Hybrid carbon nanotube reinforced composite bodies

Abstract

A composite body for cutting tools that includes a ductile phase; a plurality of carbide particles dispersed the ductile phase; and a plurality of nanotubes integrated into the composite body is disclosed. Methods of making such composite bodies and drill bits formed of such material are also disclosed.

1 . A composite body for cutting tools, comprising:
 a ductile phase;   a plurality of carbide particles dispersed the ductile phase; and   a plurality of nanotubes integrated into the composite body.   
     
     
         2 . The composite body of  claim 1 , wherein the plurality of carbide particles comprise at least one of tungsten carbide, tantalum carbide, titanium carbide, or combinations thereof. 
     
     
         3 . The composite body of  claim 1 , wherein the plurality of nanotubes comprise carbon nanotubes. 
     
     
         4 . The composite body of  claim 1 , wherein the plurality of nanotubes comprise inorganic nanotubes. 
     
     
         5 . The composite body of  claim 4 , wherein the inorganic nanotube is formed by depositing an inorganic coating by atomic layer deposition on a carbon nanotube and removing the carbon nanotube. 
     
     
         6 . The composite body of  claim 1 , wherein the plurality of nanotube materials comprises a coating deposited by atomic layer deposition disposed thereon. 
     
     
         7 . The composite body of  claim 6 , wherein the coating has a thickness ranging from about 1 to 10 nm. 
     
     
         8 . The composite body of  claim 6 , wherein the coating comprises at least one of a metal, ceramic materials, alloys thereof, or combinations thereof. 
     
     
         9 . The composite body of  claim 1 , wherein the ductile phase comprises at least one of Fe, Ni, Co, and alloys thereof. 
     
     
         10 . The composite body of  claim 1 , wherein at least one of an end cap or sidewall of the nanotubes is functionalized. 
     
     
         11 . A method of forming a composite body for a cutting tool, comprising:
 integrating a plurality of nanotubes in one of a plurality of carbide particles and a binder phase;   mixing the other of the one of a plurality of carbide particles and a binder phase; and   consolidating the mixture.   
     
     
         12 . The method of  claim 11 , wherein the plurality of nanotubes comprise carbon nanotubes. 
     
     
         13 . The method of  claim 11 , wherein the integrating comprises at least one of vapor co-deposition, mixing, spray mixing, ball milling, electromagnetic levitation, infiltration of a perform, and extrusion. 
     
     
         14 . The method of  claim 11 , wherein the integrating comprises dispersing the plurality of nanotubes in the plurality of carbide particles. 
     
     
         15 . The method of  claim 11 , wherein the integrating comprises dispersing the plurality of nanotubes into a plurality of binder particles. 
     
     
         16 . The method of  claim 11 , wherein the integrating comprises integrating the plurality of nanotubes into an infiltration binder. 
     
     
         17 . The method of  claim 11 , wherein the consolidating comprises at least one of infiltration, casting, and sintering. 
     
     
         18 . A drill bit, comprising:
 a bit body, the bit body comprising:
 a ductile phase; 
 a plurality of carbide particles dispersed the ductile phase; and 
 a plurality of nanotubes integrated into the bit body; and 
   at least one cutting element for engaging the formation disposed on the bit body.