US2008187452A1PendingUtilityA1

Method of Forming a Workpiece

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Individually held — no corporate assignee on recordPriority: Aug 11, 2006Filed: Apr 7, 2008Published: Aug 7, 2008
Est. expiryAug 11, 2026(expired)· nominal 20-yr term from priority
Inventors:David R. HallGary Peterson
B22F 2998/10E21C 35/183E21C 35/1837B28D 1/188B22F 3/1291B22F 2998/00B22F 7/06
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PatentIndex Score
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Claims

Abstract

A method of forming a ceramic metal composite workpiece comprises a step of providing a forming assembly with first and second shaping surfaces that together form a chamber. The chamber is shaped substantially similar to a desired external geometry of a green body of the workpiece, and at least one of the surfaces comprises a pressing mechanism adapted to move the surface with respect to the other surface. The method also comprises placing into the chamber a malleable composite material and an insert comprising a shape substantially similar to a desired internal surface geometry of the green body. The method also comprises a step of pressing the malleable composite material to form the green body such that at least a portion of the malleable composite material flows around at least a portion of the insert to form the green body with the desired external and internal surface geometries.

Claims

exact text as granted — not AI-modified
1 . A method of forming a ceramic metal composite workpiece, comprising the steps of:
 providing a forming assembly with first and second shaping surfaces together forming a chamber shaped substantially similar to a desired external geometry of a green body of the workpiece, and at least one of the surfaces comprising a pressing mechanism adapted to move the surface with respect to the other surface;   placing a malleable composite material and an insert comprising a shape substantially similar to a desired internal surface geometry of the green body within the chamber;   pressing the malleable composite material to form the green body such that at least a portion of the malleable composite material flows around at least a portion of the insert to form the green body with the desired external and internal surface geometries.   
     
     
         2 . The method of  claim 1 , wherein the method comprises an additional step of sintering the green body. 
     
     
         3 . The method of  claim 2 , wherein the step of sintering is done under pressure. 
     
     
         4 . The method of  claim 2 , wherein the insert vaporizes and/or melts out of the green body during the step of sintering the green body. 
     
     
         5 . The method of  claim 2 , wherein the method further comprises a step of brazing the sintered workpiece to an impact tip comprising a superhard material disposed on an impact surface of the tip. 
     
     
         6 . The method of  claim 1 , wherein the step of pressing the malleable composite material comprises pressing the material with a pressure of at least 5000 psi. 
     
     
         7 . The method of  claim 1 , wherein the insert comprises a vaporization temperature of 600° C. or lower. 
     
     
         8 . The method of  claim 1 , wherein the insert comprises a diffusion barrier. 
     
     
         9 . The method of  claim 1 , wherein the insert comprises an insert material selected from the group consisting of plastics, metals, waxes, polymers, and combinations thereof. 
     
     
         10 . The method of  claim 1 , wherein at least a portion of the insert has a shape comprising a generally spherical geometry, a generally hourglass-shaped geometry, a generally cone-shaped geometry, or combinations thereof. 
     
     
         11 . The method of  claim 1 , wherein the insert comprises at least one ledge, lip, taper, protrusion, ridge, prong, slot, or combinations thereof. 
     
     
         12 . The method of  claim 1 , wherein the insert comprises inner and outer diameters. 
     
     
         13 . The method of  claim 1 , wherein the insert comprises a thread form disposed on an outer surface of the insert. 
     
     
         14 . The method of  claim 1 , wherein the composite material comprises a tungsten carbide. 
     
     
         15 . The method of  claim 1 , wherein the composite material comprises a polycrystalline diamond. 
     
     
         16 . The method of  claim 1 , wherein the malleable composite material comprises a sintering temperature of at least 1300° C. 
     
     
         17 . The method of  claim 1 , wherein the green body comprises a ledge, lip, taper, protrusion, ridge, slot, or combinations thereof. 
     
     
         18 . The method of  claim 1 , wherein the insert is placed into the chamber prior to placing the malleable composite material in the chamber. 
     
     
         19 . The method of  claim 1 , wherein the malleable composite material is placed into the chamber prior to placing the insert in the chamber. 
     
     
         20 . The method of  claim 1 , wherein at least one of the shaping surfaces comprises an insert connection and/or release mechanism.

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