Tungsten tetraboride composite matrix and uses thereof

Patent metadata

Field	Value
Publication number	US-11920223-B2
Application number	US-202218082378-A
Country	US
Kind code	B2
Filing date	Dec 15, 2022
Priority date	Feb 6, 2017
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

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 method of preparing a composite matrix, comprising:
a) blending together a first composition having a formula (W 1-x M x X y ) n , a tungsten carbide composition of formula (WC 0.99-1.05 ) p , and a second composition of formula T q for a time sufficient to produce a powder mixture;
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 (Ir), lithium (Li), yttrium (Y) and aluminum (Al);
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;
x is from 0 to 0.999;

y is at least 4.0;
p, q, and n are each independently from 0.01 to 0.99;
p, q, and n have a sum of 1; and
wherein p, q and n are weight percentage ranges;

b) pressing the powder mixture under a pressure sufficient to generate a pellet; and
c) sintering the pellet at a temperature sufficient to produce a densified composite matrix;
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 method of claim 1 , wherein the pressure is up to 36,000 psi.

3. The method of claim 1 , wherein the pressure is from 10,000 to 36,000 psi.

4. The method of claim 1 , wherein the temperature is from 1000° C. to 2000° C.

5. The method of claim 1 , wherein the temperature is from 1500° C. to 2000° C.

6. The method of claim 1 , wherein the blending time is about 5 minutes or more.

7. The method of claim 1 , wherein composite matrix is formed by cold-press.

8. The method of claim 1 , wherein composite matrix is formed by hot-pressing, plasma spark sintering, electric current assisted (arc) sintering, or microwave sintering.

9. The method of claim 1 , wherein composite matrix is formed by plasma spark sintering.

10. The method of claim 1 , wherein X is B.

11. The method of claim 1 , wherein y is 4.

12. The method of claim 1 , wherein M is one of Re, Ta, Mn, Cr, Ta and Mn, or Ta and Cr.

13. The method of claim 1 , wherein x is 0.001 to 0.4.

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

15. The method of claim 1 , wherein p is from 0.01 to 0.85.

16. The method of claim 1 , wherein p is from 0.01 to 0.4.

17. The method of claim 1 , wherein q is from 0.01 to 0.5.

18. The method of claim 1 , wherein q is from 0.01 to 0.2.

19. The method of claim 1 , wherein n is from 0.01 to 0.9.

20. The method of claim 1 , wherein n is from 0.3 to 0.6.

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

• C22C29/14 Primary

  based on borides · CPC title