Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
  • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
  • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
  • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/02—Compacting only
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/10—Sintering only
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
  • B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
  • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B22F1/17—Metallic particles coated with metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F2005/002—Tools other than cutting tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/20—Refractory metals
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
  • B22F2302/20—Nitride
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/003—Apparatus, e.g. furnaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/02—Compacting only
  • B22F3/093—Compacting only using vibrations or friction
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/12—Both compacting and sintering
  • B22F3/14—Both compacting and sintering simultaneously
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/18—Sheet panels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/18—Dissimilar materials
  • B23K2103/24—Ferrous alloys and titanium or alloys thereof

Definitions

• Friction stir processing (“FSP”) of metals has been used to attach weldable materials to one another in a solid state joining process.
• FSP uses the motion of a pin pressed against the surface of a weldable material to generate heat and friction to move the weldable material.
• the material can plasticize and physically stir together with a second material to which the first material is joined.
• a pin, a pin and shoulder, or another“FSP tool” may be rotated in contact with a workpiece.
• a force is applied to the FSP tip to urge the FSP tool against the workpiece.
• the FSP tool is moved along the workpiece to stir the material of the workpiece.
• the physical process of mixing material from two plates joins the plates.
• FSP joins weldable materials in a solid-state process that avoids many of the potential defects of other welding processes. For example, FSP produces a stirred region along the path of the tool that is generally indistinguishable from the original material. FSP may be performed without the inclusion of an additional material or use of shield gasses. Some welding methods, such as metal-inert gas (“MIG”) welding, may introduce an additional material to create a bond. Other welding methods, such as tungsten-inert gas (“TIG”) welding, may use a non-consumable contact point to heat one or more workpieces. However, the heating may cause the one or more workpieces to attain a liquid phase and risk a phase change in the one or more workpieces. A phase change may compromise the integrity of the bond and, potentially, the workpiece, itself. To limit the possibility of a phase change or other reaction, TIG welding and similar processes utilize an inert gas“shield” around the contact area.
• MIG metal-inert gas
• TIG tungsten-inert gas
• FSP may, therefore, provide more controllable bonds in various applications.
• the predictability of FSP may be desirable during the manufacturing and/or assembly of structures or devices that experience high forces during use in environments or applications in which the structure or device may be inaccessible by operators.
• the elevated temperatures involved with FSP may allow the reaction of the FSP tool and the workpiece material.
• cubic boron nitride may react with titanium workpieces to form titanium nitride phases at the FSP zone, consuming the FSP tool in the process.
• diamond may react with ferrous workpieces to form iron carbide phase and consume the diamond FSP tool.
• cubic boron nitride, diamond, and other ultrahard materials are reactive at elevated temperatures, other materials may be beneficial for FSP at high temperatures.
• a friction stir processing (FSP) tool includes a working material.
• the working material has a matrix phase and a particulate phase.
• the matrix phase includes tungsten and an alloy material.
• the particulate phase is located within the matrix phase, and the particulate phase has an indentation hardness less than 45 Gigapascals (GPa).
• a FSP tool includes a working material.
• the working material has a matrix phase and a particulate phase.
• the matrix phase includes a tungsten-rhenium alloy.
• the particulate phase is located within the matrix phase, and the particulate phase has an indentation hardness less than 45 GPa.
• a method of manufacturing a FSP tool includes mixing a particulate precursor with a tungsten precursor and an alloy precursor to form a mixture and sintering the mixture at a sintering temperature greater than 1000 °C and a high pressure greater than 2.0 GPa.
• the particulate precursor includes particles having an indentation hardness less than 45 GPa.
• the method further includes alloying the tungsten precursor and alloy precursor to form a matrix phase including a tungsten alloy and embedding the particulate precursor as a particulate phase in the matrix phase.
• FIG. 1 is a perspective view of a friction stir processing (FSP) system, according to some embodiments of the present disclosure
• FIG. 2-1 is a side cross-sectional view of a multi-piece FSP tool, according to some embodiments of the present disclosure
• FIG. 2-2 is a side cross-sectional view of a monolithic FSP tool, according to some embodiments of the present disclosure
• FIG. 3 is a schematic representation of a microstructure of a working material, according to some embodiments of the present disclosure
• FIG. 4 is a flowchart illustrating a method of manufacturing an FSP tool, according to some embodiments of the present disclosure
• FIG. 5 is a side cross-sectional view of a working material precursor in a can, according to some embodiments of the present disclosure
• FIG. 6-1 is a schematic representation of a microstructure of a working material precursor, according to some embodiments of the present disclosure
• FIG. 6-2 is a schematic representation of a microstructure of another working material precursor, according to some embodiments of the present disclosure.
• FIG. 7 is a side cross-sectional view of applying a compressive force to a working material precursor in a can, according to some embodiments of the present disclosure.
• FIG. 8 is a perspective view of a working material blank, according to some embodiments of the present disclosure.
• This disclosure generally relates to devices, systems, and methods for increasing the wear resistance of a friction stir processing (FSP) tool for friction stir welding, joining, processing, or other friction stirring procedures. More specifically, embodiments of this disclosure relate to the design, manufacture, and use of low-cost FSP tools that may friction stir process a workpiece including ferrous and/or titanium-bearing metals and metal alloys without reaction to the workpiece.
• FSP friction stir processing
• a FSP tool includes a working surface that includes a working material of embedded particles in a tungsten alloy matrix.
• the working surface of the FSP tool may include at least a portion of a shoulder and/or a pin of the FSP tool.
• the working material may include a tungsten alloy matrix that supports a plurality of particles with an indentation hardness greater than that of the tungsten matrix and with a hardness less than 45 GPa. Such materials may be sufficiently hard to allow the FSP of high melting temperature metals and alloys without reacting with the alloys.
• materials with an indentation hardness greater than 45 GPa including cubic boron nitride and polycrystalline diamond may react with many common high melting temperature alloys, such as titanium alloys and ferrous alloys, while having a cost above embodiments of FSP tools described herein.
• FIG. 1 illustrates an embodiment of a FSP system 100 with a FSP tool 102 in contact with a first workpiece 104-1 and a second workpiece 104-2.
• Rotation of the FSP tool 102 in contact with the workpieces 104-1, 104-2 may be used to friction stir the workpieces 104-1, 104- 2 in a stirred zone 106 and create a heat affected zone 108 beyond the stirred zone 106.
• FSP includes friction stir welding a first workpiece to a second workpiece.
• the first workpiece 104-1 may be positioned contacting the second workpiece 104-2 in a butt joint 110, and the first workpiece 104-1 and second workpiece 104-2 may be joined along the butt joint 110 by FSP.
• the FSP tool 102 may flow first workpiece material and second workpiece material in a circular path and perpendicular to the butt joint 110 in the stirred zone 106 to transfer material between the first workpiece 104-1 and second workpiece 104-2, mechanically joining the first workpiece 104-1 and second workpiece 104-2 along the butt joint 110.
• Stir welding is a solid state joining process that plastically moves material of the first workpiece 104-1 and second workpiece 104-2 to interlock the first workpiece 104-1 and second workpiece 104-2 at a microstructural level.
• the first workpiece 104-1 and second workpiece 104-2 are the same material.
• the first workpiece 104-1 and the second workpiece 104-2 may be both a ferrous alloy.
• the first workpiece 104-1 and second workpiece 104-2 are different materials.
• the first workpiece 104- 1 may be a ferrous alloy
• the second workpiece 104-2 may be a titanium alloy.
• FSP includes the stirring of a workpiece 104-1, 104-2 to refine the grain structure in the stirred zone 106 and/or the heat affected zone 108 of the workpiece material.
• the crystalline structure of the workpiece material may be at least partially dependent on the manufacturing of the workpiece.
• the as-manufactured grain structure may be undesirable for a finished part.
• a cast workpiece has a random orientation (i.e., little or no texture) with a relatively large grain size with little to no deformation within each grain.
• FSP of the cast aluminum may refine the grain size to produce a smaller average grain size (increasing the boundary density of the microstructure).
• FSP of the cast aluminum may further produce internal strain within the grains. Increases in one or both of the grain boundary density and the internal strain may increase the hardness of the aluminum.
• an extruded or rolled workpiece exhibits an orientation to the grain structure (e.g., a ⁇ 101> texture or a ⁇ 00l> texture, respectively in aluminum) that is undesirable in the finished part.
• an extruded texture in an aluminum rod may increase the mechanical wear rate of the aluminum when used as an axle.
• FSP of the aluminum may mechanically alter the grain structure of the aluminum rod and/or remove the extruded texture of the rod surface.
• Orientation textures may affect other mechanical or chemical properties of the workpiece, such as anisotropic hardness or toughness, or oxidation rates.
• stir welding by FSP includes friction stirring of a first workpiece and a second workpiece adjacent one another in a lap joint with the first workpiece 104-1 overlapping a surface of the second workpiece 104-2.
• the FSP tool 102 may be positioned to contact a surface of the first workpiece 104-1 and the FSP tool 102 may be plunged into the first workpiece 104-1 and, optionally, the second workpiece 104-2 to plastically move first workpiece material and second workpiece material to interlock the first workpiece 104-1 and the second workpiece 104-2 at the lap joint.
• FIG. 2-1 is a side cross-sectional view of an embodiment of a FSP tool 202, according to the present disclosure.
• the FSP tool 202 has a single-body construction.
• the FSP tool 202 has a multi-piece construction.
• the FSP tool 202 of FIG. 2-1 has a pin 212, a shoulder 214, and a shank 216, with each being integrally formed with one another.
• the FSP tool 202 may be formed in a HPHT press in a single press cycle to form the entire pin 212, shoulder 214, and a portion of the shank 216 (see FIG. 2-1) or a full portion of the shank (see FIG. 2-2).
• the FSP tool 202 may be formed in a press at temperature greater than 1,000 °C and pressures greater than 2.0 GPa.
• the working surface 220 includes a working material 222.
• the pin 212, shoulder 214, and at least a portion of the shank 216 include or are formed of the same working material 222.
• the second material 224 includes a carbide material, such as tungsten carbide, titanium carbide, or tantalum carbide.
• the second material 224 is a dual phase material with a metal matrix to provide additional toughness to the shank 216.
• FIG. 2-2 is a cross-sectional view of an embodiment of a single body FSP tool 302 with a monolithic construction.
• the FSP tool is formed entirely of the working material 322.
• the FSP tool 302 includes a pin 312, a shoulder 314, and a shank 316 formed from or formed of a single monolithic piece of working material 322.
• a monolithic construction may be substantially uniform through the FSP tool 302.
• the FSP tool 302 has a continuous or step-wise gradient composition of the working material 322.
• FIG. 3 is a detail view of a cross-section of an embodiment of working material 422.
• the working material 422 has a composition including a particulate phase 426 and a matrix phase 428.
• the particulate phase 426 forms a percentage of the total volume of the working material 422 in a range having an upper value, a lower value, or upper and lower values including any of 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99%, or any values therebetween.
• the particulate phase 426 may be greater than 50% of the total volume of the working material 422.
• the particulate phase 426 is less than 99% of the total volume of the working material 422.
• the particulate phase 426 is between 50% and 99% of the total volume of the working material 422.
• the particulate phase 426 is between 60% and 90% of the total volume of the working material 422.
• the matrix phase 428 is the balance of the total volume of the working material 422.
• the working material 422 may be a dual phase material with no porosity, and the particulate phase 426 and the matrix phase 428 may be the sole constituent parts of the working material 422.
• the working material 422 includes at least some porosity.
• the working material 422 may have a porosity less than 5%.
• the working material 422 has a porosity less than 3%.
• the working material 422 has a porosity less than 1%.
• the working material 422 has effectively no porosity.
• the matrix phase 428 and one or more tertiary phases are the balance of the total volume.
• the working material 422 may include a precipitate phase or a residual phase from a sintering aid.
• a precipitate phase includes an oxide phase.
• a precipitate phase includes a carbide phase.
• a residual phase includes an aluminum bearing phase.
• the working material 422 includes an aluminum oxide (AI2O3) phase formed during oxidation of an aluminum sintering aid.
• the particulate phase 426 includes one or more of a variety of materials with an indentation hardness (IH) value below 45 GPa and greater than the indentation hardness of the matrix phase 426.
• the particulate phase 426 may be partially titanium nitride and partially titanium carbon nitride.
• the particulate phase 426 is partially titanium nitride, partially titanium carbon nitride, and partially tungsten boride. In at least one example, the particulate phase 426 is entirely titanium nitride, entirely titanium carbon nitride, or entirely tungsten boride
• the matrix phase 428 is a tungsten alloy.
• the tungsten alloy may have a tungsten weight percentage (wt%) in a range having an upper value, a lower value, or upper and lower values including any of 50wt%, 55wt%, 60wt%, 65wt%, 70wt%, 75wt%, 80wt%, 85wt%, 90wt%, 95wt%, 99wt%, or any values therebetween.
• the matrix phase 428 may be greater than 50wt% tungsten.
• the matrix phase 428 is less than 99wt% tungsten.
• the matrix phase 428 is between 50wt% and 99wt% tungsten.
• the matrix phase 428 is between 60wt% and 90wt% tungsten.
• the matrix phase 428 is at least 75wt% tungsten.
• the matrix phase 428 includes a tungsten rhenium alloy.
• the matrix phase 428 is 50wt% tungsten and 50wt% rhenium.
• the matrix phase 428 is 75wt% tungsten and 25wt% rhenium.
• the matrix phase 428 is 90wt% tungsten and l0wt% rhenium.
• the matrix phase 428 is a tungsten lanthanide alloy.
• the matrix phase 428 may be 99wt% tungsten and lwt% lanthanum.
• FIG. 4 is a flowchart illustrating an embodiment of a method 530 of manufacturing a FSP tool according to the present disclosure.
• the method 530 includes mixing a particulate precursor, a tungsten precursor, and an alloy precursor into a mixture at 532.
• the alloy material includes rhenium.
• the alloy material includes lanthanum.
• the method 530 optionally includes sintering the mixture at high pressure and high temperature at 534.
• the tungsten precursor and alloy precursor are provided in powder form and are combined to form the mixture prior to sintering. In other embodiments, the tungsten and alloy precursors are bonded to one another before sintering with the particulate precursor.
• the relative percentages of tungsten precursor and alloy precursor in the mixture can vary depending on the desired material properties. In some embodiments, the compound includes 25% or lower alloy precursor and 75% or higher tungsten precursor by volume.
• the method 530 further includes alloying the tungsten precursor and the alloy precursor together at the high pressure and high temperature conditions at 536. Alloying the tungsten precursor and the alloy precursor together at the high pressure and high temperature conditions may create a unique matrix material with lower porosity and higher hardness than a tungsten alloy sintered at lower temperature and pressure, even with the same elemental composition.
• the particulate precursor may be embedded in the matrix as the particulate phase at 538.
• the particulate phase is mechanically held in place by the surrounding or partially surrounding matrix phase.
• the particulate phase and matrix phase at least partially form a microstructural bond that includes a plurality of chemical bonds between the matrix phase and the particulate phase.
• FIG. 5 through FIG. 8 illustrate embodiments according to the method described herein.
• FIG. 5 is a schematic, side cross-sectional view of an embodiment of a mixture 640 in an enclosure, known as a“can” 642.
• the can 642 with the mixture 640 may be placed in a press and subjected to high pressure and high temperature conditions.
• the can 642 is optionally formed from niobium or molybdenum and transfers the heat and pressure from the press to the mixture 640 contained in the can 642.
• the elevated pressure and temperature conditions are maintained for a time sufficient to sinter the materials (and may include cycles of varying temperature and/or pressure). After the sintering process, the enclosure and its contents are cooled and the pressure reduced to ambient conditions.
• FIG. 6-1 is a detail view of an embodiment of the mixture 640.
• the mixture 640 includes a particulate precursor 644, a tungsten precursor 646, and an alloy precursor 648 in any ratio by volume described herein.
• the mixture 640 is 50% particulate precursor 644, 37.5% tungsten precursor 646, and 12.5% alloy precursor 648 by volume, excluding the void space 650 in the mixture 640.
• the void space 650 is related to the porosity of the working material.
• the HPHT conditions of the sintering process may remove some or substantially all void space 650 from the mixture 640 and/or porosity from the working material.
• the volume of each precursor material is measured before the particulate precursor 644, tungsten precursor 646, and alloy precursor 648 are homogenously combined to form the mixture 640. In other embodiments, the tungsten precursor 646 and alloy precursor 648 are bonded before mixing with the particulate precursor 644.
• FIG. 6-2 is a detail view of an example embodiment of a mixture 740 with the tungsten precursor 746 and alloy precursor 748 bonded before mixing with the particulate precursor 744.
• the tungsten precursor 746 may be coated with or attached to the alloy precursor 748 to create a powder of combined matrix precursor material including both the tungsten precursor 746 and alloy precursor 748.
• a rhenium coating may be applied to tungsten powder to form the matrix precursor that, when sintered at HPHT conditions, forms the matrix material 740.
• the tungsten precursor 746 coats the alloy precursor 748.
• the mixture 740 includes a sintering aid 752.
• an additional constituent may be added to the mixture 740 to promote sintering and promote bonding of the matrix phase, the particulate phase, or the matrix phase and particulate phase.
• the sintering aid 752 reduces or prevents the formation of oxides or carbides with the materials in the particulate phase and/or matrix phase.
• the sintering aid 752 may include a material, such as aluminum, that favorably oxidizes in the presence of oxygen in the atmosphere, consuming the oxygen and limiting formation of oxides of the materials of the particulate phase and/or matrix phase.
• FIG. 7 schematically illustrates an embodiment of the mixture 740 in a can 742 under HPHT conditions.
• the sintering process is conducted at elevated pressure 754 and temperature.
• the temperature is greater than 1,000 °C
• the pressure 754 is greater than 2.0 GPa.
• the mixture 740 is heated to a sintering temperature in a range having an upper value, a lower value, or upper and lower values including any of 1,000 °C, 1,500 °C, 2,000 °C, 2,300 °C, or any values there between.
• the sintering temperature may be greater than 1,000 °C. In other examples, the sintering temperature is less than 2,300 °C.
• the sintering temperature is between 1,000 °C and 2,300 °C. In further examples, the sintering temperature is between 1,200 °C and 2,200 °C. In at least one example, the sintering temperature is greater than 1,500 °C.
• the pressure 754 is in a range having an upper value, a lower value, or upper and lower values including any of 2.0 GPa, 3.5 GPa, 5.0 GPa, 6.5 GPa, or any values therebetween.
• the pressure 754 may be greater than 2.0 GPa.
• the pressure 754 is less than 6.5 GPa.
• the pressure 754 is between 2.0 GPa and 6.5 GPa.
• the pressure 754 is between 2.5 GPa and 6.0 GPa.
• the pressure 754 is greater than 3.0 GPa. Sintering at the HPHT conditions may remove some or substantially all of the void space of the mixture and create the micro structure of the working material including the matrix phase and particulate phase with little to no porosity.
• the blank 756 includes working material 722 and is substantially cylindrical.
• the blank 756, also known as a puck, is then machined to the final dimensions of a FSP tool or a portion of a FSP tool, such as the FSP tools described in relation to FIGS. 2-1 and 2-2.
• a FSP tool according to the present disclosure reduces manufacturing costs and/or manufacturing time compared to other FSP tools, while increasing operational lifetime of the FSP tool.
• a FSP tool including a working material according to the present disclosure may be capable of friction stir welding, joining, or processing workpieces including ferrous alloys, titanium alloys, other alloys that would otherwise react with diamond tools, cBN tools, or combinations thereof.
• a FSP tool with titanium nitride particles embedded in a tungsten-rhenium alloy matrix friction stir welds, joins, or processes workpieces that would consume a similarly constructed tool with a PCD working surface or cBN working surface.
• references to“one embodiment” or“an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
• any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein, to the extent such features are not described as being mutually exclusive.
• Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are“about” or“approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure.
• any directions or reference frames in the preceding description are merely relative directions or movements.
• any references to“up” and“down” or “above” or“below” are merely descriptive of the relative position or movement of the related elements.

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• Organic Chemistry (AREA)
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• 2019
  • 2019-05-02 US US16/401,907 patent/US11440133B2/en active Active
  • 2019-05-03 JP JP2020561814A patent/JP7389756B2/ja active Active
  • 2019-05-03 WO PCT/US2019/030533 patent/WO2019213474A1/en not_active Ceased
  • 2019-05-03 EP EP19796432.3A patent/EP3787821A4/en not_active Withdrawn

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