Abstract: There is disclosed a method of making a metallic or ceramic component, such as a cutting or forming tool, from at least two distinct powder precursors. In one embodiment, the method comprising forming a first mixture comprised of a plurality of coated particles, such as Tough-Coated Hard Powder (TCHP) composite particles created by encapsulating extremely hard core particles with very tough binder and structural materials, and at least one support powder, such as a carbide, typically WC—Co. The mixture is formed into a green body and sintered to form a functionally graded or multicomponent article. Non-limiting examples of the articles made from the disclosed methods are also disclosed and include drills, mills, cutting tools, forming tools, wires dies and mechanical components.
Abstract: Consolidated materials comprising a plurality of coated particles dispersed in a tough matrix material are disclosed. The coated particles include a plurality of core particles having an intermediate layer that substantially surrounds each of the core particles. An optional outer layer may be present on the intermediate layer. A matrix contains or substantially contains each of the coated particles, and is formed from at least one third compound including a mixture of W, WC, and/or W2C with Co. The amount of Co in the at least one third compound may range from greater than 0 to about 20 weight %. Methods for providing consolidated materials, and articles comprising such consolidated materials are also disclosed.
Abstract: There is disclosed a method of making a metallic or ceramic component, such as a cutting or forming tool, from at least two distinct powder precursors. In one embodiment, the method comprising forming a first mixture comprised of a plurality of coated particles, such as Tough-Coated Hard Powder (TCHP) composite particles created by encapsulating extremely hard core particles with very tough binder and structural materials, and at least one support powder, such as a carbide, typically WC—Co. The mixture is formed into a green body and sintered to form a functionally graded or multicomponent article. Non-limiting examples of the articles made from the disclosed methods are also disclosed and include drills, mills, cutting tools, forming tools, wires dies and mechanical components.
Abstract: Consolidated materials comprising a plurality of coated particles dispersed in a tough matrix material are disclosed. The coated particles include a plurality of core particles having an intermediate layer that substantially surrounds each of the core particles. An optional outer layer may be present on the intermediate layer. A matrix contains or substantially contains each of the coated particles, and is formed from at least one third compound including a mixture of W, WC, and/or W2C with Co. The amount of Co in the at least one third compound may range from greater than 0 to about 20 weight %. Methods for providing consolidated materials, and articles comprising such consolidated materials are also disclosed.
Abstract: A method of consolidating particulate materials into articles having combinations of properties not available by conventional processes by liquid phase sintering. These particulate materials are comprised of core particles individually coated with layers of a metal compound having a relatively higher fracture toughness than the core, such as WC or TaC. These coated particles include an outer layer comprised a metal, such as Co or Ni. The particles with these coatings are pressed to form an article and the article densified at pressures and temperatures where full density is achieved without the degradation of the material forming the core particle.