Wear-resistant member having a hard composite comprising hard constituents held in an infiltrant matrix

Abstract

A tough wear-resistant hard member that includes a hard composite member and a support that has a surface area adjacent to the hard composite member wherein the hard composite member is affixed to the support over at least a portion of the adjacent surface area of the support. The hard composite member includes a plurality of discrete hard constituents distributed in the hard composite member wherein each one of the discrete hard constituents is of a size so as to have a surface area between about 0.001 square inches and about 16 square inches. The hard composite member further contains a matrix powder that includes particles wherein substantially all of the hard particles have a size smaller than the size of the hard constituents. The hard composite member further includes an infiltrant alloy having a melting point between about 500 degrees Centigrade and about 1400 degrees Centigrade wherein the infiltrant alloy is infiltrated under heat into a mixture of the discrete hard constituents and the matrix powder so as to not effectively degrade the hard constituents upon infiltration, whereby the hard constituents and the matrix powder and the infiltrant alloy are bonded together to form the hard composite member. The support is made of a material that is bondable with the infiltrant alloy whereby the infiltrant alloy forms a joint at the joinder of the support and the hard composite member.

What is claimed is:  
     
         1 . A tough wear-resistant hard member comprising: 
 a hard composite member;    a support having a surface area adjacent to the hard composite member;    the hard composite member affixed to the support over at least a portion of the adjacent surface area of the support;    the hard composite member comprising a plurality of discrete hard constituents distributed in the hard composite member, each one of the discrete hard constituents is of a size so as to have a surface area between about 0.001 square inches and about 16 square inches;    the hard composite member further comprising a matrix powder comprising hard particles wherein substantially all of the hard particles have a size smaller than the size of the hard constituents;    the hard composite member further comprising an infiltrant alloy having a melting point between about 500 degrees Centigrade and about 1400 degrees Centigrade, and the infiltrant alloy being infiltrated under heat into a mixture of the discrete hard constituents and the matrix powder so as to not effectively degrade the hard constituents upon infiltration, whereby the hard constituents and the matrix powder and the infiltrant alloy are bonded together to form the hard composite member; and    the support being made of a material that is bondable with the infiltrant alloy whereby the infiltrant alloy forms a joint at the joinder of the support and the hard composite member.    
     
     
         2 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises one or more of the following: crushed cemented carbide particles, crushed cast carbide particles, crushed carbide particles, and cemented carbide powder, steel particles, carbonyl iron particles, and coated carbide particles.  
     
     
         3 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 50 weight percent to about 70 weight percent crushed tungsten carbide having a particle size of −80+325 mesh, between about 24 weight percent and about 32 weight percent crushed cast tungsten carbide having a particle size of −325 mesh, between about 0.8 weight percent and about 1.2 weight percent steel particles having a particle size of −325 mesh, between about 0.8 and 1.2 weight percent carbonyl iron particles having a particle size of −325 mesh, between 0 weight percent and about 7 weight percent chromium carbide particles having a particle size of −45 mesh, between 0 and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 15 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         4 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 65 weight percent and about 69 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 29 weight percent and about 33 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, between about 0.9 weight percent and about 1.1 steel particles having a particle size of −325 mesh, and between about 0.9 weight percent and about 1.1 weight percent carbonyl iron particles having a particle size of −325 mesh.  
     
     
         5 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 61 weight percent and about 66 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 27 weight percent and about 31 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, between about 0.8 weight percent and about 1.0 steel particles having a particle size of −325 mesh, between about 0.8 weight percent and about 1.0 weight percent carbonyl iron particles having a particle size of −325 mesh, and be between about 65 weight percent and about 69 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 29 weight percent and about 33 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, between about 0.9 weight percent and about 1.1 steel particles having a particle size of −325 mesh, and between about 0.9 weight percent and about 1.1 weight percent carbonyl iron particles having a particle size of −325 mesh and between about 4 weight percent and about 6 weight percent chromium carbide particles having a particle size of −45 mesh.  
     
     
         6 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 51 weight percent and about 56 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 22 weight percent and about 37 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, between about 0.7 weight percent and about 0.9 steel particles having a particle size of −325 mesh, between about 0.7 weight percent and about 0.9 weight percent carbonyl iron particles having a particle size of −325 mesh, and between about 15 weight percent and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         7 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 58 weight percent and about 63 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 25 weight percent and about 29 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, between about 0.8 weight percent and about 1.0 steel particles having a particle size of −325 mesh, between about 0.8 weight percent and about 1.0 weight percent carbonyl iron particles having a particle size of −325 mesh., and between about 8 weight percent and about 12 weight percent crushed cemented chromium carbide-nickel particles of a particle size −140+325 mesh.  
     
     
         8 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 65 weight percent and about 69 weight percent crushed tungsten carbide particles of a particle size of −80+325 mesh, between about 12 weight percent and about 17 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 12 weight percent and about 17 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, and between about 1.5 weight percent and about 2.5 weight percent nickel particles having a particle size of −325 mesh.  
     
     
         9 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 61 weight percent and about 66 weight percent crushed tungsten carbide particles of a particle size of −80+325 mesh, between about 11 weight percent and about 16 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 11 weight percent and about 16 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, and between about 1.5 weight percent and about 2.5 weight percent nickel particles having a particle size of −325 mesh, and between about 4 weight percent and about 6 weight percent chromium carbide particles having a particle size of −45 mesh.  
     
     
         10 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 51 weight percent and about 56 weight percent crushed tungsten carbide particles of a particle size of −80+325 mesh, between about 10 weight percent and about 15 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 10 weight percent and about 15 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, and between about 1.3 weight percent and about 1.9 weight percent nickel particles having a particle size of −325 mesh, and between about 15 weight percent and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         11 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 58 weight percent and about 63 weight percent crushed tungsten carbide particles of a particle size of −80+325 mesh, between about 12 weight percent and about 17 weight percent crushed tungsten carbide particles having a particle size of −325 mesh, between about 12 weight percent and about 17 weight percent crushed cast tungsten carbide particles having a particle size of −325 mesh, and between about 1.5 weight percent and about 2.5 weight percent nickel particles having a particle size of −325 mesh, and between about 7 weight percent and about 13 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         12 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 80 weight percent and about 100 weight percent crushed cobalt cemented tungsten carbide particles having a particle size of −140+325 mesh, and between 0 weight percent and about 10 weight percent chromium carbide particles having a particle size of −45 mesh, between 0 weight percent and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 15 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         13 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 100 weight percent crushed cobalt cemented tungsten carbide particles having a particle size of −140+325 mesh.  
     
     
         14 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 95 weight percent crushed cobalt cemented tungsten carbide particles having a particle size of −140+325 mesh, and about 5 weight percent chromium carbide particles having a particle size of −45 mesh.  
     
     
         15 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 80 weight percent crushed cobalt cemented tungsten carbide particles having a particle size of −140+325 mesh, and about 20 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         16 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 90 weight percent crushed cobalt cemented tungsten carbide particles having a particle size of −140+325 mesh, and about 10 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         17 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 80 weight percent and about crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 10 weight percent chromium carbide particles having a particle size of −45 mesh, between 0 weight percent and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 15 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         17 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises between about 80 weight percent and about crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 10 weight percent chromium carbide particles having a particle size of −45 mesh, between 0 weight percent and about 25 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh, and between 0 weight percent and about 15 weight percent crushed cemented chromium carbide-nickel particles having a particle size of −140+325 mesh.  
     
     
         18 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 100 weight percent and about crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh.  
     
     
         19 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 95 weight percent and about 5 weight percent chromium carbide particles having a particle size of −45 mesh.  
     
     
         20 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 80 weight percent crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh, and about 20 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         21 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 90 weight percent crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh, and about 10 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         22 . The tough wear-resistant member of  claim 1  wherein the matrix powder comprises about 85 weight percent crushed nickel cemented tungsten carbide particles having a particle size of −325 mesh, and about 15 weight percent nickel-coated tungsten carbide particles having a particle size of −325 mesh.  
     
     
         23 . A tough wear-resistant hard member comprising: 
 a support having a surface area;    a hard composite member affixed to the support over at least a portion of the surface area of the support;    the hard composite member comprising a plurality of discrete hard constituents distributed in the hard composite member, each one of the discrete hard constituents is of a size so as to have a surface area between about 0.001 square inches and about 16 square inches;    the discrete hard constituents comprise one or more of cemented carbides and ceramics; 
 sintered cemented tungsten carbide wherein a binder includes one or more of cobalt, nickel, iron and molybdenum,  
 coated sintered cemented tungsten carbide wherein a binder includes one or more of cobalt, nickel, iron and molybdenum, and the coating comprises one or more of nickel, cobalt, iron and molybdenum,  
 one or more of the carbides, nitrides, and borides of one or more of titanium, niobium, tantalum, hafnium, and zirconium,  
 tungsten carbide,  
 one or more of the coated carbides, coated nitrides, and coated borides of one or more of titanium, niobium, tantalum, hafnium, and zirconium wherein the coating comprises one or more of nickel, cobalt, iron and molybdenum;  
 coated tungsten carbide wherein the coating comprises one or more of nickel, cobalt, iron and molybdenum,  
 coated silicon carbide wherein the coating comprises one or more of nickel, cobalt, iron and molybdenum, and  
 coated silicon nitride wherein the coating comprises one or more of nickel, cobalt, iron and molybdenum;  
 coated boron carbide,  
   the hard composite member further comprising a matrix powder comprising hard particles wherein substantially all of the hard particles of the matrix powder have a smaller size than the hard constituents;    the hard composite member further comprising an infiltrant alloy having a melting point between about 500 degrees Centigrade and about 1400 degrees Centigrade, and the infiltrant alloy being infiltrated under heat into a mixture of the discrete hard constituents and the matrix powder so as to not effectively degrade the hard constituents upon infiltration, whereby the hard constituents and the matrix powder and the infiltrant alloy are bonded together to form the hard composite member; and    the support being made of a material that is bondable with the infiltrant alloy whereby the infiltrant alloy forms a joint at the joinder of the support and the hard composite member.    
     
     
         24 . The tough wear-resistant member of  claim 23  wherein the infiltrant alloy comprises between about 15 weight percent and about 55 weight percent copper, between about 1 weight percent and about 18 weight percent nickel, between about 5 weight percent and about 40 weight percent zinc, up to about 25 weight percent manganese, between about 15 weight percent and about 75 weight percent silver, and up to about 5 weight percent tin.  
     
     
         25 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises about 53 weight percent copper, about 15 weight percent nickel, about 8 weight percent zinc, and about 24 weight percent manganese.  
     
     
         26 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises about 45 weight percent copper, about 35 weight percent zinc, and about 20 weight percent silver.  
     
     
         27 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises 40 weight percent copper, about 33 weight percent zinc, about 25 weight percent silver, and about 2 weight percent tin.  
     
     
         28 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises about 42 weight percent copper, about 2 weight percent nickel, and about 56 weight percent silver.  
     
     
         29 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises about 20 weight percent copper, about 10 weight percent zinc, and about 70 weight percent silver.  
     
     
         30 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy comprises  
     
     
         31 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy has a melting point between about 600 degrees Centigrade and about 800 degrees Centigrade.  
     
     
         32 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy has a melting point between about 690 degrees Centigrade and about 770 degrees Centigrade.  
     
     
         33 . The tough wear-resistant member of  claim 24  wherein the infiltrant alloy has a melting point less than about 700 degrees Centigrade.  
     
     
         34 . The tough wear-resistant member of  claim 23  wherein the hard constituents comprise sintered cobalt cemented tungsten carbide compacts wherein the cobalt content is about 10 weight percent.  
     
     
         35 . The tough wear-resistant member of  claim 23  wherein the hard constituents comprise sintered cobalt cemented tungsten carbide compacts wherein the cobalt content is about 6 weight percent.  
     
     
         36 . The tough wear-resistant member of  claim 23  wherein the hard constituents comprise nickel-coated sintered cobalt cemented tungsten carbide compacts wherein the cobalt content is about 10 weight percent.  
     
     
         37 . A tough wear-resistant hard member comprising: 
 a hard composite member;    a support having a surface area adjacent to the hard composite member;    the hard composite member affixed to the support over at least a portion of the adjacent surface area of the support;    the hard composite member comprising a plurality of discrete hard constituents distributed in the hard composite member, each one of the discrete hard constituents is of a size so as to have a surface area between about 0.001 square inches and about 16 square inches;    the hard composite member further comprising a matrix powder comprising hard particles wherein substantially all of the hard particles have a size smaller than the size of the hard constituents;    the hard composite member further comprising an infiltrant alloy having a melting point between about 500 degrees Centigrade and about 1400 degrees Centigrade, and the infiltrant alloy being infiltrated under heat into a mixture of the discrete hard constituents and the matrix powder so as to not effectively degrade the hard constituents upon infiltration, whereby the hard constituents and the matrix powder and the infiltrant alloy are bonded together to form the hard composite member; and    the support being made of a material that is bondable with the infiltrant alloy whereby the infiltrant alloy forms a joint at the interface of the support and the hard composite member.    
     
     
         38 . The tough wear-resistant member of  claim 37  wherein the hard composite being affixed to the support over substantially all of the adjacent surface area of the support.  
     
     
         39 . The tough wear-resistant member of  claim 37  wherein the portion of the adjacent surface area of the support to which the hard composite is affixed is roughened.  
     
     
         40 . The tough wear-resistant member of  claim 37  wherein the support contains at least one bore, and at least a portion of the hard composite being contained within the bore.  
     
     
         41 . The tough wear-resistant member of  claim 37  wherein the support presenting a plurality of surface areas, and the hard composite being affixed to the support over substantially all of the plurality of surface areas.