Methods of making metal matrix composite and alloy articles

Patent metadata

Field	Value
Publication number	US-2017129015-A1
Application number	US-201715413964-A
Country	US
Kind code	A1
Filing date	Jan 24, 2017
Priority date	Mar 15, 2013
Publication date	May 11, 2017
Grant date	—

Abstract

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

First claim

That which is claimed is:

1 . A method of making a freestanding composite article comprising:
providing a temporary substrate; disposing over a surface of the temporary substrate a layered assembly comprising a layer of cobalt-based infiltration alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. heating the layered assembly to infiltrate the hard particle layer with the cobalt-based infiltration alloy providing a metal matrix composite; and separating the metal matrix composite from the temporary substrate.

2 . The method of claim 1 , wherein the hard particles comprise one or more metal carbides, metal nitrides, metal carbonitrides, metal borides, metal silicides, crushed cemented carbides, cast carbides or mixtures thereof.

3 . The method of claim 1 , wherein the cobalt-based infiltration alloy comprises 15-19 wt. % nickel, 17-21 wt. % chromium, 2-6 wt. % tungsten, 6-10 wt. % silicon, 0.5-1.2 wt. % boron, 0.2-1.0 wt. % carbon and the balance cobalt.

4 . The method of claim 1 , wherein the cobalt-based infiltration alloy comprises 20-35 wt. % chromium, 0-10 wt. % tungsten, 0-10 wt. % molybdenum, 0-2 wt. % nickel, 0-2 wt. % iron, 0-2 wt. % manganese, 0-5 wt. % silicon, 0-2 wt. % vanadium, 0-0.4 wt. % carbon, 0.5-5 wt. % boron and the balance cobalt

5 . The method of claim 1 , wherein the hard particles are present in the metal matrix composite in an amount of 20 vol. % to 90 vol. %.

6 . The method of claim 1 , wherein the metal matrix composite is fully dense.

7 . The method of claim 1 , wherein the organic binder comprises one or more polymeric materials.

8 . The method of claim 1 , wherein the cobalt-based infiltration alloy is in powder form and disposed in an additional sheet comprising organic binder.

9 . The method of claim 1 , wherein the cobalt-based infiltration alloy is provided as a sheet.

10 . The method of claim 1 , wherein the cobalt-based infiltration alloy is provided as a chunk.

11 . The method of claim 1 , wherein the metal matrix composite has a thickness or wall thickness of 100 μm to 20 mm.

12 . The method of claim 11 , wherein one or more surfaces of the metal matrix composite are shaped by the substrate.

13 . The method of claim 1 , wherein the temporary substrate is reusable.

14 . The method of claim 13 , wherein the temporary substrate is formed of or coated with a material substantially inert to the cobalt-based alloy infiltrating the hard particle layer.

15 . A method of making a freestanding metallic article comprising:
providing a temporary substrate; disposing over a surface of the temporary substrate a flexible sheet comprising organic binder and cobalt-based powder alloy; heating the sheet comprising the organic binder and the cobalt-based powder alloy to provide a sintered cobalt-based alloy article; and separating the sintered cobalt-based alloy article from the temporary substrate.

16 . The method of claim 15 , wherein the sintered cobalt-based alloy comprises 5-35 wt. % chromium, 0-35 wt. % tungsten, 0-35 wt. % molybdenum, 0-20 wt. % nickel, 0-25 wt. % iron, 0-2 wt. % manganese, 0-5 wt. % silicon, 0-5 wt. % vanadium, 0-4 wt. % carbon, 0-5 wt. % boron and the balance cobalt.

17 . The method of claim 15 , wherein the sintered cobalt-based alloy comprises 15-35 wt. % chromium, 0-35 wt. % tungsten, 0-20 wt. % molybdenum, 0-20 wt. % nickel, 0-25 wt. % iron, 0-2 wt. % manganese, 0-5 wt. % silicon, 0-5 wt. % vanadium, 0-4 wt. % carbon, 0-5 wt. % boron and the balance cobalt.

18 . The method of claim 15 , wherein the sintered cobalt-based alloy comprises 20-35 wt. % chromium, 0-10 wt. % tungsten, 0-10 wt. % molybdenum, 0-2 wt. % nickel, 0-2 wt. % iron, 0-2 wt. % manganese, 0-5 wt. % silicon, 0-2 wt. % vanadium, 0-0.4 wt. % carbon, 0-5 wt. % boron and the balance cobalt.

19 . The method of claim 15 , wherein the sintered cobalt-based alloy comprises 5-20 wt. % chromium, 0-2 wt. % tungsten, 10-35 wt. % molybdenum, 0-20 wt. % nickel, 0-5 wt. % iron, 0-2 wt. % manganese, 0-5 wt. % silicon, 0-5 wt. % vanadium, 0-0.3 wt. % carbon, 0-5 wt. % boron and the balance cobalt.

20 . The method of claim 15 , wherein the organic binder comprises one or more polymeric materials.

21 . The method of claim 15 , wherein the sintered cobalt-based alloy article has a thickness of 100 μm to 20 mm.

22 . The method of claim 15 , wherein the sintered cobalt-based alloy article is near-net-shape.

23 . The method of claim 15 , wherein the temporary substrate is reusable.

Assignees

• Kennametal Inc

Inventors

• Zheng Qingjun
• Liu Yixiong
• Faust James A
• Rowe Mark J
• De Wet Danie J
• Subbaiyan Sudharsan
• Meyer Michael J

Classifications

• B22F2302/45

  Others, including non-metals · CPC title

• B23K35/3033

  Ni as the principal constituent · CPC title

• C22C9/06

  with nickel or cobalt as the next major constituent · CPC title

• C22C38/36

  with more than 1.7% by weight of carbon · CPC title

• C22C14/00

  Alloys based on titanium · CPC title