Near-net cutting tool insert
AssigneeDiamond Innovations, Inc.
InventorsSteven W Webb, Gerold Weinl, Malin Martensson, Thomas C Easley
Life of this patent
Estimating the term…
Abstract
A method of making a near-net superhard material body includes preparing granules from a mixture of superhard powder, binders, and fluids, compacting the granules to form a soft green complex-shaped body, heating the soft green body in a furnace to form a hard green body free from residual binders, embedding one or more of the hard green bodies in a containment powder or a containment means and forming a pressure cell, sintering the cell at high pressure and high temperature, and removing the containment powder from the cell or removing the inserts from the containment means to reveal one or more near-net bodies.
Claims24
A method of making a near-net superhard material body, comprising:
- preparing a slurry from a mixture of materials comprising diamond, silicon, binders, and fluids;
- drying the slurry to remove the fluids and to form granules;
- compacting the granules to form a soft green body of defined shape;
- heating the soft green body in a furnace to remove at least a portion of the binder from the soft green body and to induce a physical reaction or a chemical reaction in a portion of the diamond and the silicon, thereby forming a hard green body;
- embedding one or more of the hard green bodies in a containment powder and compacting the containment powder to form a containment means, the containment powder comprising solid material selected from the group of graphite, sintered cermet and combinations thereof;
- sintering the hard green bodies that are positioned within the containment means in a high pressure and high temperature process and providing additional silicon that infiltrates the hard green bodies, wherein the diamond reacts with the silicon introduced in the slurry and during the high pressure and high temperature process to form silicon carbide that bonds diamonds in one or more near-net bodies from the hard green bodies.
A method of making a near-net superhard material body comprising:
- preparing a slurry from a mixture comprising diamond, silicon, binders, and fluids;
- drying the slurry to remove the fluids and to form granules;
- compacting the granules to form a soft green body of defined shape;
- heating the soft green body in a furnace to remove at least a portion of the binder from the soft green body and to induce a physical reaction or a chemical reaction in a portion of the diamond and silicon, thereby forming a hard green body;
- inserting one or more of the hard green bodies in a containment means for containing said hard green bodies, the containment means comprising solid material selected from the group of graphite, sintered cermet and combinations thereof;
- sintering the hard green bodies that are positioned within the containment means in a high pressure and high temperature process and providing additional silicon that infiltrates the hard green bodies, wherein the diamond reacts with the silicon introduced in the slurry and during the high pressure and high temperature process to form silicon carbide that bonds diamond in one or more near-net bodies that are formed from the hard green bodies.
A method of making a near-net superhard material body, comprising:
- preparing granules from a mixture of materials comprising diamond, a matrix binder, and temporary organic binders;
- compacting the granules to form a soft green body of defined shape;
- heating the soft green body to remove the temporary organic binder from the soft green body and to physically react or chemically react a portion of the diamond with the matrix binder to form a hard green body;
- inserting one or more of the hard green bodies in a containment means for containing said hard green bodies;
- sintering the soft green bodies that are positioned within the containment means in a high pressure and high temperature process and providing additional matrix binder that infiltrates the hard green bodies, wherein the diamond reacts with the matrix binder introduced in the slurry and during the high pressure and high temperature process to form a continuous matrix that bonds diamonds in one or more near-net bodies that are formed from the hard green bodies.
Dependencies are inferred from the claim text.