Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one of carbide, nitride, boride, oxide, and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.

Abstract: A cutting insert for milling operations, such as, face milling, slot milling, plunge milling, and ramping operations. The cutting insert exhibits a combination of favorable cutting edge strength, and unique cutting edge geometry, thus, allowing milling operations at relatively high feed rates. The cutting insert includes at least four cutting edges, wherein at least one of the cutting edges is a convex cutting edge. Certain embodiments of square cutting inserts will have four convex cutting edges which may be connected by nose corners. The convex cutting edge may comprise at least one of a circular arc, a portion of an ellipse, a portion of a parabola, a multi-segment spline curve, a straight line, or combinations of these. Wherein the convex cutting edge comprises a circular arc, the circular arc may have a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface.

Abstract: A double-sided cutting insert with a plurality of indexable convex cutting edges can have a top face and a bottom face, at least three convex cutting edges on each face connected by at least three nose corners, at least three peripheral side surfaces extending from each face toward a virtual middle plane; and a common lateral seating surface on each peripheral side surface. Each convex cutting edge can have at least a curved cutting edge region, and can further have a primary substantially straight cutting edge region intermediate the curved cutting edge region and the nose corner. Each peripheral side surface can further have a primary planar facet associated with the primary substantially straight cutting edge, and each face may also be single-handed in same direction.

Abstract: The present invention relates to ceramic cutting tools, such as, an aluminum oxide with zirconium oxide ceramic cutting tool with diffusion bonding enhanced layer and CVD coatings, particularly useful for machining modern metal materials. The method comprises a chemical reaction with a mixture including nitrogen and aluminum chloride introduced to form a diffusion bonding enhanced layer between the ceramic substrate and the CVD coatings. Thus formed diffusion bonding enhanced layer is highly adherent to the aluminum oxide with zirconium oxide ceramic substrate and significantly enhances the CVD coating properties, thus improving the machining performance in terms of the tool life of zirconium-based aluminum oxide with zirconium oxide ceramic cutting tools.

Abstract: Insert pockets of tool holders configured to accommodate multiple differently-shaped cutting inserts are disclosed. Cutting tool holders and cutting tool systems are also disclosed.

Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one of carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.

Abstract: An improved design of a cutting insert system includes a plurality of indexable peripheral milling cutting inserts adapted to be mounted on a peripheral milling tool holder. Each of the cutting inserts includes an insert width that is the same for each cutting insert. Each of the cutting inserts also includes a corner nose having a corner nose radius dimension that is different for each cutting insert, and an axial alignment clearance face that defines an equivalent face location and an equivalent clearance angle for each of the plurality of cutting inserts when the insert is detachably mounted on the tool holder.

Abstract: A thread rolling die includes a thread rolling region comprising a working surface including a thread form. The thread rolling region of the thread rolling die comprises a sintered cemented carbide material having a hardness in the range of 78 HRA to 89 HRA. In certain embodiments, the thread rolling die may further include at least one non-cemented carbide piece metallurgically bonded to the thread rolling region in an area of the thread rolling region that does not prevent a workpiece from contacting the working surface, and wherein the non-cemented carbide piece comprises at least one of a metallic region and a metal matrix composite region. Methods of forming a thread rolling die as embodied herein are also disclosed.

Abstract: The present invention relates to embodiments of a cutting tool holder having at least one insert pocket, wherein at least one insert pocket comprises a side surface and at least one antirotation stop protruding from the side surface. The antirotation stop may comprise at least two substantially planar surfaces. In certain embodiments, the cutting tool holder may have a pocket which comprises a bottom surface and an antirotation stop having three substantially planar surfaces that are substantially perpendicular to the bottom surface. The antirotation stop may be integral to the tool holder or may be produced separately and attached, either permanently or temporarily, to the tool holder. Embodiments may further comprise additional antirotation stops if desired by the machining application.

Abstract: The present invention relates to ceramic cutting tools, such as, a aluminum oxide with zirconium oxide ceramic cutting tool with diffusion bonding enhanced layer and CVD coatings, particularly useful for machining modern metal materials. The method comprises a chemical reaction with a mixture including nitrogen and aluminum chloride introduced to form a diffusion bonding enhanced layer between the ceramic substrate and the CVD coatings. Thus formed diffusion bonding is highly adherent to the aluminum oxide with zirconium oxide ceramic substrate and significantly enhances the CVD coating properties, and thus improving the machining performance in terms of the tool life of zirconium-based aluminum oxide with zirconium oxide ceramic cutting tools.

Abstract: The present invention relates to embodiments of a cutting tool holder having at least one insert pocket, wherein at least one insert pocket comprises a side surface and at least one antirotation stop protruding from the side surface. The antirotation stop may comprise at least two substantially planar surfaces. In certain embodiments, the cutting tool holder may have a pocket which comprises a bottom surface and an antirotation stop having three substantially planar surfaces that are substantially perpendicular to the bottom surface. The antirotation stop may be integral to the tool holder or may be produced separately and attached, either permanently or temporarily, to the tool holder. Embodiments may further comprise additional antirotation stops if desired by the machining application.

Abstract: A generally parallelogram-shaped cutting insert includes a top face; first and second main radial clearance faces, each intersecting the top face; first and second minor axial clearance faces each intersecting the top face and connecting the first and second main radial clearance faces; and a main cutting edge at the intersection of the top face and the first main radial clearance face. According to one non-limiting embodiment, the main cutting edge comprises a variable radial rake angle including a portion having a positive radial rake angle and a portion having a negative radial rake angle.

Abstract: An improved design of a cutting insert system includes a plurality of indexable peripheral milling cutting inserts adapted to be mounted on a peripheral milling tool holder. Each of the cutting inserts includes an insert width that is the same for each cutting insert. Each of the cutting inserts also includes a corner nose having a corner nose radius dimension that is different for each cutting insert, and an axial alignment clearance face that defines an equivalent face location and an equivalent clearance angle for each of the plurality of cutting inserts when the insert is detachably mounted on the tool holder.

Abstract: The present disclosure is directed to cutting tools. The disclosed cutting tools may have a wear resistant coating on a substrate. The substrate may have hard particles cemented in a binder phase. The binder may have a near-surface concentration gradient of at least one platinum group element and/or rhenium. Processes for producing cutting tools are also disclosed.

Abstract: An article in the form of one of a plate, a sheet, a cylinder, and a portion of a cylinder, which is adapted for use as at least a portion of a wear resistant working surface of a roll is disclosed. The article includes a metal matrix composite comprising a plurality of inorganic particles dispersed in a matrix material. The matrix material includes at least one of a metal and a metal alloy, wherein the melting temperature of the inorganic particles is greater than the melting temperature of the matrix material. A plurality of hard elements are embedded in the metal matrix composite. The wear resistance of the metal matrix composite is less than the wear resistance of the hard elements, and the metal matrix composite preferentially wears away when the article is in use, thereby providing or preserving gaps between each of the plurality of hard elements at a working surface of the article.

Abstract: A method for producing ammonium metatungstate from ammonium paratungstate includes preparing an ammonium paratungstate mixture including solid ammonium paratungstate and water. The mixture is contacted with a cation exchange material to lower a pH of the mixture to a pH range wherein metatungstate ion is stable and an insoluble tungstic acid is not formed. The pH of the mixture may be maintained in the pH range until the ammonium paratungstate mixture is converted into an ammonium metatungstate solution.

Abstract: A composite article includes a first composite material and a second composite material. The first composite material and the second composite material individually comprise hard particles in a binder. A concentration of ruthenium in the binder of the first composite material is different from a concentration of ruthenium in the binder of the second composite material.

Abstract: A double-sided cutting insert with a plurality of indexable convex cutting edges can have a top face and a bottom face, at least three convex cutting edges on each face connected by at least three nose corners, at least three peripheral side surfaces extending from each face toward a virtual middle plane; and a common lateral seating surface on each peripheral side surface. Each convex cutting edge can have at least a curved cutting edge region, and can further have a primary substantially straight cutting edge region intermediate the curved cutting edge region and the nose corner. Each peripheral side surface can further have a primary planar facet associated with the primary substantially straight cutting edge, and each face may also be single-handed in same direction. Additionally, in various embodiments, the top and bottom faces of the cutting insert may be formed such that they are twisted or rotated with respect to each other.

Abstract: A composite article includes a first composite material and a second composite material. The first composite material and the second composite material individually comprise hard particles in a binder. A concentration of ruthenium in the binder of the first composite material is different from a concentration of ruthenium in the binder of the second composite material.

Abstract: Composite articles, including composite rotary cutting tools and composite rotary cutting tool blanks, and methods of making the articles are disclosed. The composite article includes an elongate portion. The elongate portion includes a first region composed of a first cemented carbide, and a second region autogenously bonded to the first region and composed of a second cemented carbide. At least one of the first cemented carbide and the second cemented carbide is a hybrid cemented carbide that includes a cemented carbide dispersed phase and a cemented carbide continuous phase. At least one of the cemented carbide dispersed phase and the cemented carbide continuous phase includes at least 0.5 percent by weight of cubic carbide based on the weight of the phase including the cubic carbide.