Abstract: A method of one of manufacturing and maintaining a grinding roll comprises removably attaching an article adapted for use as a wear resistant working surface to an external surface a cylindrical core. The article includes a metal matrix composite comprising a plurality of inorganic particles dispersed in a matrix material comprising a metal or a metal alloy. The melting temperature of the inorganic particles is greater than the melting temperature of the matrix material. 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 wears away when the grinding roll is in use, thereby providing or preserving gaps between the hard elements at a working surface of the roll.

Abstract: A grinding roll includes a core comprising an external surface, and at least one wear resistant article adapted for use as a working surface that is removably attached to the external surface of the core. The at least one wear resistant article comprises a metal matrix composite comprising a plurality of inorganic particles dispersed in a metal matrix material comprising one of a metal and a metal alloy, and a plurality of hard elements interspersed in the metal matrix composite. The wear resistance of the metal matrix composite is less than the wear resistance of the hard elements.

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.

Abstract: An earth-boring bit part such as, for example, a bit body, roller cone, or mud nozzle includes a hybrid cemented carbide composite. The hybrid cemented carbide includes a cemented carbide dispersed phase, and a cemented carbide continuous phase. A method of manufacture also is disclosed.

Abstract: A method of forming a composite article by injecting at least two composite materials comprising metal carbides into a mold to form a green compact is disclosed. The composite materials may be metal powders comprising a binder metal, a hard particle. The composite material may further comprise a plastic binder. The two different composite materials are injected into the mold to form the green compact. Additionally, the composite materials may be injected through a die before entering the mold. In a specific embodiment, the die forms at least one internal channel within the green compact.

Abstract: A modular fixed cutter earth-boring bit body includes a blade support piece and at least one blade piece fastened to the blade support piece. A modular fixed cutter earth-boring bit and methods of making modular fixed cutter earth-boring bit bodies and bits also are disclosed.

Abstract: A composite sintered powder metal article including a first region including a cemented hard particle material such as, for example, cemented carbide. The article includes a second region including: a metallic material selected from a steel, nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a molybdenum alloy, cobalt, a cobalt alloy, tungsten, a tungsten alloy; and from 0 up to 30 percent by volume of hard particles. The first region is metallurgically bonded to the second region, and each of the first region and the second region has a thickness of greater than 100 microns. The second region comprises at least one mechanical attachment feature so that the composite sintered powder metal article can be attached to another article. The article comprises one of an earth boring article, a metalcutting tool, a metalforming tool, a woodworking tool, and a wear article.

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: 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.

Abstract: An article of manufacture includes a cemented carbide piece, and a joining phase that binds the cemented carbide piece into the article. The joining phase comprises a eutectic alloy material. The article of manufacture further includes a non-cemented carbide piece bound into the article of manufacture by the joining phase. An article of manufacture includes a fixed-cutter earth-boring bit body, a roller cone, and a part for an earth-boring bit.

Abstract: A method of making an article of manufacture includes positioning a cemented carbide piece comprising at least 5% of the total volume of the article of manufacture, and, optionally, a non-cemented carbide piece in a void of a mold in predetermined positions to partially fill the void and define an unoccupied space. Inorganic particles are added to the mold to partially fill the unoccupied space and provide a remainder space. The cemented carbide piece, the non-cemented carbide piece if present, and the hard particles are heated and infiltrated with a molten metal or a metal alloy. The melting temperature of the molten metal or the metal alloy is less than the melting temperature of the inorganic particles. The molten metal or metal alloy in the remainder space solidifies and binds the cemented carbide piece, the non-cemented carbide piece if present, and the inorganic particles to form the article of manufacture.

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.

Abstract: A method of making a composite sintered powder metal article includes providing a first powder comprising hard particles and a powdered binder in a first region of a mold. Providing a second powder comprising a metal or metal alloy powder in a second region of the mold, wherein the second powder contacts the first powder and comprises at least one of a metal powder and a metallic alloy powder. The first powder and the second powder are consolidated in the mold to provide a green compact. The green compact is sintered to provide a composite sintered powder metal article comprising a cemented hard particle region formed from the first powder and metallurgically bonded to a metallic second region formed from the second powder.

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, 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.

Abstract: An article of manufacture includes a cemented carbide piece and a joining phase that binds the cemented carbide piece into the article. The joining phase includes inorganic particles and a matrix material. The matrix material is a metal and a metallic alloy. The melting temperature of the inorganic particles is higher than the melting temperature of the matrix material. A method includes infiltrating the space between the inorganic particles and the cemented carbide piece with a molten metal or metal alloy followed by solidification of the metal or metal alloy to form an article of manufacture.

Abstract: A macroscopic composite sintered powder metal article including a first region including cemented hard particles, for example, cemented carbide. The article includes a second region including one of a metal and a metallic alloy selected from the group consisting of a steel, nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten alloy. The first region is metallurgically bonded to the second region, and the second region has a thickness of greater than 100 microns. A method of making a macroscopic composite sintered powder metal article is also disclosed, herein. The method includes co-press and sintering a first metal powder including hard particles and a powder binder and a second metal powder including the metal or metal alloy.

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.

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: 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: A cutting tool insert comprises a hard metal substrate having at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon-plus-nitrogen atomic ratio between 0.7 and 0.95 which causes the metal carbonitride to form projections into the ceramic coating improving adherence and fatigue strength of the ceramic coating.