Tungsten tetraboride composite matrix and uses thereof

Patent metadata

Field	Value
Publication number	US-11174538-B2
Application number	US-201815888826-A
Country	US
Kind code	B2
Filing date	Feb 5, 2018
Priority date	Feb 6, 2017
Publication date	Nov 16, 2021
Grant date	Nov 16, 2021

Abstract

Disclosed herein, in certain embodiments, are composite materials, methods, tools and abrasive materials comprising a tungsten-based metal composition, a tungsten carbide, and an alloy. In some cases, the composite materials or matrix are resistant to oxidation.

First claim

What is claimed is:

1. A composite matrix comprising:
a) a first formula (W 1-x M x X y ) n
wherein:
X is one of B, Be and Si;
M is at least one of titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), zirconium (Zr), niobium (Nb), molybdenum (Mo), ruthenium (Ru), hafnium (Hf), tantalum (Ta), rhenium (Re), osmium (Os), iridium (Jr), lithium (Li), yttrium (Y) and aluminum (Al);
x is from 0.001 to 0.999;

y is at least 4.0; and
n is from 0.01 to 0.99;

b) a tungsten carbide of formula (WC 0.99-1.05 ) p , wherein p is from 0.01 to 0.99; and
c) a second formula T q ;
wherein:
T is an alloy comprising at least one Group 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14 element in a Periodic Table of Elements; and
q is from 0.01 to 0.99;

wherein p, q, and n have a sum of 1;
wherein p, q and n are weight percentage ranges;
wherein the composite matrix has a fracture toughness of at least about 1 to 25 MPa m 1/2 as determined using the Palmquist method; and
wherein the composite matrix has a hardness of at least about 1 to 40 GPa as determined by Vickers hardness under a force of 294N (HV30).

2. The composite matrix of claim 1 , wherein X is B.

3. The composite matrix of claim 1 , wherein M is one of Re, Ta, Mn, Cr, Ta and Mn, or Ta and Cr.

4. The composite matrix of claim 1 , wherein y is 4.

5. The composite matrix of claim 1 , wherein x is 0.001 to 0.6.

6. The composite matrix of claim 1 , wherein T is an alloy comprising at least one element selected from Cu, Ni, Co, Fe, Si, Al and Ti.

7. The composite matrix of claim 1 , wherein p, q and n are weight percentage ranges.

8. The composite matrix of claim 1 , wherein the composite matrix is resistant to oxidation.

9. The composite matrix of claim 1 , wherein the composite matrix is a densified composite matrix.

10. A composite matrix comprising:
a) a tungsten tetraboride of formula (WB 4 ) n , wherein n is from 0.01 to 0.99;
b) a tungsten carbide of formula (WC 0.99-1.05 ) p , wherein p is from 0.01 to 0.99; and
c) a second formula T q ;
wherein:
T is an alloy comprising at least one Group 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14 element in a Periodic Table of Elements; and
q is from 0.01 to 0.99;

wherein p, q, and n have a sum of 1;
wherein p, q and n are weight percentage ranges;
wherein the composite matrix has a fracture toughness of about 1 to 25 MPa m 1/2 as determined using the Palmquist method; and
wherein the composite matrix has a hardness of about 1 to 40 GPa as determined by Vickers hardness under a force of 294N (HV30).

11. The composite matrix of claim 10 , wherein T is an alloy comprising at least one element selected from Cu, Ni, Co, Fe, Si, Al and Ti.

12. The composite matrix of claim 10 , wherein p, q and n are weight percentage ranges.

13. The composite matrix of claim 1 , wherein the composite matrix has a fracture toughness of at least about 5 MPa m 1/2 as determined using the Palmquist method and a hardness of at least about 5 GPa as determined by Vickers hardness under a force of 294N (HV30).

14. The composite matrix of claim 1 , wherein the composite matrix has a fracture toughness of at least about 10 MPa m 1/2 as determined using the Palmquist method and a hardness of at least about 10 GPa as determined by Vickers hardness under a force of 294N (HV30).

15. The composite matrix of claim 1 , wherein the composite matrix has a fracture toughness of about 5 to 20 MPa m 1/2 as determined using the Palmquist method and a hardness of about 5 to 30 GPa as determined by Vickers hardness under a force of 294N (HV30).

16. The composite matrix of claim 1 , wherein the composite matrix has a fracture toughness of about 10 to 20 MPa m 1/2 as determined using the Palmquist method and a hardness of about 10 to 30 GPa as determined by Vickers hardness under a force of 294N (HV30).

17. The composite matrix of claim 10 , wherein the composite matrix has a fracture toughness of at least about 5 MPa m 1/2 as determined using the Palmquist method and a hardness of at least about 5 GPa as determined by Vickers hardness under a force of 294N (HV30).

18. The composite matrix of claim 10 , wherein the composite matrix has a fracture toughness of at least about 10 MPa m 1/2 as determined using the Palmquist method and a hardness of at least about 10 GPa as determined by Vickers hardness under a force of 294N (HV30).

19. The composite matrix of claim 10 , wherein the composite matrix has a fracture toughness of about 5 to 20 MPa m 1/2 as determined using the Palmquist method and a hardness of about 5 to 30 GPa as determined by Vickers hardness under a force of 294N (HV30).

20. The composite matrix of claim 10 , wherein the composite matrix has a fracture toughness of about 10 to 20 MPa m 1/2 as determined using the Palmquist method and a hardness of about 10 to 30 GPa as determined by Vickers hardness under a force of 294N (HV30).

Assignees

• Univ California
• Supermetalix Inc

Inventors

• Kaner Richard B
• Turner Christopher L
• Keshavan Madapusi K
• Kavanaugh Jack

Classifications

• C22C1/1084

  by mechanical alloying (blending, milling) · CPC title

• C22C1/051

  Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor · CPC title

• C22C1/057

  with in situ formation of phases other than hard compounds by solid state reaction sintering, e.g. metal phase formed by reduction reaction · CPC title

• C22C1/055 Primary

  using carbon · CPC title

• C22C33/0292

  with more than 5% preformed carbides, nitrides or borides · CPC title