# US 2009/0260299 A1 · Tungsten rhenium compounds and composites and methods for forming the same

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- Number: US 2009/0260299 A1
- Document ID: US20090260299A1
- Status: Published application
- Kind: A1
- Application number: 12/148,687
- Filed: 2008-04-21
- Published: 2009-10-22
- Earliest claimed: 2008-04-21
- Assignees: Smith International, Inc.
- Inventors: Qingyuan Liu; Russell J. Steel; Scott Packer; Scott Horman
- Web page: https://patentgrep.com/patent/US20090260299A1

## CPC

- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- B22F 3/12: Both compacting and sintering (by forging B22F3/17)
- C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes}
- 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

The present invention relates to tungsten rhenium compounds and composites and to methods of forming the same. Tungsten and rhenium powders are mixed together and sintered at high temperature and high pressure to form a unique compound. An ultra hard material may also be added. The tungsten, rhenium, and ultra hard material are mixed together and then sintered at high temperature and high pressure.

## Claims

### Claim 1

A method of forming a material, comprising:
providing tungsten and rhenium; and
sintering the tungsten and rhenium at high temperature and high pressure.

### Claim 2 (depends on 1)

The method of claim 1, wherein the high temperature is within the range of approximately 1000° C. to approximately 2300° C.

### Claim 3 (depends on 1)

The method of claim 1, wherein the high pressure is within the range of approximately 20 kilobars to approximately 65 kilobars.

### Claim 4 (depends on 1)

The method of claim 1, further comprising mixing an ultra hard material with the tungsten and rhenium forming a mixture, and sintering the mixture at high temperature and high pressure to form a polycrystalline composite material.

### Claim 5 (depends on 4)

The method of claim 4, wherein the ultra hard material is selected from the group consisting of cubic boron nitride, diamond, and diamond-like carbon.

### Claim 6 (depends on 4)

The method of claim 4, wherein the ultra hard material is approximately 50% or greater of the volume of the material, and the rhenium and tungsten are approximately 50% or lower of the volume of the material.

### Claim 7 (depends on 4)

The method of claim 4, wherein the sintering the mixture comprises forming a chemical bond between the ultra hard material and at least one of the tungsten or rhenium.

### Claim 8 (depends on 7)

The method of claim 7, wherein the ultra hard material is cubic boron nitride, and wherein the forming a chemical bond comprises forming a chemical bond between at least a portion of the boron and at least a portion of the rhenium.

### Claim 9 (depends on 7)

The method of claim 7, wherein the ultra hard material is diamond, and wherein the forming a chemical bond comprises forming a chemical bond between at least a portion of the diamond and at least a portion of the tungsten.

### Claim 10 (depends on 1)

The method of claim 1, wherein a ratio of tungsten to rhenium by volume is approximately 3:1.

### Claim 11 (depends on 1)

The method of claim 1, further comprising providing a substrate, wherein sintering comprises sintering the tungsten, rhenium and the substrate.

### Claim 12

A high pressure high temperature sintered binder comprising:
tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder; and
rhenium, wherein the rhenium is within the range of approximately 1% to approximately 50% of the volume of the binder.

### Claim 13 (depends on 12)

The binder of claim 12, wherein the rhenium is approximately 25% of the total volume of the binder.

### Claim 14

A polycrystalline composite material comprising:
tungsten;
rhenium; and
a polycrystalline ultra hard material bonded to at least one of the tungsten or the rhenium.

### Claim 15 (depends on 14)

The material of claim 14 wherein said tungsten and rhenium form a binder, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and wherein the rhenium is within the range of approximately 50% to approximately 1% of the volume of the binder.

### Claim 16 (depends on 15)

The material of claim 15, wherein the ultra hard material makes up approximately 50% or higher of the volume of the polycrystalline composite material.

### Claim 17 (depends on 15)

The material of claim 15, wherein the rhenium is approximately 25% of the volume of the binder.

### Claim 18 (depends on 15)

The material of claim 15, wherein the ultra hard material is cubic boron nitride, and wherein at least a portion of the boron is chemically bonded to the rhenium.

### Claim 19 (depends on 15)

The material of claim 15, wherein the ultra hard material is diamond, and wherein at least a portion of the diamond is chemically bonded to the tungsten.

### Claim 20 (depends on 14)

The material of claim 14 wherein said tungsten, rhenium and ultra hard material define a polycrystalline ultra hard material layer and wherein the composite material further comprises a substrate bonded to said polycrystalline ultra hard material layer.

### Claim 21

A polycrystalline composite material comprising:
a binder comprising,
tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and
molybdenum, wherein the molybdenum is within the range of approximately 1% to approximately 50% of the volume of the binder; and
a polcrystalline ultra hard material.

### Claim 22 (depends on 21)

The material of claim 21 wherein said tungsten, molybdenum and ultra hard material define a polycrystalline ultra hard material layer and wherein the composite material further comprises a substrate bonded to said polycrystalline ultra hard material layer.

### Claim 23

A polycrystalline composite material comprising:
a binder comprising,
tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and
lanthanum, wherein the lanthanum is within the range of approximately 1% to approximately 50% of the volume of the binder; and
an ultra hard material.

### Claim 24 (depends on 23)

The material of claim 23 wherein said tungsten, lanthanum and ultra hard material define a polycrystalline ultra hard material layer and wherein the composite material further comprises a substrate bonded to said polycrystalline ultra hard material layer.

### Claim 25

A method of forming a polycrystalline composite material, comprising:
providing a binder comprising,
tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and
molybdenum, wherein the molybdenum is within the range of approximately 1% to approximately 50% of the volume of the binder;
providing an ultra hard material; and
sintering the ultra hard material with the binder at a high temperature and high pressure to form a polycrystalline composite material.

### Claim 26

A method of forming a polycrystalline composite material, comprising:
providing a binder comprising,
tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and
lanthanum, wherein the lanthanum is within the range of approximately 1% to approximately 50% of the volume of the binder,
providing an ultra hard material; and
sintering the ultra hard material with the binder at a high temperature and high pressure to form a polycrystalline composite material.