# US 2008/0187452 A1 · Method of Forming a Workpiece > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2008/0187452 A1 - Document ID: US20080187452A1 - Status: Published application - Kind: A1 - Application number: 12/099,038 - Filed: 2008-04-07 - Published: 2008-08-07 - Earliest claimed: 2006-08-11 - Inventors: David R. Hall; Gary Peterson - Web page: https://patentgrep.com/patent/US20080187452A1 ## CPC - B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} - B22F 3/1291: {Solid insert eliminated after consolidation} - B28D 1/188: {with exchangeable cutter bits or cutter segments} - E21C 35/183: with inserts or layers of wear-resisting material {(drill bits with wear-resistant parts E21B10/46)} - B22F 2998/00: Supplementary information concerning processes or compositions relating to powder metallurgy - B22F 2998/10: Processes characterised by the sequence of their steps - E21C 35/1837: {characterised by the shape} - 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 - B28D: WORKING STONE OR STONE-LIKE MATERIALS - E21C: MINING OR QUARRYING ## Abstract A method of forming a ceramic metal composite workpiece comprises a step of providing a forming assembly with first and second shaping surfaces that together form a chamber. The chamber is shaped substantially similar to a desired external geometry of a green body of the workpiece, and at least one of the surfaces comprises a pressing mechanism adapted to move the surface with respect to the other surface. The method also comprises placing into the chamber a malleable composite material and an insert comprising a shape substantially similar to a desired internal surface geometry of the green body. The method also comprises a step of pressing the malleable composite material to form the green body such that at least a portion of the malleable composite material flows around at least a portion of the insert to form the green body with the desired external and internal surface geometries. ## Claims ### Claim 1 A method of forming a ceramic metal composite workpiece, comprising the steps of: providing a forming assembly with first and second shaping surfaces together forming a chamber shaped substantially similar to a desired external geometry of a green body of the workpiece, and at least one of the surfaces comprising a pressing mechanism adapted to move the surface with respect to the other surface; placing a malleable composite material and an insert comprising a shape substantially similar to a desired internal surface geometry of the green body within the chamber; pressing the malleable composite material to form the green body such that at least a portion of the malleable composite material flows around at least a portion of the insert to form the green body with the desired external and internal surface geometries. ### Claim 2 (depends on 1) The method of claim 1, wherein the method comprises an additional step of sintering the green body. ### Claim 3 (depends on 2) The method of claim 2, wherein the step of sintering is done under pressure. ### Claim 4 (depends on 2) The method of claim 2, wherein the insert vaporizes and/or melts out of the green body during the step of sintering the green body. ### Claim 5 (depends on 2) The method of claim 2, wherein the method further comprises a step of brazing the sintered workpiece to an impact tip comprising a superhard material disposed on an impact surface of the tip. ### Claim 6 (depends on 1) The method of claim 1, wherein the step of pressing the malleable composite material comprises pressing the material with a pressure of at least 5000 psi. ### Claim 7 (depends on 1) The method of claim 1, wherein the insert comprises a vaporization temperature of 600° C. or lower. ### Claim 8 (depends on 1) The method of claim 1, wherein the insert comprises a diffusion barrier. ### Claim 9 (depends on 1) The method of claim 1, wherein the insert comprises an insert material selected from the group consisting of plastics, metals, waxes, polymers, and combinations thereof. ### Claim 10 (depends on 1) The method of claim 1, wherein at least a portion of the insert has a shape comprising a generally spherical geometry, a generally hourglass-shaped geometry, a generally cone-shaped geometry, or combinations thereof. ### Claim 11 (depends on 1) The method of claim 1, wherein the insert comprises at least one ledge, lip, taper, protrusion, ridge, prong, slot, or combinations thereof. ### Claim 12 (depends on 1) The method of claim 1, wherein the insert comprises inner and outer diameters. ### Claim 13 (depends on 1) The method of claim 1, wherein the insert comprises a thread form disposed on an outer surface of the insert. ### Claim 14 (depends on 1) The method of claim 1, wherein the composite material comprises a tungsten carbide. ### Claim 15 (depends on 1) The method of claim 1, wherein the composite material comprises a polycrystalline diamond. ### Claim 16 (depends on 1) The method of claim 1, wherein the malleable composite material comprises a sintering temperature of at least 1300° C. ### Claim 17 (depends on 1) The method of claim 1, wherein the green body comprises a ledge, lip, taper, protrusion, ridge, slot, or combinations thereof. ### Claim 18 (depends on 1) The method of claim 1, wherein the insert is placed into the chamber prior to placing the malleable composite material in the chamber. ### Claim 19 (depends on 1) The method of claim 1, wherein the malleable composite material is placed into the chamber prior to placing the insert in the chamber. ### Claim 20 (depends on 1) The method of claim 1, wherein at least one of the shaping surfaces comprises an insert connection and/or release mechanism.