Superhard filler hardmetal including a method of making
First Claim
1. A superhard filler hardmetal comprising:
- at least a superhard filler and a binder metal or matrix comprising at least one of cobalt, nickel, iron, and alloys thereof, the binder metal or matrix embedding the superhard filler; and
the superhard filler hardmetal having a porosity rating of substantially A00, B00 &
C00.
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Accused Products
Abstract
A superhard filler hardmetal having a superhard material filler, binder metal or matrix and in some instances at least a first hard component is disclosed. The superhard filler hardmetal has a porosity rating of substantially A06, B00, C00 or better and may be essentially pore free, i.e., A00, B00, C00. The superhard filler hardmetal is formed by mechanically mixing a superhard material, in some instances at least a first hard component and a binder metal or matrix precursor, shaping the mixture into a green body and consolidating the green body at a preselected temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form the superhard filler hardmetal. The consolidation preferably occurs without the formation of a liquid in the body and at least a portion of the time at superatmospheric pressure is at the preselected temperature. Diamond filler and boron nitride filler are examples of superhard materials usable as filler. The diamond filler may be coated to prevent its degradation during consolidation and use. Boron nitride filler optionally may be coated.
97 Citations
40 Claims
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1. A superhard filler hardmetal comprising:
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at least a superhard filler and a binder metal or matrix comprising at least one of cobalt, nickel, iron, and alloys thereof, the binder metal or matrix embedding the superhard filler; and
the superhard filler hardmetal having a porosity rating of substantially A00, B00 &
C00.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A superhard filler hardmetal manufactured by a process comprising the steps of:
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forming a mixture by mechanically mixing a superhard filler with a binder metal or matrix precursor;
shaping the mixture into a green body;
consolidating the green body at a preselected temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a superhard filler hardmetal, the consolidating occurring without the formation of a liquid in the body and at least a portion of the time at superatmospheric pressure is at the preselected temperature. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
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36. A superhard filler hardmetal having a porosity rating of substantially A00 manufactured by a process comprising the steps of:
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forming a mixture by mechanically mixing a superhard filler with a binder metal or matrix precursor;
shaping the mixture into a green body;
consolidating the green body at a temperature less than 1250 degrees Centigrade, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a superhard filler hardmetal. - View Dependent Claims (37, 38, 39)
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40. A superhard filler hardmetal having a porosity rating of substantially A00 and B00 manufactured by a process comprising the steps of:
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forming a mixture by mechanically mixing a superhard filler with a binder metal or matrix precursor;
shaping the mixture into a green body;
consolidating the green body at a temperature less than 1150 degrees Centigrade, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form a superhard filler hardmetal.
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Specification