Diamond metal composite cutter and method for making same
First Claim
1. A superhard material-metal composite product, comprisinga plurality of metal coated superhard particles, anda binder alloy having a melting point below about 1300°
- C., said binder alloy forming a matrix binding said coated superhard particles into a coherent mass,said superhard particles comprising above about 40% to about 75% by volume of said coherent mass,said metal being wetted by said binder alloy when said binder alloy is caused to flow.
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Abstract
A superhard material-metal composite product comprises a plurality of metal coated superhard particles (diamond or cubic boron nitride), and a binder alloy forming a cementing matrix which binds the coated superhard particles into a coherent mass. The binder alloy has a melting point below about 1300° C. and is capable of wetting the metal coating on the superhard particles. The superhard material-metal composite product is formed by assembling the coated particles and the binder alloy in a graphite mold, and then hot pressing at temperatures and pressures well below the temperatures and pressures of the diamond forming region. The superhard component comprises about 40% to 75% by volume of the composite product. The superhard material-metal composite product is of intermediate quality and is particularly useful in earth boring bits for drilling soft rock formations having abrasive rock stringers therein.
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Citations
78 Claims
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1. A superhard material-metal composite product, comprising
a plurality of metal coated superhard particles, and a binder alloy having a melting point below about 1300° - C., said binder alloy forming a matrix binding said coated superhard particles into a coherent mass,
said superhard particles comprising above about 40% to about 75% by volume of said coherent mass, said metal being wetted by said binder alloy when said binder alloy is caused to flow. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40)
- C., said binder alloy forming a matrix binding said coated superhard particles into a coherent mass,
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41. A superhard product, comprising
a superhard component comprising a first set of superhard particles and a second set of abrasive particles, said first set of particles being larger than said second set of particles, said particles of said second set substantially surrounding and being substantially located in the interstices between said particles of said first set, said particles of said first and second sets each being coated with a metal coating, said superhard component further including a binder alloy having a melting point less than about 1300° - C. and forming a cementing matrix binding said coated particles to each other, said superhard component having a superhard particle content in the range of above about 40% to about 75% by volume.
- View Dependent Claims (42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54)
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55. A superhard cutter for an earth boring bit, comprising
a base member, a superhard component bonded to said base member, said superhard component comprising a first set of superhard particles having a size in the range of about 50 to 2,000 microns in diameter, and a second set of abrasive particles having a size in the range of about 25 to 75 microns in diameter, said second set of particles substantially surrounding and being substantially located in the interstices between said particles of said first set, said particles of said first set being coated with a metallic coating that is about 2 to 10 microns thick, and said particles of said second set being coated with a metallic coating that is about 1 to 10 microns thick, said superhard component further including a binder alloy forming a matrix binding said coated particles to each other and to said base member, said binder alloy having a melting point in the range of about 650 to 1300° - C. and being capable of wetting said coated particles,
said superhard component having a superhard particle content in the range of above about 40% to about 75% by volume. - View Dependent Claims (56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67)
- C. and being capable of wetting said coated particles,
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68. A method for forming a superhard material-metal composite product at temperatures and pressures below the diamond forming range of temperatures and pressures, comprising
packing a charge of superhard particles into a container, said superhard particles being coated with a metal coating, introducing a binder alloy into said container, said binder alloy having a melting point of less than 1300° - C. and being capable of wetting said coated superhard particles when caused to flow,
heating said superhard particles and said binder alloy to a temperature between about 650 to 1300°
C. while applying a pressure in the range of about 1,000 to 20,000 psi, thereby causing said binder alloy to flow and to wet said coated superhard particles, andremoving said pressure and allowing said superhard particles and said binder alloy to cool. - View Dependent Claims (69, 70, 71, 72, 73, 74, 75, 76, 77, 78)
- C. and being capable of wetting said coated superhard particles when caused to flow,
Specification