Method of joining sintered parts of different sizes and shapes

Abstract

A method of joining a plurality of parts to form a unitary body. At least two sintered parts are provided. At least one of the sintered parts has at least one internal cavity. Each of the parts is formed of a hard metal composition of material. The at least two sintered parts are assembled into the shape of a unitary body. Each of the at least two sintered parts has a joining surface and when each joining surface is brought into contact the surfaces form a bonding interface therebetween. The assembled parts are subjected to a vacuum or gas atmosphere, without the application of external pressure, and to a temperature sufficient to fuse the at least two sintered parts together at the bonding interface to form the unitary body.

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         26 . A wear resistant tool comprising:
 a plurality of sintered parts, each of the plurality of sintered parts being formed of a hard metal composition of material, at least one of the sintered parts having at least one internal cavity, wherein the plurality of sintered parts can be assembled into a shape of a unitary body; and   a joining surface disposed on each of the plurality of sintered parts, wherein when the parts are assembled each joining surface is brought into contact to form a bonding interface therebetween, such that when the assembled parts are subject to a vacuum or gas atmosphere, without the application of external pressure, and to a temperature sufficient to fuse the plurality of parts, the plurality of sintered parts are joined together at a respective bonding interface to form the unitary body.   
     
     
         27 . The wear resistant tool of  claim 26 , wherein each of the plurality of sintered parts has a different size. 
     
     
         28 . The wear resistant tool of  claim 26 , wherein each of the plurality of sintered parts has a different shape. 
     
     
         29 . The wear resistant tool of  claim 26 , wherein the hard metal composition of material is cemented carbide. 
     
     
         30 . The wear resistant tool of  claim 29 , wherein the cemented carbide has a hard phase of tungsten carbide and of one or more carbides, nitrides or carbonitrides selected from a group of titanium, chromium, vanadium, tantalum, niobium bonded by a metal phase selected from the group of cobalt, nickel, iron and combinations thereof. 
     
     
         31 . The wear resistant tool of  claim 29 , wherein each of the plurality of sintered parts is made of the same cemented carbide. 
     
     
         32 . The wear resistant tool of  claim 29 , wherein each of the plurality of sintered parts is made of different cemented carbide. 
     
     
         33 . The wear resistant tool of  claim 26 , wherein the hard metal composition of material is a cermet. 
     
     
         34 . The wear resistant tool of  claim 33 , wherein the cermet has a hard phase selected from the a group of one or more carbides, nitrides or carbonitrides of titanium, chromium, vanadium, tantalum, niobium bonded by a metallic phase selected from the group of cobalt, nickel, iron and combinations thereof. 
     
     
         35 . The wear resistant tool of  claim 26 , wherein the plurality of sintered parts each have a sintering temperature, the assembled parts being heated to a temperature lower than a melting point of the sintered part having a lowest of the sintering temperature of the plurality of sintered parts to fuse the parts at the bonding interface. 
     
     
         36 . The wear resistant tool of  claim 26 , wherein each of the plurality of sintered parts is a different size. 
     
     
         37 . The wear resistant tool of  claim 26 , wherein the at least one internal cavity is a channel. 
     
     
         38 . The wear resistant tool of  claim 37 , further comprising a thermal conductive material disposed in the at least one internal channel. 
     
     
         39 . The wear resistant tool of  claim 38 , wherein the thermal conductive material is selected from the group of copper, fluid, liquid coolant and porous foam. 
     
     
         40 . The wear resistant tool of  claim 37 , further comprising a vibration minimizing material disposed in the at least one internal channel. 
     
     
         41 . The wear resistant tool of  claim 40 , wherein the vibration minimizing material is selected from a group of fluid, alumina spheres and alumina coated spheres. 
     
     
         42 . The method of  claim 40 , wherein the vibration minimizing material is a block of alumina or alumina-coated material movably disposed within the at least one internal cavity. 
     
     
         43 . The wear resistant tool of  claim 26 , wherein at least one of the sintered parts is a hollow tube and further comprising a strengthening material disposed therein. 
     
     
         44 . The wear resistant tool of  claim 43 , wherein the strengthening material is high speed steel.