Tungsten tetraboride composite matrix and uses thereof

Patent metadata

Field	Value
Publication number	US-2018223397-A1
Application number	US-201815888826-A
Country	US
Kind code	A1
Filing date	Feb 5, 2018
Priority date	Feb 6, 2017
Publication date	Aug 9, 2018
Grant date	—

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 (Ir), 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; and
wherein p, q, and n have a sum of 1.

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; and

wherein p, q, and n have a sum of 1.

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 . A method of preparing a densified 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 0.001 to 0.999;

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

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.

14 . The method of claim 13 , wherein the pressure is up to 36,000 psi.

15 . The method of claim 13 , wherein the temperature is from 1000° C. to 2000° C.

16 . The method of claim 13 , wherein X is B.

17 . The method of claim 13 , wherein y is 4.

18 . The method of claim 13 , wherein T is an alloy comprising at least one element selected from Cu, Ni, Co, Fe, Si, Al and Ti.

19 . The method of claim 13 , wherein p, q and n are weight percentage ranges.

20 . The method of claim 13 , wherein the densified composite matrix is resistant to oxidation.

Assignees

• Univ California
• Supermetalix Inc

Inventors

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

Classifications

• C22C33/0292

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

• B24D18/0009

  using moulds or presses · CPC title

• C22C29/08

  based on tungsten carbide · CPC title

• C22C29/14 Primary

  based on borides · CPC title

• C22C1/1084

  by mechanical alloying (blending, milling) · CPC title