High-Performance Hardmetal Materials

Abstract

Hardmetal compositions each including hard particles having a first material and a binder matrix having a second, different material comprising rhenium or a Ni-based superalloy. Tungsten may also be used a binder matrix material. A two-step sintering process may be used to fabricate such hardmetals at relatively low sintering temperatures in the solid-state phase to produce substantially fully-densified hardmetals. A hardmetal coating or structure may be formed on a surface by using a thermal spray method.

1 . A material, comprising:
 hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and   a binder matrix that binds the hard particles and comprises a Ni-based superalloy and cobalt.   
   
   
       2 . The material as in  claim 1 , wherein the hard particles are between about 45% to about 98% of a total weight of the material. 
   
   
       3 . The material as in  claim 1 , wherein the hard particles comprise WC and TiC. 
   
   
       4 . The material as in  claim 3 , wherein WC and TiC are between about 58% to about 98%, and up to about 24% of a total weight of the material, respectively, and
 wherein cobalt and the nickel-based superalloy are up to about 33% and about 29% of the total weight of the material, respectively.   
   
   
       5 . The material as in  claim 1 , wherein the hard particles comprise WC and TaC. 
   
   
       6 . The material as in  claim 5 , wherein WC and TaC are between about 61% to about 98%, and up to about 24% of a total weight of the material, respectively, and
 wherein cobalt and the nickel-based superalloy are up to about 28% and about 25% of the total weight of the material, respectively.   
   
   
       7 . A material, comprising:
 hard particles comprising hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and   a binder matrix that binds the hard particles and comprises a nickel-based superalloy.   
   
   
       8 . The material as in  claim 7 , wherein the at least one carbide comprise TiC and Mo 2 C. 
   
   
       9 . The material as in  claim 8 , wherein TiC and Mo 2 C are between about 30% to about 90% and up to about 40% of a total weight of the material, respectively; and
 wherein the nickel-based superalloy is between about 4% to about 41% of the total weight of the material.   
   
   
       10 . The material as in  claim 7 , wherein the at least one carbide comprise Mo 2 C, and wherein the hard particles further comprise TiN. 
   
   
       11 . The material as in  claim 10 , wherein TiN and Mo 2 C are up to about 91% and up to about 38% of a total weight of the material, respectively; and
 wherein the nickel-based superalloy is between about 4% to about 38% of the total weight of the material.   
   
   
       12 . The material as in  claim 10 , wherein the at least one carbide comprise TiC. 
   
   
       13 . The material as in  claim 12 , wherein TiC, TiN and Mo 2 C are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and
 wherein the nickel based superalloy which is between about 4% to about 40% of the total weight of the material.   
   
   
       14 . The material as in  claim 10 , wherein the at least one carbide comprise TiC, WC, TaC, VC and Cr 2 C 3 . 
   
   
       15 . The material as in  claim 14 , wherein TiC, TiN, Mo 2 C, WC, and TaC are up to about 90%, about 90%, about 25%, about 42%, and about 36% of a total weight of the material, respectively, and VC and Cr 2 C 3  are up to about 14% and 18% of the total weight of the material, respectively; and
 wherein the nickel based superalloy is between about 2% to about 40% of the total weight of the material.   
   
   
       16 . A material, comprising:
 hard particles comprising hard particles comprising TiN and at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and   a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy and cobalt.   
   
   
       17 . The material as in  claim 16 , wherein the at least one carbide comprise TiC and Mo 2 C. 
   
   
       18 . The material as in  claim 17 , wherein TiC, TiN and Mo 2 C are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and
 wherein rhenium, the nickel-based superalloy and cobalt are up to about 64%, about 40% and about 42% of the total weight of the material, respectively.   
   
   
       19 . The material as in  claim 16 , wherein the at least one carbide comprise TiC, Mo 2 C, WC, TaC, VC and Cr 2 C 3 . 
   
   
       20 . The material as in  claim 19 , wherein TiC, TiN, Mo 2 C, WC, and TaC are up to about 89%, about 90%, about 26%, about 42%, and about 33% of a total weight of the material, respectively, and VC and Cr 2 C 3  are up to about 16% and 18% of the total weight of the material, respectively; and
 wherein rhenium, the nickel-based superalloy and cobalt are up to about 63%, about 39% and about 42% of the total weight of the material, respectively.