Abstract: Systems, methods, and articles of manufacture related to composite materials are discussed herein. These materials can be based on a mixture of diamond particles with a matrix and fibers or fabrics. The matrix can be formed into the composite material through optional pressurization and via heat treatment. These materials display exceptionally low friction coefficient and superior wear resistance in extreme environments.

Abstract: A method of making a hard particle-dispersed metal matrix-bonded composite, includes the steps of mixing hard particles and ductile metal particles to yield a mixture, and sintering the mixture under a pressure of less than 2.0 GPa and at a temperature of less than 1200° C. for a sufficient time to yield the composite. A composite material made by the above method is disclosed.

Abstract: A method for rapidly synthesizing polycrystalline diamond, includes the steps of machining a large monolithic graphite piece, placing the starting graphite piece in direct contact with an activator piece composed of a nickel-base alloy, and subjecting the contacting pieces to high static pressure and high temperature for a time sufficient to cause the starting monolithic graphite piece to undergo complete transformation into diamond to yield monolithic polycrystalline diamond.

Abstract: A design for high pressure/high temperature apparatus and reaction cell to achieve ˜30 GPa pressure in ˜1 cm volume and ˜100 GPa pressure in ˜1 mm volumes and 20-5000° C. temperatures in a static regime. The device includes profiled anvils (28) action on a reaction cell (14, 16) containing the material (26) to be processed. The reaction cell includes a heater (18) surrounded by insulating layers and screens. Surrounding the anvils are cylindrical inserts and supporting rings (30-48) whose hardness increases towards the reaction cell. These volumes may be increased considerably if applications require it, making use of presses that have larger loading force capability, larger frames and using larger anvils.

Abstract: A composite material composed of a matrix phase bonded by a carbon binder phase derived from sintered carbon nanoparticles such as, for example, fullerenes. The present invention further relates to a method of making such composite materials which includes the steps of dispersing a sufficient amount of carbon nanoparticles into a matrix phase, and compressing the carbon nanoparticles-containing matrix phase at a sufficient pressure and temperature over a sufficient time to facilitate the conversion of the carbon nanoparticles into a nanostructured carbon binder phase, thereby yielding the composite material.

Abstract: A new class of carbon materials and their synthesis. The new carbon materials are formed by high pressure and high temperature processing of fullerene based carbon powder. The new carbon materials are harder than graphite and can be harder than steel (what the starting fullerenes are single wall nanotubes) or almost as hard as diamond (when the starting fullerened arm C60 buckyballs). The physical attributes of the materials can also be controlled by the pressing and heating parameters. These new carbon materials are conductive like graphite and unlike diamond which is an insulator. The materials can be formed by powder metallurgy techniques into any shape (cylinders, balls, tubes, rods, cones, foils, fibers or others). The new materials can also be readily doped, converted to diamond, formed within a porous composite or converted to diamond within the porous composite.

Abstract: A design for high pressure/high temperature apparatus and reaction cell to achieve ˜30 GPa pressure in ˜1 cm volume and ˜100 GPa pressure in ˜1 mm volumes and 20-5000° C. temperatures in a static regime. The device includes profiled anvils (28) action on a reaction cell (14, 16) containing the material (26) to be processed. The reaction cell includes a heater (18) surrounded by insulating layers and screens. Surrounding the anvils are cylindrical inserts and supporting rings (30-48) whose hardness increases towards the reaction cell. These volumes may be increased considerably if applications require it, making use of presses that have larger loading force capability, larger frames and using larger anvils.

Abstract: A method for fabricating a triphasic composite such as a WC/Co/diamond composite with a high volume fraction of diamond in a WC/Co matrix. The method involves sintering of a WC/Co powder compact to develop a porous preform, which displays some rigidity and strength, infiltrating the porous preform with a controlled distribution of carbon, and high pressure/high temperature treatment of the carbon-containing WC/Co preform to transform the carbon to diamond. The distribution of diamond in the composite can be functionally graded to provide a WC/Co core and a diamond-enriched surface, wherein all three phases form an interconnected structure in three dimensions. Such a tricontinuous structure combines high strength and toughness with superior wear resistance, making it attractive for applications in machine tools and drill bits.

Abstract: A method for fabricating a triphasic composite such as a WC/Co/diamond composite with a high volume fraction of diamond in a WC/Co matrix. The method involves sintering of a WC/Co powder compact to develop a porous preform, which displays some rigidity and strength, infiltrating the porous preform with a controlled distribution of carbon, and high pressure/high temperature treatment of the carbon-containing WC/Co preform to transform the carbon to diamond. The distribution of diamond in the composite can be functionally graded to provide a WC/Co core and a diamond-enriched surface, wherein all three phases form an interconnected structure in three dimensions. Such a tricontinuous structure combines high strength and toughness with superior wear resistance, making it attractive for applications in machine tools and drill bits.