Binder compositions of tungsten tetraboride and abrasive methods thereof

Patent metadata

Field	Value
Publication number	US-2022023996-A1
Application number	US-202117307600-A
Country	US
Kind code	A1
Filing date	May 4, 2021
Priority date	Jan 25, 2016
Publication date	Jan 27, 2022
Grant date	—

Abstract

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

First claim

1 .- 80 . (canceled)

81 . A method of manufacturing a composite material, wherein the composite material comprises:
(a) a compound of formula (W 1-x M x X y ) n ,
wherein:
W is tungsten (W);
X is one of boron (B), beryllium (Be) and silicon (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), scandium (Sc), yttrium (Y) or aluminum (Al);
x is from 0 to 0.999;
y is at least 4.0;
n is from 0.001 to 0.999; and

(b) a metal or alloy of formula T q ,
wherein:
T is an alloy which is a combination of two or more group 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14 transition metal elements in the Periodic Table of Elements;
q is from 0.001 to 0.999;

the sum of q and n is 1; and
q and n are weight percentages;
wherein the method of manufacturing the composite material comprises:
i) combining (W 1-x M x X y ) n and T q to produce a mixture of (W 1-x M x X y ) n and T q ;
ii) blending the mixture (W 1-x M x X y ) n and T q to produce a blended mixture of (W 1-x M x X y ) n and T q ;
ii) loading the blended mixture of (W 1-x M x X y ) n and T q into a die;
iii) inserting the die into a Spark Plasma Sintering furnace;
iv) applying pulses of electric current through the die to produce the composite material of (W 1-x M x X y ) n and T q .

82 . The method of claim 81 , wherein the composite material is densified.

83 . The method of claim 81 , wherein the die comprises graphite.

84 . The method of claim 81 , wherein the pulses of electric current are 60 Amps or more.

85 . The method of claim 81 , wherein the pulses of electric current are direct current.

86 . The method of claim 81 , wherein pressure is applied to the die before or during the application of the pulses of electric current.

87 . The method of claim 86 , wherein the pressure is up to 36,000 psi.

88 . The method of claim 81 , wherein the die is heated before or during the application of the pulses of electric current.

89 . The method of claim 88 , wherein the die is heated to between 1000° C. and 2000° C.

90 . The method of claim 81 , wherein the (W 1-x M x X y ) n has a median particle size of about 1 μm to about 750 μm.

91 . The method of claim 81 , wherein the T q has a median particle size of about 45 μm or less.

92 . The method of claim 81 , wherein X is B.

93 . The method of claim 81 , wherein M comprises at least one of Re, Ta, Mn, Cr, Hf, Ta, Zr, or Y.

94 . The method of claim 81 , wherein M comprises at least two of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, Nb, Mo, Ru, Hf, Ta, Re, Os, Ir, Li, Sc, Y, or Al.

95 . The method of claim 81 , wherein M comprises Re, Ta, Mn, or Cr.

96 . The method of claim 81 , wherein x is from 0.001 to 0.4.

97 . The method of claim 81 , wherein T comprises at least one of Co, Fe, Ni, or Sn.

98 . The method of claim 81 , wherein q is 0.5 or less.

99 . The method of claim 81 , wherein the composite material has an average Vicker's hardness of about 10 to about 30 GPa as measured under a force of 9.8 N (1 kgf).

100 . The method of claim 81 , wherein the composite material is resistant to oxidation.

Assignees

• Univ California

Inventors

• Kavanaugh Jack
• Kaner Richard B
• Turner Chris
• Alkopov Georgly

Classifications

• C22C32/0089

  with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass · CPC title

• C22C32/0078

  only silicides · CPC title

• C22C32/0073

  only borides · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title