Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques
OwnerGerhard B. Beckmanninventor
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Abstract
A self-renewing cutting tool or cutting element is formed by bonding an overcoat, cladding or layer of highly abrasive, very durable material on a surface of a substrate or load-bearing element. The cutting layer is a composite structure and includes appropriately sized, multi-edged pieces of a superhard material, such as tungsten carbide, dispersed in a softer material which produces high strength bonds between and among the pieces and the substrate or load-bearing element.
Claims18
A method of manufacturing a composite structure comprising the steps of:
- providing a substrate;
- providing a plurality of pieces of a first material having cutting edges on the substrate;
- placing a powder of a second material on the substrate in intimate contact with the plurality of pieces to form a precursor;
- and
- subjecting the precursor to a densification process that comprises hot isostatic pressing (HIP), thereby converting the powder and plurality of pieces of the first material to a substantially fully dense composite cladding bonded to the substrate, the composite cladding having pieces of the first material interspersed with the second material, at least some cutting edges of the first material initially lying beneath a surface of the second material and being exposable by wear of the second material.
A method of manufacturing a composite structure comprising the steps of:
- providing a substrate;
- providing a plurality of pieces of a first material having cutting edges on the substrate, wherein the pieces of the first material each have an irregular, nonuniform shape;
- placing a powder of a second material on the substrate in intimate contact with the plurality of pieces to form a precursor;
- and
- subjecting the precursor to a densification process, thereby converting the powder and plurality of pieces of the first material to a substantially fully dense composite cladding bonded to the substrate, the composite cladding having pieces of the first material interspersed with the second material, at least some cutting edges of the first material initially lying beneath a surface of the second material and being exposable by wear of the second material.
A method of manufacturing a composite structure comprising the steps of:
- providing a plurality of pieces of a first material having cutting edges;
- placing a second material in intimate contact with the plurality of pieces of the first material to form a precursor, the second material having a hardness that is less than ½ as hard as the first material;
- and
- subjecting the precursor to a densification process that comprises hot isostatic pressing (HIP), thereby converting the powder and plurality of pieces of the first material to a substantially fully dense composite cladding, the composite cladding having pieces of the first material interspersed with the second material, at least some cutting edges of the first material initially lying beneath a surface of the second material and being exposable by wear of the second material.
A method of manufacturing a composite structure comprising the steps of:
- providing a plurality of pieces of a first material having cutting edges, wherein the pieces of the first material each have an irregular, nonuniform shape;
- placing a second material in intimate contact with the plurality of pieces of the first material to form a precursor, the second material having a hardness that is less than ½ as hard as the first material;
- and
- subjecting the precursor to a densification process, thereby converting the powder and plurality of pieces of the first material to a substantially fully dense composite cladding, the composite cladding having pieces of the first material interspersed with the second material, at least some cutting edges of the first material initially lying beneath a surface of the second material and being exposable by wear of the second material.
Dependencies are inferred from the claim text.