Metal article and method for producing the same

• US 5,441,553 A
• Filed: 09/29/1993
• Issued: 08/15/1995
• Est. Priority Date: 05/22/1987
• Status: Expired due to Term

• Current Assignee: Exxon Research and Engineering Company (Exxon Mobil Corporation)
• Original Assignee: Exxon Research and Engineering Company (Exxon Mobil Corporation)
• Inventors: Polizzotti, Richard S., McCandlish, Larry E., Kugler, Edwin L.
• Primary Examiner(s): Walsh, Donald P.
• Assistant Examiner(s): JENKINS, DANIEL J
• Application Number:
  US08/128,182
• Time in Patent Office: 685 Days
• Field of Search: 75/240, 75/230, 75/236, 75/243, 75/244
• US Class Current: 75/230
• CPC Class Codes: B22F 9/30 with decomposition of metal compounds, e.g. by pyrolysis
• CPC Class Codes: C22C 1/053 with in situ formation of hard compounds
• CPC Class Codes: C22C 1/056 using gas
• CPC Class Codes: C22C 29/08 based on tungsten carbide
• CPC Class Codes: Y10S 75/953 Producing spheres

Abstract

A compacted, single phase or multiphase composite article. Particles for use in the compacted article are produced by providing a precursor compound containing at least one or at least two metals and a coordinating ligand. The compound is heated to remove the coordinating ligand therefrom and increase the surface area thereof. It may then be reacted so that at least one metal forms a metal-containing compound. The particles may be consolidated to form a compacted article, and for this purpose may be used in combination with graphite or diamonds. The metal-containing compound may be a nonmetallic compound including carbides, nitrides and carbonitrides of a refractory metal, such as tungsten. The metal-containing compound may be dispersed in a metal matrix, such as iron, nickel or cobalt. The dispersed nonmetallic compound particles are no larger than about 0.1 micron in particle size and have a volume fraction greater than about 0.15 within the metal matrix.

Claims

1. A compacted multiphase composite article comprising diamonds and multiphase composite particles, said multiphase composite particles consisting of a metal matrix, having therein a volume fraction greater than about 0.15 of substantially uniform and homogeneous distribution of hard phase non-metallic compound particles that are no larger than about 0.1 micron.

2. The article of claim 1 wherein said metal matrix is a metal selected from the group consisting of cobalt, nickel and iron.

3. The article of claim 2 wherein said nonmetallic compound is selected from the group consisting of carbides, nitrides and carbonitrides.

4. The article of claim 3 wherein said nonmetallic compound is tungsten carbide.

5. The article of claim 1 wherein said metal matrix is cobalt.

6. A compacted, multiphase composite article comprising multiphase composite particles consisting of a metal matrix having therein a volume fraction greater than about 0.15 of substantially uniform and homogeneous distribution of non-metallic compound particles no larger than about 0.1 micron.

7. The article of claim 6 wherein said metal matrix is a metal selected from the group consisting of cobalt, nickel and iron.

8. The article of claim 7 wherein said nonmetallic compound is selected from the group consisting of carbides, nitrides and carbonitrides.

9. The article of claim 8 wherein said nonmetallic compound is tungsten carbide.

10. The article of claim 8 wherein said metal matrix is cobalt.