Ferrous disintegrable powder compact, method of making and article of same

A process for preparing a sintered disintegrable powder compact, the process comprising:

• combining:
• a primary particle comprising a ferrous alloy which comprises carbon;
• and
• a secondary particle to form a composition;
• compacting the composition to form a preform;
• and
• sintering the preform to form the sintered disintegrable powder compact by
• forming a matrix from the secondary particle, the matrix comprising a matrix material, the matrix material comprising aluminum, calcium, cobalt, copper, magnesium, manganese, molybdenum, nickel, silicon, zinc, a rare earth element, or a combination thereof;
• and
• forming a plurality of dispersed particles from the primary particle, the dispersed particles comprising a particle core material dispersed in the matrix, the particle core material comprising the ferrous alloy which comprises carbon, the dispersed particles having a size of 50 nm to 800 nm, and the matrix being continuous and comprising a network that substantially surrounds the dispersed particles;
• wherein the sintered disintegrable powder compact is configured to disintegrate in response to contact with a disintegration fluid,
• the primary particle and secondary particle have different standard electrode potentials;
• and
• the matrix and the plurality of dispersed particles have different standard electrode potentials.

A sintered disintegrable powder compact comprising:

• a matrix, the matrix comprising a ferrous alloy which comprises carbon;
• a plurality of dispersed particles comprising a particle core material dispersed throughout the matrix, the particle core material comprising aluminum, calcium, cobalt, copper, iron, magnesium, manganese, molybdenum, nickel, silicon, zinc, a rare earth element, or a combination thereof;
• wherein the matrix and the plurality of dispersed particles have different standard electrode potentials,
• the dispersed particles are not a carbide;
• and
• the sintered disintegrable powder compact is free of metal nitrides.