# US 11,111,563 B2 · High strength and erosion resistant powder blends

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- Number: US 11,111,563 B2
- Document ID: US11111563B2
- Status: Granted
- Kind: B2
- Application number: 16/084,106
- Filed: 2018-09-10
- Published: 2020-02-27
- Granted: 2021-09-07
- Earliest claimed: 2017-10-19
- Assignees: Global Tungsten & Powders Corp.
- Applicants: Global Tungsten & Powders Corp.
- Inventors: Ravi K. Enneti; Kevin Prough; Keith Newman
- Web page: https://patentgrep.com/patent/US11111563B2

## CPC

- C22C 1/1084: {by mechanical alloying (blending, milling)}
- C22C 9/00: Alloys based on copper
- C22C 29/08: based on tungsten carbide
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B22F 2998/10: Processes characterised by the sequence of their steps
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER

## Abstract

Composites comprising various fractions of ultra coarse (UC) tungsten carbide (WC) and cast carbide (CC), along with composites comprising fractions of UC-WC and CC having various particle size and showing an improved strength and erosion resistance, and methods for making the inventive composites.

## Claims

### Claim 1

A method for preparing a composite comprising:
a) contacting about 40-70 wt % of a first fraction of ultra coarse tungsten carbide
with about 30-60 wt % a first fraction of cast carbide (CC) to form a blend, wherein the blend has a tap density of about 9-11.5 g/cm3;
b) tapping the blend for at least 5 cycles; and
c) infiltrating the tapped blend with a copper containing alloy, thereby forming the composite,
wherein the formed composite exhibits volume loss of at least 20% lower as compared to a conventional GM-6 metal powder when measured accordingly to ASTM G65 and ASTM G76.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first fraction of ultra-coarse tungsten carbide has a particle size from about 44 micrometers (325 mesh) to about 177 micrometers (80 mesh).

### Claim 3 (depends on 1)

The method of claim 1, wherein the first fraction of cast carbide has a particle size from 44 micrometers (325 mesh) to about 250 micrometers (60 mesh).

### Claim 4 (depends on 1)

The method of claim 1, wherein the first fraction of ultra-coarse tungsten carbide is present in an amount of about 60%.

### Claim 5 (depends on 4)

The method of claim 4, wherein the first fraction of cast carbide is present in an amount 40%.

### Claim 6 (depends on 4)

The method of claim 4, wherein the first fraction of ultra-coarse tungsten carbide has a particle size of at least about 44 micrometers (325 mesh).

### Claim 7 (depends on 4)

The method of claim 4, wherein the first fraction of cast carbide has a particle size of smaller than about 250 micrometers (60 mesh) but greater than about 125 micrometers (120 mesh).

### Claim 8 (depends on 1)

The method of claim 1, further comprising a step of mixing the blend with greater than 0 wt % to about 5 wt % of nickel prior to the step of infiltrating.

### Claim 9 (depends on 1)

The method of claim 1, further comprising a step of mixing the blend with greater than 0 wt % to about 5 wt % of iron prior to the step of infiltrating.

### Claim 10 (depends on 1)

The method of claim 1, further comprising a step of mixing the blend with one or more of: (a) from about 5 to about 25 wt % of a second fraction of ultra-coarse tungsten carbide having a particle size of greater than 63 micrometer (230 mesh) but smaller than 88 micrometer (170 mesh); (b) from about 5 to about 25 wt % of a third fraction of ultra-coarse tungsten carbide having a particle size of greater than 44 micrometer (325 mesh) but smaller than 63 micrometer (230 mesh); (c) from about 5 to about 25 wt % of a second fraction of cast carbide having a particle size of greater than 63 micrometer (230 mesh) but smaller than 88 micrometer (170 mesh); or d) from about 5 to about 25 wt % of a third fraction of cast carbide having a particle size of greater than 63 micrometer (230 mesh) but smaller than 125 micrometer (120 mesh) prior to the step of infiltrating.

### Claim 11 (depends on 1)

The method of claim 1, wherein the formed composite exhibits a Transverse Rupture Strength (TRS) of greater than 120 KSI.

### Claim 12 (depends on 1)

The method of claim 1, wherein the formed composite exhibits a volume loss under abrasion testing according to ASTM G65 of less than about 6 mm3.

### Claim 13 (depends on 1)

The method of claim 1, wherein the cast carbide has a plurality of particles having a microstructured surface.

### Claim 14 (depends on 1)

The method of claim 1, wherein the method comprises tapping the blend for at least 50 cycles.

### Claim 15 (depends on 14)

The method of claim 14, wherein the formed composite exhibits an average volume loss under abrasion testing according to ASTM G65 from 4.26 mm3 to 4.86 mm3.

### Claim 16 (depends on 14)

The method of claim 14, wherein the formed composite exhibits an average Transverse Rupture Strength (TRS) of from 133.6 KSI to 144.6 KSI.

### Claim 17 (depends on 14)

The method of claim 14, further comprising a step of mixing the blend with greater than 0 wt % to about 5 wt % of nickel prior to the step of infiltrating.

### Claim 18 (depends on 14)

The method of claim 14, further comprising a step of mixing the blend with greater than 0 wt % to about 5 wt % of iron prior to the step of infiltrating.