Abstract: A friction stir welding anvil and method of producing a friction stir welding anvil that precludes diffusion or mechanical bonding of the anvil to the work pieces are provided. The alternatives for producing such an anvil comprise coating the anvil with diffusion barriers such as oxides, nitrides, intermetallics, and/or refractory metals; manufacturing an anvil either completely or partially from the same; or placing a coating of such materials in the form of a thin sheet or a powder between the anvil and the work pieces. The anvil disclosed herein exhibits high strength and hardness even at elevated temperatures, such as those greater than 800° C., so as to prevent the anvil from mechanically or diffusion bonding to the work pieces and so as to minimize, or eliminate altogether, anvil deformation.

Abstract: The present invention relates to a method of joining segments of high melting temperature materials, that includes frictionally heating a first high melting temperature material and a second high melting temperature material wherein the first high melting temperature material and second high melting temperature material are welded together, without substantially changing the macrostructure and/or the microstructure of the first high melting temperature material and the second high melting temperature material, after application of a frictional force.

Abstract: A friction stir welding system that enables clamping of a pipe to enable friction stir welding around the pipe OD, a movable mandrel that provides a counter-force to the pressure exerted on the outside of a pipe by a tool, and a system for providing friction stir welding and repair inside a nuclear vessel in an underwater environment.

Abstract: A system and method of using friction stir welding and friction stir processing to perform crack repair or preventative maintenance of various materials and structures, wherein the structures include pipeline, ships, and nuclear reactor containment vessels, wherein the friction stir welding and processing can be performed on various materials including metal matrix composites, ferrous alloys, non-ferrous alloys, and superalloys, and wherein the friction stir welding and processing can be performed remotely and in harsh environments such as underwater or in the presence of radiation.

Abstract: A friction stir welding anvil and method of producing a friction stir welding anvil that precludes diffusion or mechanical bonding of the anvil to the work pieces are provided. The alternatives for producing such an anvil comprise coating the anvil with diffusion barriers such as oxides, nitrides, intermetallics, and/or refractory metals; manufacturing an anvil either completely or partially from the same; or placing a coating of such materials in the form of a thin sheet or a powder between the anvil and the work pieces. The anvil disclosed herein exhibits high strength and hardness even at elevated temperatures, such as those greater than 800° C., so as to prevent the anvil from mechanically or diffusion bonding to the work pieces and so as to minimize, or eliminate altogether, anvil deformation.

Abstract: A friction stir welding anvil and method of producing a friction stir welding anvil that precludes diffusion or mechanical bonding of the anvil to the work pieces are provided. The alternatives for producing such an anvil comprise coating the anvil with diffusion barriers such as oxides, nitrides, intermetallics, and/or refractory metals; manufacturing an anvil either completely or partially from the same; or placing a coating of such materials in the form of a thin sheet or a powder between the anvil and the work pieces. The anvil disclosed herein exhibits high strength and hardness even at elevated temperatures, such as those greater than 800° C., so as to prevent the anvil from mechanically or diffusion bonding to the work pieces and so as to minimize, or eliminate altogether, anvil deformation.

Abstract: A method wherein a superhard abrasive material is sintered and simultaneously bonded to a sintered cemented carbide body inside a container under elevated pressure and temperature conditions (HP/HT-treatment), whereby said cemented carbide body is in contact with at least one other cemented carbide body which after the sintering is removed, is disclosed. At least the cemented carbide surfaces in contact with each other during the HP/HT-treatment is at least one coated with a 1-10 &mgr;m thick layer of a refractory oxide. The method is particularly applicable for making cemented carbide cutting inserts provided a superabrasive material and with a hole for clamping to a tool holder whereby said hole is filled with a cemented carbide plug during the HP/HT-treatment and removed thereafter. Preferably, both the plug and the insert blank are coated.

Abstract: An improved polycrystalline diamond composite (“PDC”) cutter with secondary PDC cutting surfaces in addition to a primary PDC cutting surface is formed comprising of at least two wafers of cemented carbide bonded together. The secondary cutting surfaces are formed by compacting and sintering diamond in grooves formed at the surface of the wafers. Wafers of different grades of cemented carbide may be used. Moreover, different grades of diamond may be compacted and sintered in different grooves.

Abstract: An improved polycrystalline diamond composite (“PDC”) cutter with secondary PDC cutting surfaces in addition to a primary PDC cutting surface is formed comprising of at least two wafers of cemented carbide bonded together. The secondary cutting surfaces are formed by compacting and sintering diamond in grooves formed at the surface of the wafers. Wafers of different grades of cemented carbide may be used. Moreover, different grades of diamond may be compacted and sintered in different grooves.

Abstract: A center cutting or plunging end mill or ball nose end mill has one or more spiral grooves and flutes in the walls of a mill body of cemented tungsten carbide. Each groove includes polycrystalline diamond or cubic boron nitride formed in situ along a leading edge of each flute. Such a groove extends across the cutting end of the mill so that the mill can be used for center cutting or plunging. The vein of diamond-like material may extend to the center of the mill body or may extend almost all of the way to the center, leaving an area of tungsten carbide exposed at the center of the mill body. A high temperature-high pressure press is used for forming the polycrystalline diamond-like veins in situ within the grooves in the mill.

Abstract: A center cutting or plunging end mill or ball nose end mill has one or more spiral grooves and flutes in the walls of a mill body of cemented tungsten carbide. Each groove includes polycrystalline diamond or cubic boron nitride formed in situ along a leading edge of each flute. Such a groove extends across the cutting end of the mill so that the mill can be used for center cutting or plunging. The vein of diamond-like material may extend to the center of the mill body or may extend almost all of the way to the center, leaving an area of tungsten carbide exposed at the center of the mill body. A high temperature-high pressure press is used for forming the polycrystalline diamond-like veins in situ within the grooves in the mill.

Abstract: According to the present invention there is provided a method of making a cutting insert with a hole for clamping to a tool holder wherein a super-hard abrasive material is sintered and simultaneously bonded to a sintered cemented carbide body with a hole inside a container under elevated pressure and temperature conditions. During sintering the hole is filled with a plug which after sintering is removed.

Abstract: A high pressure/high temperature process is disclosed for making polycrystalline diamond or CBN compacts having chip control surfaces formed thereon. Making these chip control surfaces is accomplished by pre-forming the indentations or raised dimples within the can used in the HP/HT process.

Abstract: An improved polycrystalline diamond composite ("PDC") cutter with secondary PDC cutting surfaces in addition to a primary PDC cutting surface is formed comprising of at least two wafers of cemented carbide bonded together. The secondary cutting surfaces are formed by compacting and sintering diamond in grooves formed at the surface of the wafers. Wafers of different grades of cemented carbide may be used. Moreover, different grades of diamond may be compacted and sintered in different grooves.

Abstract: A method for manufacturing cutting tools having diamond-like cutting edges or surfaces which are formed by bonding high shear compaction diamond or cubic boron nitride (CBN) ropes or strips in helical grooves formed on the cutting tool outer surface. The strips are formed by slitting a sheet of high shear compaction diamond or CBN material. The ropes are formed by rolling the strips between grooved rollers.

Abstract: A metal cutting insert comprises a carbide substrate, and at least one body of superhard abrasive material, such as PCD or PCBN, bonded to an edge surface of the substrate and extending from one side surface to the other side surface of the substrate. There can be a plurality of superhard bodies disposed at respective corners of the substrate. The abrasive material is applied to the substrate in a container and then sintered and simultaneously bonded to the substrate by an elevated pressure/temperature step. Inserts can be made in rod form (i.e., in one piece) and then the rod can be transversely sliced into thin inserts; or the inserts can be made in separate pieces, with or without separators within the container.

Abstract: A cutting tool for woodworking applications has a tungsten carbide substrate and a hard layer bonded to the substrate at high temperature and high pressure, i.e. where diamond or cubic boron nitride is thermodynamically stable. The hard layer comprises polycrystalline diamond or polycrystalline cubic boron nitride, and a supporting cobalt phase including adjuvant alloying materials for providing oxidation and corrosion resistance. Typical alloying elements include nickel, aluminum, silicon, titanium, molybdenum and chromium. Such materials also retard transformation of cobalt from the HCP to the FCC crystal structure at high temperature. The hard layer has an as-pressed surface parallel to the substrate and is only about 0.3 millimeters thick. An additional secondary phase including a carbide, nitride and carbonitride of metals such as titanium may also be present in the PCD or PCBN layer.

Abstract: A center cutting or plunging end mill or ball nose end mill has one or more spiral grooves and flutes in the walls of a mill body of cemented tungsten carbide. Each groove includes polycrystalline diamond or cubic boron nitride formed in situ along a leading edge of each flute. Such a groove extends across the cutting end of the mill so that the mill can be used for center cutting or plunging. The vein of diamond-like material may extend to the center of the mill body or may extend almost all of the way to the center, leaving an area of tungsten carbide exposed at the center of the mill body. A high temperature-high pressure press is used for forming the polycrystalline diamond-like veins in situ within the grooves in the mill.

Abstract: A metal cutting insert comprises a carbide substrate, and at least one body of superhard abrasive material, such as PCD or PCBN, bonded to an edge surface of the substrate and extending from one side surface to the other side surface of the substrate. There can be a plurality of superhard bodies disposed at respective corners of the substrate. The abrasive material is applied to the substrate in a container and then sintered and simultaneously bonded to the substrate by an elevated pressure/temperature step. Inserts can be made in rod form (i.e., in one piece) and then the rod can be transversely sliced into thin inserts; or the inserts can be made in separate pieces, with or without separators within the container.

Abstract: An end mill forms at least a pair of spiral grooves or flutes in the mill side walls. Each groove includes polycrystalline diamond formed along a leading edge of each flute. A process for forming the diamond edged on the PCD material bonded within the flute.