Method for fabrication and sintering composite inserts

A method for making a composite wear resistant element comprising the steps of:

• (a) providing particulate material comprising
• (i) abrasion resistant particles, and
• (ii) binding material;
• (b) sintering said material using microwave radiation as a heat source thereby forming a wear resistant element;
• (c) providing a structure which is formed by sintering a second mix of particulate materials under high pressure and high temperature;
• and
• (d) brazing said wear resistant clement to said structure using microwave radiation as a source of heat thereby forming said composite wear resistant element.

A method for making a wear resistant element comprising the steps of:

• (a) providing particulate material which is at least partially absorptive of microwave radiation, said particulate material comprising
• (i) abrasion resistant particles, and
• (ii) binding material;
• (b) forming said particulate material in a desired shape for said wear resistant element;
• (c) exposing said particulate material to microwave radiation;
• and
• (d) sintering said particulate material by means of heat generated within said particulate material by the absorption of said microwave radiation.

A method for fabricating an article comprising a support structure and a wear resistant layer affixed thereto, said method comprising the steps of:

• (a) providing a transparent source of microwave radiation;
• (b) defining a transparent cavity to receive microwave radiation from said source;
• (c) positioning wear resistant material in said transparent cavity prior to exposure to microwave radiation;
• and
• (d) conveying said material within said transparent cavity into microwave radiation so that said material is sintered on exposure to said microwave radiation to thereby form a resistant layer.

A method for making a wear resistant structure, the method comprising the steps of:

• (a) providing a support with a wear resistant layer affixed thereto;
• (b) providing a source of microwave radiation;
• (c) exposing said support and said layer to microwave radiation;
• and
• (d) elevating the temperature of said support and said layer to an annealing temperature of said layer, as a result of absorption of said microwave radiation by said layer, thereby forming said wear resistant structure comprising said support and an annealed wear resistant layer affixed thereto.

A method for making a wear resistant element with reduced grain size, the method comprising:

• (a) providing a source of microwave radiation;
• (b) directing radiation from said source into a central cavity;
• (c) positioning material within said central cavity;
• (d) increasing the temperature of said material absorption of microwave radiation by said material, wherein
• (i) said central cavity is transparent to microwave radiation, and
• (ii) said absorption of microwave radiation by said material increases as the temperature of said material increases;
• and
• (e) conveying said material within said central cavity so that said material is uniformly exposed to said microwave radiation thereby forming said wear resistant element.

A method for fabricating an article comprising a support structure and a wear resistant layer affixed thereto, wherein grain size of material comprising said wear resistant layer is minimized, said method comprising the steps of:

• (a) providing a source of microwave radiation;
• (b) directing four radiation in an oven having a central cavity;
• (c) positioning said material into said central cavity, wherein said oven is transparent to microwave radiation;
• and
• (d) conveying said material within said central cavity so that said material is sintered by uniformly exposure to said microwave radiation thereby forming said wear resistant layer by heating said material with said microwave radiation, wherein the rate of absorption of microwave radiation by said material increases as the temperature of said material increases.