertical wall 34. The mold 30 defines the internal volume. The assembly further includes a top piece 36 that fits into the inlet of the mold 30. It should be understood that the use of the top piece 36 is an addition depending on the desired degree of atmospheric pressure control.

 The steel rod 42 is placed inside the mold before the powder mixture is poured there. Part of the steel rod 42 is inside the powder mixture 40, and the other part of the steel rod 42 is outside the mixture. The rod 42 has at the end of the grooves 43, which are located inside the powder mixture.

 As for the contents of mold 30, there are many carbon (graphite) blanks 38 placed at selected positions inside the mold so as to be in selected positions on the surface of the finished product. The matrix powder 40 is a carbide-based powder that is poured into a mold 30 so that it closely touches the carbon (graphite) preforms 38. The composition of the matrix 40 powder will be given later.

Once the carbon (graphite) preforms 40 are installed and the matrix powder 40 is poured into the mold 30, the impregnating alloy 44 is placed close to the powder mixture in the mold. The lid 36 is then placed on the mold, and the mold is placed in an oven and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) so that the impregnating material melts and impregnates the powder mass. The result is an intermediate product in which the impregnating material binds the powder together, also attaching the powder mass to the steel bar, and the composite material attaches to the steel bar, and carbon (graphite) blanks define (form) recesses on the surface of the impregnated mass.

 Carbon (graphite) preforms are removed from the bonded mass, and inserts from a composite material based on diamond having a shape similar to the shape of a carbon (graphite) preform are soldered into the recesses to form the final product. Typically, drill heads have a layer of individual diamonds on the surface.

 FIG. 3 illustrates a portion of the tool, generally indicated at 50. The tool 50 has an outer surface to which individual diamond elements 52 are attached.

Comparative samples
The following comparative samples were made and tested, and the results of these tests are further presented.

 Comparative sample A contains a powder matrix mixture having the following composition and size distribution: approximately 67.10 weight percent is macrocrystalline tungsten carbide, having the following size distribution: from 18.0 to 22.0 weight percent of macrocrystalline tungsten carbide particles have a size of 80 + 120 mesh. (more than 125 micrometers and less than or equal to 177 micrometers), from 25.0 to 30.0 weight percent of macrocrystalline particles of tungsten carbide have a size of 120 + 170 mesh. (more than 88 micrometers and less than or equal to 125 micrometers), from 29.0 weight percent to 33.0 weight percent of macrocrystalline tungsten carbide particles have a size of -170 + 230 mesh. (more than 63 micrometers and less than or equal to 88 micrometers), from 18 weight percent to 22.0 weight percent of macrocrystalline particles of tungsten carbide have a size of 230 + 325 mesh. (more than 44 micrometers and less than or equal to 63 micrometers), and up to 5.0 weight percent of macrocrystalline tungsten particles has a size of 325 mesh. (less than or equal to 44 micrometers). The matrix further contains approximately 30.9 weight percent of crushed cast tungsten carbide particles having a size of 325 mesh. (less than or equal to 44 micrometers), 1.00 weight percent of iron having an average particle diameter of between 3 micrometers and 5 micrometers, and 1.00 weight percent of grade 4600 steel having a particle size of 325 mesh. (less than or equal to 44 micrometers). Grade 4600 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 the rest is iron.

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Comparative sample B contains a powder matrix mixture having the following composition and size distribution: about 68 weight percent of macrocrystalline tungsten carbide having a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers); 15 weight percent 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 nickel type 123, from the International Nickel Company, and is the only (special) spiky powder of the correct form. Chemical analysis and physical characteristics available from commercial literature reveal the following: chemical analysis shows the composition of: maximum 0.1 carbon, maximum 0.15 oxygen, maximum 0.001 sulfur, maximum 0.01 iron; and the rest is nickel. The average particle size is 3 - 7 micrometers (the size of the holes of the "fishing sieve"), bulk density 1.8 - 2.7 gram / cm ³ and the specific surface area is 0.34 - 0.44 m ² / g.

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROEIL 53 impregnating material and heated to approximately 1478 ^° K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

 Comparative sample B contains a powder matrix mixture having the following composition and size distribution: 67.0 weight percent of crushed tungsten carbide cast having the following particle size distribution: from 18 to 22.0 weight percent of crushed tungsten carbide particles have a size of 80 + 120 mesh. (more than 125 micrometers and less than or equal to 177 micrometers), from 25.0 to 30.0 weight percent of particles of crushed cast tungsten carbide have a size of 120 + 170 mesh. (more than 88 micrometers and less than or equal to 125 micrometers), from 29.0 weight percent to 33.0 weight percent of particles of crushed cast tungsten carbide have a size of 170 + 230 mesh. (more than 63 micrometers and less than or equal to 88 micrometers), from 18.0 weight percent to 22.0 weight percent of particles of crushed cast tungsten carbide have a size of 230 + 325 mesh. (more than 44 micrometers and less than or equal to 63 micrometers), and up to 5.0 weight percent particles of crushed cast tungsten carbide have a size of 325 mesh. (less than or equal to 44 micrometers). The component further has 31.0 weight percent particles of crushed cast tungsten carbide having a size of 325 mesh. (less than or equal to 44 micrometers), 1.0 weight percent of iron particles having a size of 325 mesh. (less than or equal to 44 micrometers), and 1.0 weight percent of the particles of steel 4600, having a size of 325 mesh. (less than or equal to 44 micrometers).

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Comparative sample D contains a powder matrix mixture having the following composition and size distribution: about 64 weight percent of macrocrystalline tungsten carbide having a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers); 14 weight percent macrocrystalline tungsten carbide having a size of 325 mesh. (less than or equal to 44 micrometers); 14 weight percent 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 nickel type 123, from the International Nickel Company, and is the only (special) spiky powder of the correct form. Chemical analysis and physical characteristics available from commercial literature reveal the following: chemical analysis shows the composition of: maximum 0.1 carbon, maximum 0.15 oxygen, maximum 0.001 sulfur, maximum 0.01 iron and the rest is nickel. The average particle size is 3 - 7 micrometers (the size of the holes of the "fishing sieve"), bulk density 1.8 - 2.7 gram / cm ³ and the specific surface area is 0.34 - 0.44 m ² / g.

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Authentic samples
The following authentic samples of the present invention were made and tested, and test results are also presented below.

Sample N 1
Sample No. 1 contains a powder matrix mixture having the following composition and size distribution: 100 weight percent of particles of crushed sintered cemented macrocrystalline tungsten carbide having a particle size of 140 + 325 mesh. (more than 44 micrometers and less than or equal to 105 micrometers). The composition of cemented macrocrystalline tungsten carbide contains 13 weight percent cobalt and 87 weight percent macrocrystalline tungsten carbide, in which macrocrystalline tungsten carbide has an average particle size of between about 5 micrometers and 25 micrometers.

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 2
Sample No. 2 contains a powder matrix mixture containing the following: 100 weight percent of particles of crushed sintered cemented macrocrystalline tungsten carbide having a size of 140 + 270 mesh. (more than 63 micrometers and less than or equal to 105 micrometers). The composition of cemented macrocrystalline tungsten carbide contains 6 weight percent cobalt and 94 weight percent macrocrystalline tungsten carbide, in which tungsten carbide has an average particle size of between about 5 micrometers and 25 micrometers.

The impregnating material was MACROFIL 53. The composition of MACROFIL 53 was previously determined. This powder mixture was placed in the mold with the MACROFIL 53 impregnating material, and heated to approximately 1478 ^° K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 3
Sample No. 3 contains a powder matrix mixture having the following composition and particle size distribution:
(a) about 50.25 weight percent of the mixture are macrocrystalline tungsten carbide particles, with a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers); and
(b) about 25.00 weight percent of the mixture consists of particles of crushed sintered cemented macrocrystalline tungsten carbide with a particle size of 120 mesh. (less than or equal to 125 micrometers); and having the following composition: approximately 6 weight percent cobalt, maximum 1.0 weight percent iron, maximum 1.0 weight percent tantalum, maximum 1.0 weight percent titanium, maximum 0.5 weight percent niobium, maximum 0.5 weight percent other impurities, and the rest is macrocrystalline tungsten carbide having an average particle size between about 5 micrometers and 25 micrometers; and
(c) approximately 23.25 weight percent of the mixture is cast tungsten carbide having a particle size of 270 mesh. (less than or equal to 53 micrometers) with fine particles removed;
(g) approximately 0.75 weight percent of the mixture is grade 4600 steel having a particle size of 325 mesh. (less than or equal to 44 micrometers); and
(d) approximately 0.75 weight percent of the mixture is iron having an average particle size of 3 to 5 micrometers.

This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 4
Sample N 4 contains a powder matrix mixture, which has the following composition and particle size distribution:
(a) about 33.50 weight percent of the mixture are particles of macrocrystalline tungsten carbide, with a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers);
(b) about 50.00 weight percent of the mixture are particles of crushed sintered cemented macrocrystalline tungsten carbide with a particle size of 120 mesh. (less than or equal to 125 micrometers); and having the following composition: approximately 6 weight percent cobalt, maximum 1.0 weight percent iron, maximum 1.0 weight percent tantalum, maximum 1.0 weight percent titanium, maximum 0.5 weight percent niobium, maximum 0.5 weight percent other impurities, and the rest is macrocrystalline tungsten carbide having an average particle size between about 5 micrometers and 25 micrometers; and
(c) approximately 15.50 weight percent of the mixture is cast tungsten carbide having a particle size of 270 mesh. (less than or equal to 53 micrometers) with fine particles removed;
(g) approximately 0.50 weight percent of the mixture is grade 4600 steel having a particle size of 325 mesh. (less than or equal to 44 micrometers); and
(d) approximately 0.50 weight percent of the mixture is iron having an average particle size of 3 to 5 micrometers.

This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 5
Sample No. 5 contains a powder matrix mixture, which has the following composition and particle size distribution:
(a) about 16.75 weight percent of the mixture are particles of macrocrystalline tungsten carbide, with a particle size of 80 + 325 mesh. (more than 44 micrometers and less than or equal to 177 micrometers);
(b) about 75.00 weight percent of the mixture are crushed sintered cemented macrocrystalline tungsten carbide particles with a particle size of 120 mesh. (less than or equal to 125 micrometers); and having the following composition: approximately 6 weight percent cobalt, maximum 1.0 weight percent iron, maximum 1.0 weight percent tantalum, maximum 1.0 weight percent titanium, maximum 0.5 weight percent niobium, maximum 0.5 weight percent other impurities, and the rest is macrocrystalline tungsten carbide having an average particle size between about 5 micrometers and 25 micrometers; and
(c) approximately 7.75 weight percent of the mixture is cast tungsten carbide having a particle size of 270 mesh. (less than or equal to 53 micrometers) with fine particles removed;
(g) approximately 0.25 weight percent of the mixture is grade 4600 steel having a particle size of 325 mesh. (less than or equal to 44 micrometers); and
(d) approximately 0.25 weight percent of the mixture is iron having an average particle size of 3 to 5 micrometers.

This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 6
Sample No. 6 contains a powder matrix mixture, which has the following composition and particle size distribution:
(a) about 100 weight percent of the mixture are crushed sintered cemented macrocrystalline tungsten carbide particles having a size of 120 mesh. (less than or equal to 125 micrometers) and having the following composition: about 6 weight percent cobalt, maximum 1.0 weight percent iron, maximum 1.0 weight percent tantalum, maximum 1.0 weight percent titanium, maximum 0.5 weight percent niobium, maximum 0.5 weight percent other impurities, and the rest macrocrystalline tungsten carbide having an average particle size of between about 5 micrometers and 25 micrometers.

This powder mixture was placed in the mold with the MACROFIL 53 impregnating material and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Sample N 7
Sample No. 7 contains a powder matrix 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 contains: 0.1 weight percent cemented macrocrystalline tungsten carbide having a particle size. - 80 + 120 mesh. (more than 125 micrometers and less than or equal to 177 micrometers); 11.4 weight percent cemented macrocrystalline tungsten carbide having a particle size of 120 + 170 mesh. (more than 88 micrometers and less than or equal to 125 micrometers); 41.1 weight percent of cemented macrocrystalline tungsten carbide having a particle size of 170 + 230 mesh. (more than 63 micrometers and less than or equal to 88 micrometers); 44.5 weight percent of cemented macrocrystalline tungsten carbide having a particle size of 230 + 325 mesh. (more than 44 micrometers and less than or equal to 63 micrometers); and 2.9 weight percent cemented macrocrystalline tungsten carbide having a particle size of 325 + 400 mesh. (more than 37 micrometers and less than or equal to 44 micrometers).

This powder mixture was placed in the mold with the MACROFIL 53 impregnating material, and heated to approximately 1478 K (2200 ^° F, 1204 ^° C) until the impregnating material sufficiently impregnated the powder mass so as to bind it together. Then the mass was allowed to cool.

Samples N 8 and N 9
Samples N 8 and N 9 are the same as sample N 7.

To form cemented macrocrystalline tungsten carbide for samples N 7 through NS, macrocrystalline tungsten carbide was mixed with 10 weight percent nickel, the powder mixture was sintered for one hour at a temperature of 1644 K (1371 ^° C (2500 ^° F)). The sintered material was then crushed into particles with the sizes defined in examples 7 through 9.

Test results
Impact tests (impact resistance, impact strength) were carried out in accordance with the procedure using an impact machine (impact strength). The machine had a hammer, which, when dropped, created an impact force of the load on the control sample (test copy). To calculate the impact resistance, the load required to break the specimen and the time required to break the specimen were used. This test was carried out using a tower of a falling hammer equipped with a sword (hammer hammer). This test is a three-point bending test with a high degree of deformation, which measures the amount of energy required to break a pin of a sample with a diameter of half an inch (1.27 cm).

 Tensile strength tests were carried out in accordance with the procedure in which a cylindrical pin of impregnated material was placed in a clamp mount. Then a load was applied to the pin until it collapsed. Then, the tensile strength was calculated based on the actual load and size of the pin sample.

 Hardness tests were carried out in accordance with ASTM (American Society for Testing Materials) standard B347-85.

 The results of tests for impact resistance, transverse tensile strength and hardness are carried out further for six samples and three comparative samples.

Sample N 1
Shock Resistance - 6.41 J (4.728 ft-lbs)
Tensile strength - 9765 kg / cm ² , 957338 KPa, (136 thousand pounds / sq. Inch)
Rockwell Hardness C - 29.2
Sample N 2
Shock Resistance - 9.21 J (6.792 ft-lbs)
Tensile strength - 13211 kg / cm ² , 1.26 • 10 ⁶ KPa, (184 thousand pounds / sq. Inch)
Rockwell Hardness C - 44.8
Sample N 3
Shock Resistance - 4.77 J (3.516 ft-lbs)
Tensile strength - 7539 kg / cm ² , 739117 KPa, (105 thousand pounds / sq. Inch)
Rockwell Hardness C - 33.6
Sample N 4
Shock Resistance - 6.53 J (4.819 ft-lbs)
Tensile strength - 9405 kg / cm ² , 922240 KPa, (131 thousand pounds / sq. Inch)
Rockwell Hardness C - 42.2
Sample N 5
Shock Resistance - 7.08 J (5.222 ft-lbs)
Tensile strength - 10985 kg / cm ² , 1.08 • 10 ⁶ KPa, (153 thousand pounds / sq. Inch)
Rockwell Hardness C - 44.3
Sample N 6
Shock Resistance - 11.33 J (8.356 ft-lbs)
Tensile strength - 11631 kg / cm ² , 1.14 • 10 ⁶ KPa, (162 thousand pounds / sq. Inch)
Rockwell C hardness - 42.5
Sample N 7
Shock Resistance - 12.54 J (9.249 ft-lbs)
Tensile strength - 15508 kg / cm ² , 1.52 • 10 ⁶ KPa, (216 thousand pounds / sq. Inch)
Rockwell Hardness C - 41.7
Sample N 8
Shock - 10.73 J (7.912 ft-lbs)
Tensile strength - 14503 kg / cm ² , 1.42 • 10 ⁶ KPa, (202 thousand pounds / sq. Inch)
Rockwell Hardness C - 35.4
Sample N 9
Shock - 10.06 J (7.421 ft-lbs)
Tensile strength - 13713 kg / cm ² , 1.34 • 10 ² KPa, (191 thousand pounds / sq. Inch)
Rockwell Hardness C - 36.3
Sample A
Shock Resistance - 3.7 J (2.730 ft-lbs)
Tensile strength - 8329 kg / cm ² , 816640 KPa, (116 thousand pounds / square inch)
Rockwell Hardness C - 38.3
Sample B
Shock Resistance - 4.2 J (3.094 lb-ft)
Tensile strength - 8185 kg / cm ² 802550 KPa, 114 thousand pounds / sq. Inch)
Rockwell Hardness C - 31.5
Sample B
Shock Resistance - 3.34 J (2.466 ft-lbs)
Tensile strength - 6893 kg / cm ² , 675840 KPa, (96 thousand pounds / sq. Inch)
Rockwell Hardness C - 38.7
Sample D
Impact Resistance (------- (----- foot pounds)
Tensile strength - 9190 kg / cm ² , 901120 KPa, (128 thousand pounds / sq. Inch)
Rockwell Hardness C - ----
The abrasion test was performed in accordance with the Riley-Stoker method (ASTM Standard B611) using a 26 kg counterweight. These results are presented below;
Sample - Weight Loss (Top / Bottom)
Sample N 1 - 426.5 / 373.9
Sample N 2 - 373.3 / 298.2
Sample N 3 - 427.6 / 423.5
Sample N 4 - 394.4 / 387.4
Sample N 5 - 382.7 / 375.1
Sample N 6 - 339.8 / 374.0
Sample N 7 - 344.8 / -
Sample N 8 - 350.4 / 257.2
Sample N 9 - 357.4 / 331.7
Sample A - 439.9 / 443.5
Sample B - 472.1 / 466.4
Sample B - 322.3 / 329.0
Sample D - 419.4 / 406.5
^* disk (coins)
The units for measuring weight loss are grams at fifty wheel revolutions.

For the erosion resistance test procedure, the test consisted in exposing disks made of matrix material to high pressure water flow along with abrasive sand for a certain time. The test parameters were set as follows:
Water pressure 7.0 • 10 ³ kPa (1000 psi).

 The size of small grains of sand is 50-70 (fine) ASTM.

 The nozzle size is # 4-15 degrees.

 Test duration 1 minute.

 The angle of incidence (collision) is 20 degrees.

 The test setup consisted of a large high-pressure water pump, a sand barrel, a nozzle (nozzle) of the feed system with a trigger and hoses to connect it all together. The procedure used for the test was to weigh the disc, place it in the sandblast mount, and sandblast the disc for one minute, then weigh it again to measure erosion losses. The device used to weigh the disk was Mettler's scales with an accuracy of = 0.002 grams. The disc was cleaned and dried before each weighing. Two tests were performed on each side of the disc.

 The flow rates (flow rate) of water and sand were also controlled. The average water flow throughout the test was approximately 0.126 kg / s (0.126 l / s, 2 gallons per minute). The average sand flow rate throughout the test was approximately 4.9 g / s (0.65 lbs / min), with some notable increase over the course of the test. The accuracy of the sand flow measurement was approximately ± 0.38 g / s (± 0.05 pounds / minute). This test procedure is in accordance with ASTM G76, except that it uses a liquid stream instead of a gas stream.

 These test results were normalized to account for changes (variations) in the sand flow. Weight loss is expressed in grams.

Sample - Weight Loss (Top / Niv.)
Sample N 1 - 0.25 / 0.19
Sample N 2 - 0.16 / 0.13
Sample N 3 - 0.12 / 0.13
Sample N 4 - 0.13 / 0.10
Sample N 5 - 0.11 / 0.13
Sample N 6 - 0.10 / 0.03
Sample N 7 - ----
Sample N 8 - 0.05 / 0.04
Sample N 9 - ----
Sample A - 0.42 / 0.37
Sample B - 0.38 / 0.37
Sample B - 0.17 / 0.17
Sample D - 0.12 / 0.09
^* disk
Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the detailed description or application of the invention disclosed herein. It is understood that the detailed description and examples of the invention should be considered only as illustrated, while the true capabilities (scope) and essence of the invention are indicated by the following claims.

Claims (17)

 1. The matrix powder for molding together with the impregnating material into a matrix containing particles of crushed sintered cemented tungsten carbide, in which the binder metal is cobalt, characterized in that it contains a powder mixture having the following composition and particle size distribution: a) up to 50 weight .% powder of tungsten carbide with a particle size greater than 44 microns and less than or equal to 177 microns, b) up to 75 wt.% particles of crushed sintered cemented tungsten carbide with a particle size less than or equal to 177 microns, containing of about 6 wt.% cobalt, a maximum of 1.0 wt.% iron, a maximum of 1.0 wt.% tantalum, a maximum of 0.5 wt.% niobium, a maximum of 0.5 wt. % of other impurities and the rest is tungsten carbide having an average particle size of from about 5 to 25 microns, c) up to 24 wt.% cast tungsten carbide having an average particle size of less than or equal to 53 microns, g) from about 0.5 to 1 5 wt.% Predominantly iron having an average particle size of from about 3 to 5 microns.  2. The matrix powder according to claim 1, characterized in that the iron component contains from about 0.25 to 0.75 wt.% Steel grade 4600 with a particle size less than or equal to 44 microns and from about 0.25 to 0.75 weight .% iron having a particle size of from about 3 to 5 microns.  3. The matrix powder according to claim 1, characterized in that the powder mixture contains approximately 50 wt.% Particles of tungsten carbide and approximately 25 wt.% Crushed sintered cemented tungsten carbide.  4. The matrix powder according to claim 1, characterized in that the powder mixture contains approximately 34 wt.% Tungsten carbide and approximately 50 wt.% Crushed sintered cemented tungsten carbide.  5. The matrix powder according to claim 1, characterized in that the powder mixture contains approximately 17 wt.% Tungsten carbide and approximately 75 wt.% Crushed cemented tungsten carbide.  6. The matrix powder for molding together with the impregnating material into a matrix containing particles of crushed sintered cemented tungsten carbide, in which the binder metal is nickel, characterized in that it contains a powder mixture having the following composition and particle size distribution: a) up to 50 weight .% powder of tungsten carbide with a particle size greater than 44 microns and less than or equal to 177 microns, b) up to 75 wt.% particles of crushed sintered cemented tungsten carbide with a particle size less than or equal to 177 microns, containing of about 6 wt.% nickel, up to 1 wt.% iron, a maximum of 1.0 wt.% tantalum, a maximum of 1.0 wt.% titanium, a maximum of 0.5 wt. % niobium, maximum 0.5 weight. % of other impurities and the rest is tungsten carbide having an average particle size of from about 5 to 25 microns, c) up to 24 wt.% cast tungsten carbide having an average particle size of less than or equal to 53 microns, g) from about 0.5 to 1 5 wt.% Predominantly iron having an average particle size of from about 3 to 5 microns.  7. The matrix powder according to claim 6, characterized in that the iron component contains from about 0.25 to 0.75 wt.% Steel grade 4600, having a particle size less than or equal to 44 microns and from about 0.25 to 0.75 weight. % iron having a particle size of from about 3 to 5 microns.  8. The matrix powder according to claim 6, characterized in that the powder mixture contains about 50 wt.% Particles of tungsten carbide and about 25 wt.% Particles of crushed sintered cemented tungsten carbide.  9. The matrix powder according to claim 6, characterized in that the powder mixture contains approximately 34 wt.% Particles of tungsten carbide and approximately 50 wt.% Particles of crushed sintered cemented tungsten carbide.  10. The matrix powder according to claim 6, characterized in that the powder mixture contains approximately 17 wt.% Particles of tungsten carbide and approximately 75 wt.% Particles of crushed sintered cemented tungsten carbide.  11. The diamond composite structural element containing the support and attached to the support diamond composite compound containing a matrix, characterized in that the matrix is formed by heating the powder mixture in the presence of an impregnating material, while the powder mixture contains particles of crushed sintered cemented tungsten carbide having a size greater than 37 microns and less than or equal to 177 microns, and containing from about 5 to 20 wt.% a binder metal and from about 80 to 95 weight. % tungsten carbide.  12. The diamond composite structural element according to claim 11, characterized in that the powder contains approximately 100 wt.% Particles of crushed sintered cemented tungsten carbide with a particle size greater than 44 microns and less than or equal to 177 microns.  13. The diamond composite structural member of claim 12, wherein the binder metal is cobalt.  14. The diamond composite structural member of claim 12, wherein the binder metal is nickel.  15. The diamond composite structural element according to claim 11, characterized in that the particles of crushed sintered cemented tungsten carbide contain particles of crushed sintered cemented macrocrystalline tungsten carbide.  16. The diamond component of construction according to claim 11, characterized in that the impregnating material contains from about 50 to 70 wt.% Copper, from about 10 to 20 wt.% Nickel, and from about 15 to 25 wt.% Zinc.  17. The diamond component of construction according to claim 11, characterized in that the impregnating material contains from about 45 to 60 wt.% Copper, from about 10 to 20 wt.% Nickel, from about 4 to 12 wt.% Manganese, boron and silicon. Priority on points:
02/01/95 - according to claims 1 - 5, 11 - 13 and 15 - 17;
12/18/95 - according to paragraphs 6 - 10 and 14.

Images