Microwave sintering

Abstract

A carbide composite that includes carbide particles having an average particle size of less than about 100 nanometers and a metallic binder disposed around the carbide particles is disclosed. The carbide composite may also include carbide particles having an average particle size ranging from 3 to 10 microns.

1 . A cutting element comprising: 
 a substrate formed from a carbide composite, the carbide composite comprising: 
 tungsten carbide particles; and  
 a metallic binder,  
   wherein the tungsten carbide particles have a particle size ranging from 10 to 100 nm, and wherein the carbide composite has a hardness greater than 85 Rockwell A.    
     
     
         2 . The cutting element of  claim 1 , wherein the tungsten carbide particles having a particle size ranging from 10 to 100 nm comprise from about 10 to 100 percent of the tungsten carbide particles.  
     
     
         3 . A method for making a wear resistant element, comprising: 
 providing a mixture of green carbide particles and a metallic binding material; and    sintering the mixture with microwave energy to form a composite having a first carbide region and a second carbide region, wherein the first carbide region has an average particle size of less than about 100 nm and the second carbide region has an average particle size ranging from about 3 to about 10 μm.    
     
     
         4 . A carbide composite, comprising: 
 a first carbide having an average particle size of less than about 100 nm;    a second carbide having an average particle size ranging from about 3 to about 10 μm;    and    a metallic binder disposed around the carbide particles.    
     
     
         5 . The carbide composite of  claim 3 , wherein the composite is formed by a process selected from microwave sintering, plasma assisted sintering, pressure assisted sintering, explosive compaction, and rapid omnidirectional compaction.  
     
     
         6 . The carbide composite of  claim 3 , wherein the metallic binder is selected from cobalt, nickel, iron, and alloys thereof.  
     
     
         7 . The carbide composite of  claim 3 , wherein the carbide composite comprises from about 10 to about 40 weight percent metallic binder.  
     
     
         8 . The carbide composite of  claim 3 , wherein the carbide composite has a hardness greater than about 85 Rockwell A.  
     
     
         9 . The carbide composite of  claim 3 , wherein the first carbide is in an amount ranging from 10 to 50 percent of the metallic binder.  
     
     
         10 . The method of  claim 3 , wherein carbide particles of the second carbide region are surrounded by carbide particles of the first carbide region.  
     
     
         11 . The method of  claim 3 , wherein the carbide particles of the first carbide region are uniformly distributed in the metallic binder phase.  
     
     
         12 . A carbide composite, comprising: 
 a first carbide region;    a second carbide region; and    a metallic binder phase disposed around carbide particles of the first and second carbide regions, wherein the first carbide region has an average particle size less than an average particle size of the second carbide region, and wherein the composite is formed by a rapid consolidation process.    
     
     
         13 . The carbide composite of  claim 12 , wherein the composite is formed by a microwave sintering process.  
     
     
         14 . The carbide composite of  claim 12 , wherein the metallic binder is selected from cobalt, nickel, iron, and alloys thereof.  
     
     
         15 . The carbide composite of  claim 12 , wherein the carbide composite comprises from about 10 to about 40 weight percent metallic binder.  
     
     
         16 . The carbide composite of  claim 12 , wherein each carbide particle of the second carbide region is surrounded by carbide particles of the first carbide region.  
     
     
         17 . The carbide composite of  claim 12 , wherein the carbide particles of the first carbide region are uniformly distributed in the metallic binder phase.  
     
     
         18 . The carbide composite of  claim 12 , wherein the first carbide region comprises carbide particles having an average carbide particle size less than 100 nm and the second carbide region comprises carbide particles having an average carbide particle size from 3 to 10 μm.  
     
     
         19 . The carbide composite of  claim 12 , wherein the first carbide region is in an amount ranging from 10 to 50 percent of the metallic binder.  
     
     
         20 . The carbide composite of  claim 12 , further comprising a third carbide region having a third average particle size.