Tough coated hard particles consolidated in a tough matrix material
AssigneeAllomet Corporation
InventorsJohn M. Keane, Randall M. German
Life of this patent
Estimating the term…
Abstract
Consolidated materials comprising a plurality of coated particles dispersed in a tough matrix material are disclosed. The coated particles include a plurality of core particles having an intermediate layer that substantially surrounds each of the core particles. An optional outer layer may be present on the intermediate layer. A matrix contains or substantially contains each of the coated particles, and is formed from at least one third compound including a mixture of W, WC, and/or W2C with Co. The amount of Co in the at least one third compound may range from greater than 0 to about 20 weight %. Methods for providing consolidated materials, and articles comprising such consolidated materials are also disclosed.
Claims22
A consolidated material, comprising:
- coated particles in a matrix, said coated particles comprising
- a core material;
- and
- at least one intermediate layer on said core material, wherein said at least one intermediate layer comprises a material different from said core material and said intermediate layer has a fracture toughness higher than said core material,
- wherein said matrix comprises a mixture of first particles comprising W or WC with second particles comprising Co, and/or said matrix comprises an alloy of Co with W and/or WC, Co being present in said matrix in an amount ranging from greater than 0 to about 20 weight %.
A sintered material, comprising:
- coated particles in a matrix, wherein said coated particles comprise
- a plurality of core particles comprising a core material consisting essentially of at least one first compound chosen from cubic boron nitride and diamond;
- and
- at least one intermediate layer around substantially each of said plurality of core particles, said at least one intermediate layer consisting essentially of at least one second compound different in composition from said first compound, said second compound having a fracture toughness higher than said first compound;
- and
- wherein said matrix surrounds or substantially surrounds each or substantially each of said coated particles, said matrix comprising at least one third compound comprising a mixture of first particles comprising tungsten and/or tungsten carbide with second particles comprising cobalt, and/or said at least one third compound comprises particles of an alloy of tungsten and/or tungsten carbide with cobalt, cobalt being present in said third compound in an amount ranging from greater than 0 to about 20 weight %.
A method of providing a consolidated article, comprising:
- providing a plurality of core particles comprising a core material;
- providing at least one intermediate layer on substantially each of said plurality of core particles to form coated particles, wherein said at least one intermediate layer comprises a material different from said core material and has a fracture toughness higher than said core material;
- mixing said coated particles with a powder of a matrix material to form a mixed powder, wherein said matrix material comprises a mixture of first particles comprising tungsten and/or tungsten carbide with second particles comprising cobalt, and/or said matrix comprises particles of an alloy of tungsten and/or tungsten carbide with cobalt, cobalt being present in said matrix material in an amount ranging from greater than 0 to about 20 weight %;
- shaping said mixed powder into an article;
- and
- consolidating said article such that said layer of matrix contains or substantially contains each of said coated particles.
A drawing die comprising a consolidated material, the consolidated material comprising:
- coated particles in a matrix, said coated particles comprising
- a core material;
- and
- at least one intermediate layer on said core material, wherein said at least one intermediate layer comprises a material different from said core material and has a fracture toughness higher than said core material,
- wherein:
- said core material consists essentially of diamond, cubic boron nitride, Al2O3, B4C, TiB2, TiC, TiN, Ti(C,N), WS2, ZrN, and ZrO2 and mixtures and alloys thereof;
- said at least one intermediate layer on said core material comprises at least one of W, WC, W2C, Ti(C, N), TiC, and TiN, optionally alloyed or compounded with cobalt;
- and
- said matrix comprises a mixture of first particles comprising W or WC with second particles comprising Co, and/or said matrix comprises an alloy of Co with W and/or WC, Co being present in said matrix in an amount ranging from greater than 0 to about 20 weight %.
Dependencies are inferred from the claim text.