Composite constructions with ordered microstructure

A composite construction comprising:

• a first structural phase comprising a hard material selected from the group consisting of cermet materials, polycrystalline diamond, and mixtures thereof;
• and
• a second structural phase formed from hard material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof, the second structural phase being relatively more ductile than the first structural phase to control crack propagation through the composite construction by plastically deforming, the second structural phase being in contact with at least a portion of the first structural phase;
• wherein the composite construction has a material microstructure that includes repeated structural units comprising an ordered arrangement of two or more first structural phases that are each separated from one another by a substantially continuous second structural phase.

A rotary cone rock bit comprising:

• a bit body including at least one journal pin extending from a leg portion of the bit;
• a cutter cone rotatably mounted on the journal pin;
• and
• an insert disposed along a surface of the cutter cone, the insert comprising a composite construction positioned along a working surface of the insert, the composite construction having an ordered microstructure of repeating structural units, each structural unit comprising:
• a first structural phase comprising a hard material selected from the group consisting of cermet materials, polycrystalline diamond, and mixtures thereof;
• and
• a second structural phase comprising hard material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof, the second structural phase being relatively softer than that of the first structural phase and being in contact with at least a portion of the first structural phase.

A preconsolidated/presintered composite construction comprising:

• a first structural phase comprising precursor materials for forming a hard consolidated/sintered material selected from the group consisting of cermets, polycrystalline diamond, and mixtures thereof;
• and
• a second structural phase comprising precursor materials for forming a consolidated/sintered material that is relatively softer than the consolidated and sintered first structural phase, the second structural phase being in contact with at least a portion of the first structural phase;
• wherein the preconsolidated/presintered composite construction includes repeated structural units that each comprise an ordered microstructure of the first and second structural phases.

A method for producing a preconsolidated/presintered composite construction having an ordered material microstructure, the method comprising the steps of:

• processing a precursor material used to form a consolidated/sintered material selected from the group consisting of cermets, polycrystalline diamond, and mixtures there into the form of a first structural phase;
• processing a precursor material used to form a consolidated/sintered material that is relatively softer than the consolidated/sintered material of the first structural phase into the form of a second structural phase;
• and
• combining the first and second structural phases together to form a material microstructure having an ordered arrangement of repeated structural units each formed from the first and second structural phases.

A method for forming a composite construction having an ordered microstructure comprising the steps of:

• forming a preconsolidated/presintered green-state composite construction by:
• processing a precursor material used to form a consolidated/sintered material selected from the group consisting of cermets, polycrystalline diamond, and mixtures there into the form of a first structural phase;
• processing a precursor material used to form a consolidated/sintered material that is relatively softer than the consolidated/sintered material of the first structural phase into the form of a second structural phase;
• combining the first and second structural phases together to form a green-state part having a material microstructure with an ordered arrangement of repeated structural units each formed from the first and second structural phases;
• consolidating the green-state composite construction at high pressure and at a temperature below a liquification temperature of any of the precursor materials for a determined amount of time to form a consolidated/sintered composite construction having an ordered microstructure.

A method for forming a composite construction having an ordered microstructure comprising the steps of:

• forming a preconsolidated/presintered green-state composite construction by:
• processing a precursor material used to form a consolidated/sintered material selected from the group consisting of cermets, polycrystalline diamond, and mixtures there into the form of a first structural phase;
• processing a precursor material used to form a consolidated/sintered material that is relatively softer than the consolidated/sintered material of the first structural phase into the form of a second structural phase;
• combining the first and second structural phases together to form a green-state part having a material microstructure with an ordered arrangement of repeated structural units each formed from the first and second structural phases;
• placing the green-state part into a high-temperature ceramic container comprising glass powder disposed therein;
• heating the ceramic container to a consolidation temperature above a liquification temperature of the glass powder but below a liquification temperature of the precursor materials;
• and
• isostatically pressing the ceramic container within a closed die to produce a consolidated/sintered composite construction comprising the ordered microstructure of the green-state part.