US20070034048A1 - Hardmetal materials for high-temperature applications - Google Patents

Hardmetal materials for high-temperature applications Download PDF

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US20070034048A1
US20070034048A1 US11/507,928 US50792806A US2007034048A1 US 20070034048 A1 US20070034048 A1 US 20070034048A1 US 50792806 A US50792806 A US 50792806A US 2007034048 A1 US2007034048 A1 US 2007034048A1
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binder
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hardmetals
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US11/507,928
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Shaiw-Rong Liu
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Worldwide Strategy Holdings Ltd
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Genius Metal Inc
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Priority claimed from US10/453,085 external-priority patent/US6911063B2/en
Priority claimed from US11/081,928 external-priority patent/US7645315B2/en
Priority to US11/507,928 priority Critical patent/US20070034048A1/en
Application filed by Genius Metal Inc filed Critical Genius Metal Inc
Assigned to GENIUS METAL, INC. reassignment GENIUS METAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIU, SHAIW-RONG SCOTT
Priority to EP07717159A priority patent/EP1982001A4/en
Priority to BRPI0707371-2A priority patent/BRPI0707371A2/en
Priority to US11/669,791 priority patent/US7857188B2/en
Priority to PCT/US2007/002719 priority patent/WO2007089882A2/en
Priority to JP2008553346A priority patent/JP2009543696A/en
Priority to CA002641029A priority patent/CA2641029A1/en
Publication of US20070034048A1 publication Critical patent/US20070034048A1/en
Priority to IL193160A priority patent/IL193160A0/en
Assigned to GENIUS METAL, INC. reassignment GENIUS METAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GENIUS METAL, INC.
Assigned to WORLDWIDE STRATEGY HOLDINGS LIMITED reassignment WORLDWIDE STRATEGY HOLDINGS LIMITED CORRECTIVE ASSIGNMENT TO CORRECT THE ASSIGNEE PREVIOUSLY RECORDED ON REEL 021994 FRAME 0416. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: GENIUS METAL, INC.
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • This application relates to hardmetal compositions, their fabrication techniques, and associated applications.
  • Hardmetals include various composite materials and are specially designed to be hard and refractory, and exhibit strong resistance to wear. Examples of widely-used hardmetals include sintered or cemented carbides or carbonitrides, or a combination of such materials. Some hardmetals, called cermets, have compositions that may include processed ceramic particles (e.g., TiC) bonded with binder metal particles. Certain compositions of hardmetals have been documented in the technical literature. For example, a comprehensive compilation of hardmetal compositions is published in Brookes' World Dictionary and Handbook of Hardmetals, sixth edition, International Carbide Data, United Kingdom (1996).
  • Hardmetals may be used in a variety of applications. Exemplary applications include cutting tools for cutting metals, stones, and other hard materials, wire-drawing dies, knives, mining tools for cutting coals and various ores and rocks, and drilling tools for oil and other drilling applications. In addition, such hardmetals also may be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.
  • hardmetals may be formed by first dispersing hard, refractory particles of carbides or carbonitrides in a binder matrix and then pressing and sintering the mixture. The sintering process allows the binder matrix to bind the particles and to condense the mixture to form the resulting hardmetals.
  • the hard particles primarily contribute to the hard and refractory properties of the resulting hardmetals.
  • the hardmetal materials described below include materials comprising hard particles having a first material, and a binder matrix having a second, different material.
  • the hard particles are spatially dispersed in the binder matrix in a substantially uniform manner.
  • the first material for the hard particles may include, for example, materials based on tungsten carbide, materials based on titanium carbide, materials based on a mixture of tungsten carbide and titanium carbide, other carbides, nitrides, borides, silicides, and combinations of these materials.
  • the second material for the binder matrix may include, among others, rhenium, a mixture of rhenium and cobalt, a nickel-based superalloy, a mixture of a nickel-based superalloy and rhenium, a mixture of a nickel-based superalloy, rhenium and cobalt, and these materials mixed with other materials.
  • Tungsten may also be used as a binder matrix material in hardmetal materials.
  • the nickel-based superalloy may be in the ⁇ - ⁇ ′ metallurgic phase.
  • the volume of the second material may be from about 3% to about 40% of a total volume of the material.
  • the binder matrix may comprise rhenium in an amount at or greater than 25% of a total weight of the binder matrix of the final material.
  • the second material may include a Ni-based superalloy.
  • the Ni-based superalloy may include Ni and other elements such as Re for certain applications.
  • Fabrication of the hardmetal materials of this application may be carried out by, according to one implementation, sintering the material mixture under a vacuum condition and performing a solid-phase sintering under a pressure applied through a gas medium.
  • Such hardmetals may also be coated on surfaces using thermal spray methods to form either hardmetal coatings and hardmetal structures.
  • Advantages arising from various implementations of the described hardmetal materials may include one or more of the following: superior hardness in general, enhanced hardness at high temperatures, and improved resistance to corrosion and oxidation.
  • a material can include hard particles comprising at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al 4 C 3 , ThC 2 , MO 2 C, SiC and B 4 C; and a binder matrix that binds the hard particles and comprises rhenium.
  • a material can include hard particles comprising at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN; and a binder matrix that binds the hard particles and comprises rhenium.
  • a material can include hard particles comprising at least one boride selected from at least one of HfB 2 , ZrB 2 , TaB 2 , TiB 2 , NbB 2 , and WB; and a binder matrix that binds the hard particles and comprises rhenium.
  • hard particles comprising at least one boride selected from at least one of HfB 2 , ZrB 2 , TaB 2 , TiB 2 , NbB 2 , and WB.
  • FIG. 1 shows one exemplary fabrication flow in making a hardmetal according to one implementation.
  • FIG. 2 shows an exemplary two-step sintering process for processing hardmetals in a solid state.
  • FIGS. 3, 4 , 5 , 6 , 7 , and 8 show various measured properties of selected exemplary hardmetals.
  • FIGS. 9 and 10 illustrate examples of the thermal spray methods.
  • compositions of hardmetals are important in that they directly affect the technical performance of the hardmetals in their intended applications, and processing conditions and equipment used during fabrication of such hardmetals.
  • the hardmetal compositions also can directly affect the cost of the raw materials for the hardmetals, and the costs associated with the fabrication processes. For these and other reasons, extensive efforts have been made in the hardmetal industry to develop technically superior and economically feasible compositions for hardmetals. This application describes, among other features, material compositions for hardmetals with selected binder matrix materials that, together, provide performance advantages.
  • Material compositions for hardmetals of interest include various hard particles and various binder matrix materials.
  • the hard particles may be formed from carbides of the metals in columns IVB (e.g., TiC, ZrC, HfC), VB (e.g., VC, NbC, TaC), and VIB (e.g., Cr 3 C 2 , MO 2 C, WC) in the Periodic Table of Elements.
  • nitrides formed by metals elements in columns IVB (e.g., TiN, ZrN, HfN) and VB (e.g., VN, NbN, and TaN) in the Periodic Table of Elements may also be used.
  • one material composition for hard particles that is widely used for many hardmetals is a tungsten carbide, e.g., the mono tungsten carbide (WC).
  • Various nitrides may be mixed with carbides to form the hard particles. Two or more of the above and other carbides and nitrides may be combined to form WC-based hardmetals or WC-free hardmetals. Examples of mixtures of different carbides include but are not limited to a mixture of WC and TiC, and a mixture of WC, TiC, and TaC.
  • nitrides, carbonitrides, borides, and silicides may also be used as hard particles for hardmetals. Examples of various suitable hard particles are described in this application.
  • the binder matrix may include one or more transition metals in the eighth column of the Periodic Table of Elements, such as cobalt (Co), nickel (Ni), and iron (Fe), and the metals in the 6B column such as molybdenum (Mo) and chromium (Cr). Two or more of such and other binder metals may be mixed together to form desired binder matrices for bonding suitable hard particles.
  • Some binder matrices for example, use combinations of Co, Ni, and Mo with different relative weights.
  • the hardmetal compositions described here were developed in part based on a recognition that the material composition of the binder matrix may be specially configured and tailored to provide high-performance hardmetals to meet specific needs of various applications.
  • the material composition of the binder matrix has significant effects on other material properties of the resulting hardmetals, such as the elasticity, the rigidity, and the strength parameters (including the transverse rupture strength, the tensile strength, and the impact strength).
  • the inventor recognized that it was desirable to provide the proper material composition for the binder matrix to better match the material composition of the hard particles and other components of the hardmetals in order to enhance the material properties and the performance of the resulting hardmetals.
  • these hardmetal compositions use binder matrices that include rhenium, a nickel-based superalloy or a combination of at least one nickel-based superalloy and other binder materials.
  • suitable binder materials may include, among others, rhenium (Re) or cobalt.
  • a Ni-based superalloy exhibits a high material strength at a relatively high temperature.
  • the resulting hardmetal formed with such a binder material can benefit from the high material strength at high temperatures of rhenium and Ni-superalloy and exhibit enhanced performance at high temperatures.
  • a Ni-based superalloy also exhibits superior resistance to corrosion and oxidation, and thus, when used as a binder material, can improve the corresponding resistance of the hardmetals.
  • compositions of the hardmetals described in this application may include the binder matrix material from about 3% to about 40% by volume of the total materials in the hardmetals so that the corresponding volume percentage of the hard particles is about from 97% to about 60%, respectively.
  • the binder matrix material in certain implementations may be from about 4% to about 35% by volume out of the volume of the total hardmetal materials. More preferably, some compositions of the hardmetals may have from about 5% to about 30% of the binder matrix material by volume out of the volume of the total hardmetal materials.
  • the weight percentage of the binder matrix material in the total weight of the resulting hardmetals may be derived from the specific compositions of the hardmetals.
  • the binder matrices may be formed primarily by a nickel-based superalloy, and by various combinations of the nickel-based superalloy with other elements such as Re, Co, Ni, Fe, Mo, and Cr.
  • a Ni-based superalloy of interest may comprise, in addition to Ni, elements Co, Cr, Al, Ti, Mo, W, and other elements such as Ta, Nb, B, Zr and C.
  • Ni-based superalloys may include the following constituent metals in weight percentage of the total weight of the superalloy: Ni from about 30% to about 70%, Cr from about 10% to about 30%, Co from about 0% to about 25%, a total of Al and Ti from about 4% to about 12%, Mo from about 0% to about 10%, W from about 0% to about 10%, Ta from about 0% to about 10%, Nb from about 0% to about 5%, and Hf from about 0% to about 5%.
  • Ni-based superalloys may also include either or both of Re and Hf, e.g., Re from 0% to about 10%, and Hf from 0% to about 5%.
  • Ni-based superalloy with Re may be used in applications under high temperatures.
  • a Ni-based super alloy may further include other elements, such as B, Zr, and C, in small amounts.
  • Compounds TaC and NbC have similar properties to a certain extent and may be used to partially or completely substitute or replace each other in hardmetal compositions in some implementations. Either one or both of HfC and NbC also may be used to substitute or replace a part or all of TaC in hardmetal designs.
  • Compounds WC, TiC, TaC may be produced individually and then mixed to form a mixture or may be produced in a form of a solid solution.
  • the mixture may be selected from at least one from a group consisting of (1) a mixture of WC, TiC, and TaC, (2) a mixture of WC, TiC, and NbC, (3) a mixture of WC, TiC, and at least one of TaC and NbC, and (4) a mixture of WC, TiC, and at least one of HfC and NbC.
  • a solid solution of multiple carbides may exhibit better properties and performances than a mixture of several carbides.
  • hard particles may be selected from at least one from a group consisting of (1) a solid solution of WC, TiC, and TaC, (2) a solid solution of WC, TiC, and NbC, (3) a solid solution of WC, TiC, and at least one of TaC and NbC, and (4) a solid solution of WC, TiC, and at least one of HfC and NbC.
  • the nickel-based superalloy as a binder material may be in a ⁇ - ⁇ ′ phase where the ⁇ ′ phase with a FCC structure mixes with the ⁇ phase.
  • the strength increases with temperature within a certain extent.
  • Another desirable property of such a Ni-based superalloy is its high resistance to oxidation and corrosion.
  • the nickel-based superalloy may be used to either partially or entirely replace Co in various Co-based binder compositions.
  • the inclusion of both of rhenium and a nickel-based superalloy in a binder matrix of a hardmetal can significantly improve the performance of the resulting hardmetal by benefiting from the superior performance at high temperatures from presence of Re while utilizing the relatively low-sintering temperature of the Ni-based superalloy to maintain a reasonably low sintering temperature for ease of fabrication.
  • the relatively low content of Re in such binder compositions allows for reduced cost of the binder materials so that such materials be economically feasible.
  • Such a nickel-based superalloy may have a percentage weight from several percent to 100% with respect to the total weight of all material components in the binder matrix based on the specific composition of the binder matrix.
  • a typical nickel-based superalloy may primarily comprise nickel and other metal components in a ⁇ - ⁇ ′ phase strengthened state so that it exhibits an enhanced strength which increases as temperature rises.
  • Various nickel-based superalloys may have a melting point lower than the common binder material cobalt, such as alloys under the trade names Rene-95, Udimet-700, Udimet-720 from Special Metals which comprise primarily Ni in combination with Co, Cr, Al, Ti, Mo, Nb, W, B, and Zr.
  • cobalt such as alloys under the trade names Rene-95, Udimet-700, Udimet-720 from Special Metals which comprise primarily Ni in combination with Co, Cr, Al, Ti, Mo, Nb, W, B, and Zr.
  • the nickel-based superalloy can be used in the binder to provide a high material strength and to improve the material hardness of the resulting hardmetals, at high temperatures near or above 500° C.
  • Tests of some fabricated samples have demonstrated that the material hardness and strength for hardmetals with a Ni-based superalloy in the binder can improve significantly, e.g., by at least 10%, at low operating temperatures in comparison with similar material compositions without Ni-based superalloy in the binder.
  • the following table show measured hardness parameters of samples P65 and P46A with Ni-based superalloy in the binder in comparison with samples P49 and P47A with pure Co as the binder, where the compositions of the samples are listed in Table 4.
  • hardmetal samples with Ni-based superalloy in the binder can exhibit a material hardness that is significantly higher than that of similar hardmetal samples without having a Ni-based superalloy in the binder.
  • Ni-based superalloy as a binder material can also improve the resistance to corrosion of the resulting hardmetals or cermets in comparison with hardmetals or cermets using the conventional cobalt as the binder.
  • a nickel-based superalloy may be used alone or in combination with other elements to form a desired binder matrix.
  • Other elements that may be combined with the nickel-based superalloy to form a binder matrix include but are not limited to, another nickel-based superalloy, other non-nickel-based alloys, Re, Co, Ni, Fe, Mo, and Cr.
  • Rhenium as a binder material may be used to provide strong bonding of hard particles and in particular can produce a high melting point for the resulting hardmetal material.
  • the melting point of rhenium is about 3180° C., much higher than the melting point of 1495° C. of the commonly-used cobalt as a binder material. This feature of rhenium partially contributes to the enhanced performance of hardmetals with binders using Re, e.g., the enhanced hardness and strength of the resulting hardmetals at high temperatures. Re also has other desired properties as a binder material.
  • the hardness, the transverse rapture strength, the fracture toughness, and the melting point of the hardmetals with Re in their binder matrices can be increased significantly in comparison with similar hardmetals without Re in the binder matrices.
  • a hardness Hv over 2600 Kg/mm 2 has been achieved in exemplary WC-based hardmetals with Re in the binder matrices.
  • the melting point of some exemplary WC-based hardmetals, i.e., the sintering temperature has shown to be greater than 2200° C.
  • the sintering temperature for WC-based hardmetals with Co in the binders in Table 2.1 in the cited Brookes is below 1500° C.
  • a hardmetal with a high sintering temperature allows the material to operate at a high temperature below the sintering temperature.
  • tools based on such Re-containing hardmetal materials may operate at high speeds to reduce the processing time and the overall throughput of the processing.
  • Re as a binder material in hardmetals
  • the desirable high-temperature property of Re generally leads to a high sintering temperature for fabrication.
  • the oven or furnace for the conventional sintering process needs to operate at or above the high sintering temperature.
  • Ovens or furnaces capable of operating at such high temperatures, e.g., above 2200° C. can be expensive and may not be widely available for commercial use.
  • U.S. Pat. No. 5,476,531 discloses a use of a rapid omnidirectional compaction (ROC) method to reduce the processing temperature in manufacturing WC-based hardmetals with pure Re as the binder material from 6% to 18% of the total weight of each hardmetal. This ROC process, however, is still expensive and is generally not suitable for commercial fabrication.
  • ROC rapid omnidirectional compaction
  • hardmetal compositions and the composition methods described here may provide or allow for a more practical fabrication process for fabricating hardmetals with either Re or mixtures of Re with other binder materials in the binder matrices.
  • this two-step process makes it possible to fabricate hardmetals where Re is at or more than 25% of the total weight of the binder matrix of the resulting hardmetal.
  • Such hardmetals with Re at or more than 25% may be used to achieve a high hardness and a high material strength at high temperatures.
  • Ni-based superalloy has exceptionally strength and oxidation resistance under 1000° C.
  • a mixture of a Ni-based superalloy and Re where Re is the dominant material in the binder may be used to improve the strength and oxidation resistance of the resulting hardmetal using such a mixture as the binder.
  • the addition of Re into a binder primarily comprised of a Ni-based superalloy can increase the melting range of the resulting hardmetal, and improve the high temperature strength and creep resistance of the Ni-based superalloy binder.
  • the percentage weight of the rhenium in the binder matrix should be between a several percent to essentially 100% of the total weight of the binder matrix in a hardmetal.
  • the percentage weight of rhenium in the binder matrix should be at or above 5%.
  • the percentage weight of rhenium in the binder matrix may be at or above 10% of the binder matrix.
  • the percentage weight of rhenium in the binder matrix may be at or above 25% of the total weight of the binder matrix of the resulting hardmetal.
  • Hardmetals with such a high concentration of Re may be fabricated at relatively low temperatures with a two-step process described in this application.
  • a hardmetal composition includes dispersed hard particles having a first material, and a binder matrix having a second, different material that includes rhenium, where the hard particles are spatially dispersed in the binder matrix in a substantially uniform manner.
  • the binder matrix may be a mixture of Re and other binder materials to reduce the total content of Re to in part reduce the overall cost of the raw materials and in part to explore the presence of other binder materials to enhance the performance of the binder matrix.
  • binder matrices having mixtures of Re and other binder materials include, mixtures of Re and at least one Ni-based superalloy, mixtures of Re, Co and at least one Ni-based superalloy, mixtures of Re and Co, and others.
  • WC-based compositions are referred to as “hardmetals” and the TiC-based compositions are referred to as “cermets.”
  • cermets TiC particles bound by a mixture of Ni and Mo or a mixture of Ni and Mo 2 C are cermets.
  • Cermets as described here further include hard particles formed by mixtures of TiC and TiN, of TiC, TiN, WC, TaC, and NbC with the binder matrices formed by the mixture of Ni and Mo or the mixture of Ni and Mo 2 C.
  • three different weight percentage ranges for the given binder material in the are listed.
  • the binder may be a mixture of a Ni-based superalloy and cobalt, and the hard particles may a mixture of WC, TiC, TaC, and NbC.
  • the binder may be from about 2% to about 40% of the total weight of the hardmetal. This range may be set to from about 3% to about 35% in some applications and may be further limited to a smaller range from about 4% to about 30% in other applications.
  • Fabrication of hardmetals with Re or a nickel-based superalloy in binder matrices may be carried out as follows. First, a powder with desired hard particles such as one or more carbides or carbonitrides is prepared. This powder may include a mixture of different carbides or a mixture of carbides and nitrides. The powder is mixed with a suitable binder matrix material that includes Re or a nickel-based superalloy. In addition, a pressing lubricant, e.g., a wax, may be added to the mixture.
  • a pressing lubricant e.g., a wax
  • the mixture of the hard particles, the binder matrix material, and the lubricant is mixed through a milling or attriting process by milling or attriting over a desired period, e.g., hours, to fully mix the materials so that each hard particle is coated with the binder matrix material to facilitate the binding of the hard particles in the subsequent processes.
  • the hard particles should also be coated with the lubricant material to lubricate the materials to facilitate the mixing process and to reduce or eliminate oxidation of the hard particles.
  • pressing, pre-sintering, shaping, and final sintering are subsequently performed to the milled mixture to form the resulting hardmetal.
  • the sintering process is a process for converting a powder material into a continuous mass by heating to a temperature that is below the melting temperature of the hard particles and may be performed after preliminary compacting by pressure. During this process, the binder material is densified to form a continuous binder matrix to bind hard particles therein. One or more additional coatings may be further formed on a surface of the resulting hardmetal to enhance the performance of the hardmetal.
  • FIG. 1 is a flowchart for this implementation of the fabrication process.
  • the manufacture process for cemented carbides includes wet milling in solvent, vacuum drying, pressing, and liquid-phase sintering in vacuum.
  • the temperature of the liquid-phase sintering is between melting point of the binder material (e.g., Co at 1495° C.) and the eutectic temperature of the mixture of hardmetal (e.g., WC-Co at 1320° C.).
  • the sintering temperature of cemented carbide is in a range of 1360 to 1480° C.
  • manufacture process is same as conventional cemented carbide process.
  • the principle of liquid phase sintering in vacuum is applied in here.
  • the sintering temperature is slightly higher than the eutectic temperature of binder alloy and carbide.
  • the sintering condition of P17 (25% of Re in binder alloy, by weight) is at 1700° C. for one hour in vacuum.
  • FIG. 2 shows a two-step fabrication process based on a solid-state phase sintering for fabricating various hardmetals described in this application.
  • hardmetals that can be fabricated with this two-step sintering method include hardmetals with a high concentration of Re in the binder matrix that would otherwise require the liquid-phase sintering at high temperatures.
  • This two-step process may be implemented at relatively low temperatures, e.g., under 2200° C., to utilize commercially feasible ovens and to produce the hardmetals at reasonably low costs.
  • the liquid phase sintering is eliminated in this two-step process because the liquid phase sintering may not be practical due to the generally high eutectic temperatures of the binder alloy and carbide. As discussed above, sintering at such high temperatures requires ovens operating at high temperatures which may not be commercially feasible.
  • the first step of this two-step process is a vacuum sintering where the mixture materials for the binder matrix and the hard particles are sintered in vacuum.
  • the mixture is initially processed by, e.g., wet milling, drying, and pressing, as performed in conventional processes for fabricating cemented carbides.
  • This first step of sintering is performed at a temperature below the eutectic temperature of the binder alloy and the hard particle materials to remove or eliminate the interconnected porosity.
  • the second step is a solid phase sintering at a temperature below the eutectic temperature and under a pressured condition to remove and eliminate the remaining porosities and voids left in the sintered mixture after the first step.
  • a hot isostatic pressing (HIP) process may be used as this second step sintering. Both heat and pressure are applied to the material during the sintering to reduce the processing temperature which would otherwise be higher in absence of the pressure.
  • a gas medium such as an inert gas may be used to apply and transmit the pressure to the sintered mixture.
  • the pressure may be at or over 1000 bar.
  • Application of pressure in the HIP process lowers the required processing temperature and allows for use of conventional ovens or furnaces.
  • the temperatures of solid phase sintering and HIPping for achieving fully condensed materials are generally significantly lower than the temperatures for liquid phase sintering.
  • the sample P62 which uses pure Re as the binder may be fully densified by vacuum sintering at 2200° C.
  • ultra fine hard particles with a particulate dimension less than 0.5 micron can reduce the sintering temperature for fully densifying the hardmetals (fine particles are several microns in size).
  • the use of such ultra fine WC allows for sintering temperatures to be low, e.g., around 2000° C. This two-step process is less expensive than the ROC method and may be used to commercial production.
  • TABLE 2 provides a list of code names (lot numbers) for some of the constituent materials used to form the exemplary hardmetals, where H1 represents rhenium, and L1, L2, and L3 represent three exemplary commercial nickel-based superalloys.
  • H1 represents rhenium
  • L1, L2, and L3 represent three exemplary commercial nickel-based superalloys.
  • TABLE 3 further lists compositions of the above three exemplary nickel-based superalloys, Udimet720(U720), Rene'95(R-95), and Udimet700(U700), respectively.
  • TABLE 4 lists compositions of exemplary hardmetals, both with and without rhenium or a nickel-based superalloy in the binder matrices.
  • the material composition for Lot P17 primarily includes 88 grams of T32 (WC), 3 grams of 132 (TiC), 3 grams of A31 (TaC), 1.5 grams of H1 (Re) and 4.5 grams of L2 (R-95) as binder, and 2 grams of a wax as lubricant.
  • Lot P58 represents a hardmetal with a nickel-based superalloy L2 as the only binder material without Re. These hardmetals were fabricated and tested to illustrate the effects of either or both of rhenium and a nickel-based superalloy as binder materials on various properties of the resulting hardmetals.
  • TABLES 5-8 further provide summary information of compositions and properties of different sample lots as defined above.
  • FIGS. 3 through 8 show measurements of selected hardmetal samples of this application.
  • FIGS. 3 and 4 show measured toughness and hardness parameters of some exemplary hardmetals for the steel cutting grades.
  • FIGS. 5 and 6 show measured toughness and hardness parameters of some exemplary hardmetals for the non-ferrous cutting grades. Measurements were performed before and after the solid-phase sintering HIP process and the data suggests that the HIP process significantly improves both the toughness and the hardness of the materials.
  • FIG. 7 shows measurements of the hardness as a function of temperature for some samples. As a comparison, FIGS. 7 and 8 also show measurements of commercial C2 and C6 carbides under the same testing conditions, where FIG. 7 shows the measured hardness and FIG.
  • I32 TiC from AEE Ti-302 I21 TiB 2 from AEE, Ti-201, 1-5 ⁇ m A31 TaC from AEE, TA-301 Y31 Mo 2 C from AEE, MO-301 D31 VC from AEE, VA-301 B1 Co from AEE, CO-101 K1 Ni from AEE, Ni-101 K2 Ni from AEE, Ni-102 I13 TiN from Cerac, T-1153 C21 ZrB2 from Cerac, Z-1031 Y6 Mo from AEE Mo + 100, 1-2 ⁇ m L6 Al from AEE Al-100, 1-5 ⁇ m R31 B 4 C from AEE Bo-301, 3 ⁇ m T3.8 WC Particle size 0.8 ⁇ m, Alldyne T3.4 WC Particle size 0.4 ⁇ m, OMG T3.2 WC Particle size 0.2 ⁇ m, OMG
  • the exemplary categories of hardmetal compositions are described below to illustrate the above general designs of the various hardmetal compositions to include either of Re and Nickel-based superalloy, or both.
  • the exemplary categories of hardmetal compositions are defined based on the compositions of the binder matrices for the resulting hardmetals or cermets.
  • the first category uses a binder matrix having pure Re
  • the second category uses a binder matrix having a Re—Co alloy
  • the third category uses a binder matrix having a Ni-based superalloy
  • the fourth category uses a binder matrix having an alloy having a Ni-based superalloy in combination with of Re with or without Co.
  • hard and refractory particles used in hardmetals of interest may include, but are not limited to, carbides, nitrides, carbonitrides, borides, and silicides.
  • Carbides include WC, TiC, TaC, HfC, NbC, Mo 2 C, Cr 2 C 3 , VC, ZrC, B 4 C, and SiC.
  • Nitrides include TiN, ZrN, HfN, VN, NbN, TaN, and BN.
  • Examples of Carbonitrides include Ti(C,N), Ta(C,N), Nb(C,N), Hf(C,N), Zr(C,N), and V(C,N).
  • Examples of Borides include TiB 2 , ZrB 2 , HfB 2 , TaB 2 , VB 2 , MoB 2 , WB, and W 2 B.
  • examples of Silicides are TaSi 2 , Wsi 2 , NbSi 2 , and MoSi 2 .
  • the above-identified four categories of hardmetals or cermets can also use these and other hard and refractory particles.
  • the Re may be approximately from 5% to 40% by volume of all material compositions used in a hardmetal or cermet.
  • the sample with a lot No. P62 in TABLE 4 has 10% of pure Re, 70% of WC, 15% of TiC, and 5% of TaC by volume. This composition approximately corresponds to 14.48% of Re, 75.43% of WC, 5.09% of TiC and 5.0% of TaC by weight.
  • the Specimen P62-4 was vacuum sintered at 2100° C. for about one hour and 2158° C. for about one hour. The density of this material is about 14.51 g/cc, where the calculated density is 14.50 g/cc.
  • the average hardness Hv is 2627 ⁇ 35 Kg/mm 2 for 10 measurements taken at the room temperature under a load of 10 Kg.
  • the measured surface fracture toughness K sc is about 7.4 ⁇ 10 6 Pa m 1/2 estimated by Palmvist crack length at a load of 10 Kg.
  • P66 in TABLE 4 This sample has about 20% of Re, 60% of WC, 15% of TiC, and 5% of TaC by volume in composition. In the weight percentage, this sample has about 27.92% of Re, 62.35% of WC, 4.91% of TiC, and 4.82% of TaC.
  • the Specimen P66-4 was first processed with a vacuum sintering process at about 2200° C. for one hour and was then sintered in the solid-phase with a HIP process to remove porosities and voids. The density of the resulting hardmetal is about 14.40 g/cc compared to the calculated density of 15.04 g/cc.
  • the average hardness Hv is about 2402 ⁇ 44 Kg/mm 2 for 7 different measurements taken at the room temperature under a load of 10 Kg.
  • the surface fracture toughness K sc is about 8.1 ⁇ 10 6 Pa m 1/2 .
  • the sample P66 and other compositions described here with a high concentration of Re with a weight percentage greater than 25%, as the sole binder material or one of two or more different binder materials in the binder, may be used for various applications at high operating temperatures and may be manufactured by using the two-step process based on solid-phase sintering.
  • the microstructures and properties of Re bound multiples types of hard refractory particles may provide advantages over Re-bound WC material.
  • Re bound WC—TiC—TaC may have better crater resistance in steel cutting than Re bound WC material.
  • Another example is materials formed by refractory particles of MO 2 C and TiC bound in a Re binder.
  • the Re—Co alloy may be about from 5 to 40 Vol % of all material compositions used in the composition.
  • the Re-to-Co ratio in the binder may vary from 0.01 to 0.99 approximately.
  • Inclusion of Re can improve the mechanical properties of the resulting hardmetals, such as hardness, strength and toughness special at high temperature compared to Co bounded hardmetal. The higher Re content is the better high temperature properties are for most materials using such a binder matrix.
  • the sample P31 in TABLE 4 is one example within this category with 2.5% of Re, 7.5% of Co, and 90% of WC by volume, and 3.44% of Re, 4.40% of Co and 92.12% of WC by weight.
  • the Specimen P31-1 was vacuum sintered at 1725C for about one hour. slight under sintering with some porosities and voids.
  • the density of the resulting hardmetal is about 15.16 g/cc (calculated density at 15.27 g/cc).
  • the average hardness Hv is about 1889 ⁇ 18 Kg/mm 2 at the room temperature under 10 Kg and the surface facture toughness K sc is about 7.7 ⁇ 10 6 Pa ⁇ m 1/2 .
  • the Specimen P31-1 was treated with a hot isostatic press (HIP) process at about 1600C/15 Ksi for about one hour after sintering.
  • HIP hot isostatic press
  • the HIP reduces or substantially eliminates the porosities and voids in the compound to increase the material density.
  • the measured density is about 15.25 g/cc (calculated density at 15.27 g/cc).
  • the measured hardness Hv is about 1887 ⁇ 12 Kg/mm 2 at the room temperature under 10 Kg.
  • the surface fracture toughness K sc is about 7.6 ⁇ 10 6 Pa ⁇ m 1/2 .
  • P32 in TABLE 4 with 5.0% of Re, 5.0% of Co, and 90% of WC in volume (6.75% of Re, 2.88% of Co and 90.38% of WC in weight).
  • the Specimen P32-4 was vacuum sintered at 1800C for about one hour.
  • the measured density is about 15.58 g/cc in comparison with the calculated density at 15.57 g/cc.
  • the measured hardness Hv is about 2065 Kg/mm 2 at the room temperature under 10 Kg.
  • the surface fracture toughness K sc is about 5.9 ⁇ 10 6 Pa ⁇ m 1/2 .
  • the Specimen P32-4 was also HIP at 1600C/15 Ksi for about one hour after Sintering.
  • the measured density is about 15.57 g/cc (calculated density at 15.57 g/cc).
  • the average hardness Hv is about 2010 ⁇ 12 Kg/mm 2 at the room temperature under 10 Kg.
  • the surface fracture toughness K sc is about 5.8 ⁇ 10 6 Pa ⁇ m 1/2 .
  • the third example is P33 in TABLE 4 which has 7.5% of Re, 2.5% of Co, and 90% of WC by volume and 9.93% of Re, 1.41% of Co and 88.66% of WC by weight.
  • the Specimen P33-7 was vacuum sintered at 1950C for about one hour and was under sintering with porosities and voids.
  • the measured density is about 15.38 g/cc (calculated density at 15.87 g/cc).
  • the measured hardness Hv is about 2081 Kg/mm 2 at the room temperature under a force of 10 Kg.
  • the surface fracture toughness K sc is about 5.6 ⁇ 10 6 Pa ⁇ m 1/2 .
  • the Specimen P33-7 was HIP at 1600C/15Ksi for about one hour after Sintering.
  • the average hardness Hv is measured at about 2039 ⁇ 18 Kg/mm 2 at the room temperature under 10 Kg.
  • the surface fracture toughness Ksc is about 6.5 ⁇ 10 6 Pa m 1/2 .
  • the samples P55, P56, P56A, and P57 in TABLE 4 are also examples for the category with a Re—Co alloy as the binder matrix. These samples have about 1.8% of Re, 7.2% of Co, 0.6% of VC except that P57 has no VC, and finally WC in balance. These different compositions are made to study the effects of hardmetal grain size on Hv and Ksc. TABLE 5 lists the results. TABLE 6 Properties of Ni-based superalloys, Ni, Re, and Co Test ° Temp. C.
  • the third category is based on binder matrices with Ni-based superalloys from 5 to 40% in volume of all materials in the resulting hardmetal.
  • Ni-based superalloys are a family of high temperature alloys with ⁇ ′ strengthening. Three different strength alloys, Rene′95, Udimet 720 , and Udimet 700 are used as examples to demonstrate the effects of the binder strength on mechanical properties of the final hardmetals.
  • the Ni-based superalloys have a high strength specially at elevated temperatures. Also, these alloys have good environmental resistance such as resistance to corrosion and oxidation at elevated temperature.
  • Ni-based superalloys can be used to increase the hardness of Ni-based superalloy bound hardmetals when compared to Cobalt bound hardmetals.
  • the tensile strengths of the Ni-based superalloys are much stronger than the common binder material cobalt as shown by TABLE 6. This further shows that Ni-based superalloys are good binder materials for hardmetals.
  • P58 in TABLE 4 which has 7.5% of Rene′95, 0.6% of VC, and 91.9% of WC in weight and compares to cobalt bound P54 in TABLE 4 (8% of Co, 0.6% of VC, and 91.4% of WC).
  • the hardness of P58 is significant higher than P54 as shown in TABLE 7.
  • TABLE 7 Comparison of P54 and P58 Hv, Ksc Sintering HIP Kg/mm 2 ⁇ 10 6 Pa ⁇ m 1/2 P54-1 1350 C./1 hr 1305° C.
  • the fourth category is Ni-based superalloy plus Re as binder, e.g., approximately from 5% to 40% by volume of all materials in the resulting hardmetal or cermet. Because addition of Re increases the melting point of binder alloy of Ni-based superalloy plus Re, the processing temperature of hardmetal with Ni-based superalloy plus Re binder increases as the Re content increases.
  • Several hardmetals with different Re concentrations are listed in TABLE 8. TABLE 9 further shows the measured properties of the hardmetals in TABLE 8.
  • TABLE 8 Hardmetal with a binder comprising Ni-based superalloy and Re Sintering Composition, weight % Temperature Re Rene95 U-700 U-720 WC TiC TaC Re to Binder Ratio ° C.
  • Ni-based superalloy plus Re and Co as binder which is also about 5% to 40% by volume.
  • Exemplary compositions of hardmetals bound by Ni-based superalloy plus Re and Co are list in TABLE 10.
  • Ni-based superalloys not only exhibit excellent strengths at elevated temperatures but also possess outstanding resistances to oxidation and corrosion at high temperatures.
  • Ni-based superalloys have complex microstructures and strengthening mechanisms. In general, the strengthening of Ni-based superalloys is primarily due to precipitation strengthening of ⁇ - ⁇ ′ and solid-solution strengthening. The measurements the selected samples demonstrate that Ni-based superalloys can be used as a high-performance binder materials for hardmetals.
  • TABLE 11 lists compositions of selected samples by their weight percentages of the total weight of the hardmetals.
  • the WC particles in the samples are 0.2 ⁇ m in size.
  • TABLE 12 lists the conditions for the two-step process performed and measured densities, hardness parameters, and toughness parameters of the samples.
  • the sample P54 uses the conventional binder consisting of Co.
  • the Ni-superalloy R-95 is used in the sample P58 to replace Co as the binder in the sample P54.
  • the Hv increases from 2090 of P54 to 2246 of P58.
  • the mixture of Re and Co is used to replace Co as binder and the corresponding Hv increases from 2090 of P54 to 2133 of P56.
  • the samples P72, P73, P74 have the same Re content but different amounts of Co and R95.
  • the mixtures of Re, Co, and R95 are used in samples P73 and P74 to replace the binder having a mixture of Re and Co as the binder in the sample 72.
  • TABLE 15 further shows measured hardness parameters under various temperatures for the selected samples, where the Knoop hardness H k were measured under a load of 1 Kg for 15 seconds on a Nikon QM hot hardness tester and R is a ratio of H k at an elevated testing temperature over H k at 25° C.
  • the hot hardness specimens of C2 and C6 carbides were prepared from inserts SNU434 which were purchased from MSC Co. (Melville, N.Y.). TABLE 15 (each measured value at a given temperature is an averaged value of 3 different measurements) Testing Temperature, ° C. Lot No.
  • Inclusion of Re in the binder matrices of the hardmetals increases the melting point of binder alloys that include Co—Re, Ni superalloy-Re, Ni superalloy-Re—Co.
  • the melting point of the sample P63 is much higher than the temperature of 2200° C. used for the solid-phase sintering process.
  • Hot hardness values of such hardmetals with Re in the binders e.g., P17 to P63
  • the above measurements reveal that an increase in the concentration of Re in the binder increases the hardness at high temperatures.
  • the sample P62A with pure Re as the binder has the highest hardness.
  • the sample P63 with a binder composition of 94% of Re and 6% of the Ni-based superalloy R95 has the second highest hardness.
  • the samples P40A(71.9% Re-29.1% R95), P49(69.9% Re-30.1% R95), P51(88.5% Re-11.5% R95), and P50(71.9% Re-28.1% R95) are the next group in their hardness.
  • the sample P48 with 62.5% of Re and 37.5% of R95 in its binder has the lowest hardness at high temperatures among the tested materials in part because its Re content is the lowest.
  • a hardmetal or cermet may include TiC and TiN bonded in a binder matrix having Ni and Mo or MO 2 C.
  • the binder Ni of cermet can be fully or partially replaced by Re, by Re plus Co, by Ni-based superalloy, by Re plus Ni-based superalloy, and by Re plus Co and Ni-based superalloy.
  • Samples P38 and P39 are examples of Ni-bound cermets.
  • the sample P34 is an example of Rene95-bound Cermet.
  • TABLES 17-29 list additional compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications.
  • TABLE 17 Compositions that use pure Re as a binder for binding a carbide from carbides of IVb, Vb, & VIb columns of the Periodic Table or a nitride from nitrides of IVb & Vb columns Composition Composition Composition Estimated Range 1 Range 2 Range 3 Melting Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
  • Compositions that use Ni-based superalloy(NBSA) in a binder for binding a nitride from nitrides of IVb &Vb columns of the Periodic Table.
  • compositions that use Re and Ni-based superalloy (Re + NBSA) in a binder for binding a carbide from carbides of IVb, Vb, & VIb or a nitride from nitrides of IVb & Vb.
  • the range of the binder is from 1% Re + 99% superalloy to 99% Re + 1% superalloy.
  • Composition Range 1 Composition Range 2
  • Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + NBSA) - Re 0.03 to 0.13 to 0.04 to 0.17 to 0.05 to 0.21 to TiC 39.6 73.6 34.7 69.3 29.7 64.3 NBSA 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 39.6 51.1 34.7 45.9 29.7 40.4 TiC 60 to 97 26.1 to 65 to 96 30.5 to 70 to 95 35.5 to 92 95.1 93.6 (Re + NBSA) - Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to ZrC 39.6 67.7 34.7 62.9 29.7 57.5 NBSA 0.03 to 0.03 to 0.04 to 0.05 to 0.05 to 0.06 to 39.6 44.1 34.7 39.0 29.7 33.8 ZrC 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 42 to 94 (Re +
  • compositions that use Re and Co (Re + Co) in a binder for binding a carbide from carbides of IVb, Vb, & VIb or a nitride from nitrides of IVb & Vb.
  • the range of Binder is from 1% Re + 99% Co to 99% Re + 1% Co.
  • compositions that use Ni-based superalloy (NBSA) and Co in a binder for binding a carbide from carbides of IVb, Vb, & VIb or a nitride from nitrides of IVb & Vb.
  • the range of Binder is from 1% NBSA + 99% Co to 99% NBSA + 1% Co.
  • compositions that use Re, Ni-based superalloy (NBSA), and Co in a binder for binding a carbide from carbides of IVb, Vb, & VIb or a nitride from nitrides of IVb & Vb.
  • NBSA Ni-based superalloy
  • Binder is from 0.5% Re + 0.5% Co + 99% superalloy to 99% Re + 0.5% Co + 0.5% Superalloy to 0.5% Re + 99% Co + 0.5% Superalloy Composition Composition Composition Composition Range 1 Range 2 Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + Co + NBSA) - Re 0.015 to 0.06 to 0.02 to 0.08 to 0.025 to 0.1 to 64.3 TiC 39.6 73.6 34.65 69.3 29.7 NBSA 0.015 to 0.02 to 0.02 to 0.03 to 0.025 to 0.035 to 39.6 51.3 34.65 46.0 29.7 40.5 Co 0.015 to 0.03 to 0.02 to 0.036 to 0.025 to 0.045 to 39.6 54.3 34.65 49.0 29.7 43.5 TiC 60 to 97 26 to 95 65 to 96 30 to 94 70 to 95 35 to 92 (Re + Co + NBSA) - Re 0.015 to 0.05 to 0.
  • Compositions that use Re and Ni-based superalloy (NBSA) in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + NBSA) - Re 0.03 to 39.6 0.04 to 52 0.04 to 34.65 0.06 to 48 0.05 to 29.7 0.07 to 45 WC + TiC NBSA 0.03 to 39.6 0.015 to 29 0.04 to 34.65 0.02 to 26 0.05 to 29.7 0.026 to 23 WC 40 to 96 40 to 98 43 to 94.5 44 to 97 45 to 93 48 to 96.6 TiC 1 to 48 0.3 to 24 1.5 to 45 0.5 to 22 2 to 42 0.6 to 21 (Re + NBSA) - Re 0.03 to 39.6 0.04 to 47 0.04 to 34.65 0.055 to 42 0.05 to 29.7 0.07 to 37 WC + TaC
  • compositions that use Re and Co in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + Co) - Re 0.03 to 39.6 0.04 to 53 0.04 to 34.65 0.055 to 48 0.05 to 29.7 0.07 to 43 WC + TiC Co 0.03 to 39.6 0.017 to 31 0.04 to 34.65 0.023 to 28 0.05 to 29.7 0.03 to 26 WC 40 to 96 40 to 98 43 to 94.5 44 to 97 45 to 93 48 to 96 TiC 1 to 48 0.3 to 23 1.5 to 45 0.5 to 22 2 to 42 0.6 to 21 (Re + Co) - Re 0.03 to 39.6 0.04 to 47 0.04 to 34.65 0.055 to 42 0.05 to 29.7 0.07 to 37 WC + TaC CO 0.03 to 39.6 0.017 to 28 0.04 to 34
  • Binder is from 0.5% Re + 99.5% superalloy to 99.5% Re + 0.5% Superalloy to 0.5% Re + 0.5% Superalloy + 99% Co.
  • TABLE 30 Compositions that use Re as a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % Re - Re 3 to 30 9.5 to 65 4 to 27 13 to 60 5 to 25 15 to 58 TiC + Mo 2 C TiC 43 to 97 19 to 88 48 to 92 23 to 79 51 to 90 25 to 75 Mo 2 C 0 to 27 0 to 38 0 to 26 0 to 36 0 to 24 0 to 33 Re - Re 3 to 30 9 to 63 4 to 27 12 to 58 5 to 25 15 to 56 TiN + Mo 2 C TiN 43 to 97 21 to 89 48 to
  • compositions that use Ni-based superalloy (NBSA) as a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % NBSA - NBSA 3 to 30 4 to 41 4 to 27 5 to 37 5 to 25 6 to 34 TiC + Mo 2 C TiC 43 to 94 30 to 90 48 to 92 35 to 87 51 to 90 37 to 84 Mo 2 C 3 to 27 4 to 40 4 to 26 6 to 39 5 to 24 8 to 36 NBSA - NBSA 3 to 30 4 to 38 4 to 27 5 to 34 5 to 25 6 to 32 TiN + Mo 2 C TiN 43 to 94 32 to 91 48 to 92 37 to 88 51 to 90 40 to 85 Mo 2 C 3 to 27 4 to 38 4 to 26 6 to 37
  • compositions that use Re and Ni-based superalloy (NBSA) in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + NBSA) - Re 0.03 to 29.7 0.1 to 64 0.04 to 26.73 0.13 to 60 0.05 to 24.75 0.16 to 57 TiC + TiN + Mo 2 C NBSA 0.03 to 29.7 0.03 to 40 0.04 to 26.73 0.05 to 36 0.05 to 24.75 0.06 to 34 TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84 TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85 Mo 2 C
  • compositions that use Re and Ni in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Composition Range 1 Composition Range 2 Composition Range 3 Material Volume % Weight % Volume % Weight % Volume % Weight % (Re + Ni) - Re 0.03 to 29.7 0.1 to 64 0.04 to 26.73 0.13 to 60 0.05 to 24.75 0.16 to 57
  • TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 83 TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85 Mo 2 C 3 to 27 3 to 38 4 to 26 4 to 37
  • compositions that use Re and Co in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 83 TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85 Mo 2 C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5
  • compositions that use Ni-based superalloy (NBSA) and Co in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84 TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 86 Mo 2 C 3
  • compositions that use Ni-based superalloy (NBSA) and Ni in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Compositions that use Re, Co, and Ni-based superalloy (NBSA) in a binder for binding TiC and Mo 2 C, or TiN and Mo 2 C, or TiC, TiN, and Mo 2 C, or TiC, TiN, Mo 2 C, WC, TaC, VC, and Cr 2 C 3
  • compositions that use Re, Ni, and Ni-based superalloy (NBSA) in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Compositions that use Re, Ni, and Co in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • Compositions that use Co, Ni, and Ni-based superalloy (NBSA) in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • compositions that use Re, Ni, Co, and Ni-based superalloy (NBSA) in a binder for binding TiC + Mo 2 C, or TiN + Mo 2 C, or TiC + TiN + Mo 2 C, or TiC + TiN + Mo 2 C + WC + TaC + VC + Cr 2 C 3
  • TABLES 42-51 list additional examples of various compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications. Similar to some compositions described above, some compositions in TABLES 42-51 may be particularly useful for applications at high temperatures as indicated in the last row under “estimated melting points.”
  • binder matrix materials with rhenium, a nickel-based superalloy or a combination of both can enhance material performance at high temperatures.
  • Tungsten is typically used as a constituent element in various hard particles such as carbides, nitrides, carbonitrides, borides, and silicides.
  • tungsten can significantly raise the melting point of the final hardmetal materials to the range of about 2500 to about 3500° C.
  • hardmetals using W-based binder matrix materials can be used in applications at high temperatures that may not be possible with other materials.
  • certain compositions that use a binder matrix based on tungsten (W) shown in TABLES 43-48 show expected high melting points around 3500° C.
  • each nitride may be substituted by a combination of a nitride and carbide as the hard particle material.
  • a material under this design includes hard particles comprising at least one nitride from nitrides of IVB and VB columns in the periodic table and 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 and cobalt.
  • Re Re 3 to 40 12.5 to 4 to 35 16 to 71 5 to 30 20 to 67 2700 to Bound 76 3000 TiB 2 TiB 2 60 to 97 24 to 65 to 96 29 to 84 70 to 95 33 to 80 87.5 Re Re 3 to 40 9.5 to 4 to 35 12.5 to 5 to 30 15 to 60 2800 to Bound 70 65 3000 ZrB 2 ZrB 2 60 to 97 30 to 65 to 96 35 to 70 to 95 40 to 85 90.5 87.5 Re Re 3 to 40 5.5 to 4 to 35 7 to 50 5 to 30 9 to 3000 to Bound 55.5 44.5 3200 HfB 2 HfB 2 60 to 97 44.5 to 65 to 96 50 to 93 70 to 95 55.5 to 94.5 91 Re Re 3 to 40 11 to 73 4 to 35 14.5 to 5 to 30 18 to 64 2000 to Bound 69 2500 VB 2 VB 2 60 to 97 27 to 89 65 to 96 31 to 70 to 95 36 to 82 85.5 Re Re 3 to 40 8 to 66 4 to 35 11 to
  • Composition Composition Composition Estimated Range 1 Range 2 Range 3 Melting Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
  • Re and W bound a carbide from carbides of IVb, Vb, & VIb or a nitride from nitrides of IVb & Vb.
  • the range of Binder is from 1% Re + 99% W to 99% Re + 1% W.
  • Composition Composition Composition Estimated Range 1 Range 2 Range 3 Melting Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
  • the range of Binder is from 1% Re + 99% Co to 99% Re + 1% Co.
  • the range of Binder is from 1% Re + 99% Co to 99% Re + 1% Co.
  • the range of Binder is from 1% Re + 99% Mo to 99% Re + 1% Mo.
  • the range of Binder is from 1% Re + 99% Cr to 99% Re + 1% Cr.
  • compositions for hardmetals or cermets may be used for a variety of applications.
  • a material as described above may be used to form a wear part in a tool that cuts, grinds, or drills a target object by using the wear part to remove the material of the target object.
  • a tool may include a support part made of a different material, such as a steel.
  • the wear part is then engaged to the support part as an insert.
  • the tool may be designed to include multiple inserts engaged to the support part.
  • some mining drills may include multiple button bits made of a hardmetal material. Examples of such a tool includes a drill, a cutter such as a knife, a saw, a grinder, and a drill.
  • hardmetals descried here may be used to form the entire head of a tool as the wear part for cutting, drilling or other machining operations.
  • the hardmetal particles may also be used to form abrasive grits for polishing or grinding various materials.
  • such hardmetals may also be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.
  • the hardmetals described here may be used to manufacture cutting tools for machining metals, alloys, composite materials, plastic materials, wooden materials, and others.
  • the cutting tools may include indexable inserts for turning, milling, boring and drilling, drills, end mills, reamers, taps, hobs and milling cutters. Since the temperature of the cutting edge of such tools may be higher than 500° C. during machining, the hardmetal compositions for high-temperature operating conditions described above may have special advantages when used in such cutting tools, e.g., extended tool life and improved productivity by such tools by increasing the cutting speed.
  • the hardmetals described here may be used to manufacture tools for wire drawing, extrusion, forging and cold heading. Also as mold and Punch for powder process. In addition, such hardmetals may be used as wear-resistant material for rock drilling and mining.
  • the hardmetal materials described in this application may be fabricated in bulk forms or as coatings on metal surfaces. Coatings with such new hardmetal materials may be advantageously used to form a hard layer on a metal surface to achieve desired hardness that would otherwise be difficult to achieve with the underlying metal material. Bulk hardmetal materials based on the compositions in this application may be expensive and hence the use of coatings on less expensive metals with lower hardness may be used to reduce the costs of various components or parts with high hardness.
  • a number of powder processes for producing commercial hardmetals may be used to manufacture the hardmetals of this application.
  • a binder alloy with Re higher than 85% in weight may be fabricated by the process of solid phase sintering to eliminate open porosities then HIP replaces liquid phase sintering.
  • FIG. 9 shows a flowchart for several fabrication methods for materials or structures from the above hardmetal compositions.
  • alloy powders for the binders and the hard particle powders may be mixed with a milling liquid in a wet mixing process with or without a lubricant (e.g., wax).
  • the fabrication flows on the left hand side of FIG. 9 are for fabricating hardmetals with lubricated wet mixing.
  • the mixture is first dried by vacuum drying or spray drying process to produce lubricated grade powder.
  • the lubricated grade power is shaped into a bulky material via pill pressing, extruding, or cold isostatic press (CIP) and shaping.
  • CIP cold isostatic press
  • the bulky material is then heated to remove the lubricant and is sintered in a presintering process.
  • the material may be processed via several different processes.
  • the material may be processed via a liquid phase sintering in vacuum or hydrogen and then further processed by a HIP process to form the final hardmetal parts.
  • the material after the presintering may go through a solid phase sintering to eliminate open porosity and then a HIP process to form the final hardmetal parts.
  • the unlubricated grade power after the drying process may be processed in two different ways to form the final hardmetal parts.
  • the first way as illustrated simply uses hot pressing to complete the fabrication.
  • the second way uses a thermal spray forming process to form the grade powder on a metal substrate in vacuum.
  • the metal substrate is removed to leave the structure by the thermal spray forming as a free-standing material as the final hardmetal part.
  • the free-standing material may be further processed by a HIP process to reduce the porosities if needed.
  • a thermal spray process may be used under a vacuum condition to produce large parts coated with hardmetal materials. For example, surfaces of steel parts and tools may be coated to improve their hardness and thus performance.
  • FIG. 10 shows an exemplary flow chart of a thermal spray process.
  • thermal spray processes are known for coating metal surfaces.
  • ASM Handbook Vol. 7 (P408, 1998) describes the thermal spray as a family of particulate/droplet consolidation processes capable of forming metals, ceramics, intermetallics, composites, and polymers into coatings or freestanding structures.
  • powder, wire, or rods can be injected into combustion or arc-heated jets, where they are heated, melted or softened, accelerated, and directed toward the surface, or substrate, being coated.
  • the particles or droplets rapidly solidify, cool, contract, and incrementally build up to form a deposit on a target surface.
  • the thin “splats” may undergo high cooling rates, e.g., in excess of 10 6 K/s for metals.
  • a thermal spray process may use chemical (combustion) or electrical (plasma or arc) energy to heat feed materials injected into hot-gas jets to create a stream of molten droplets that are accelerated and directed toward the substrates being coated.
  • Various thermal spray processes are shown in FIGS. 3 and 4 in ASM Handbook Vol. 7, pages 409-410.
  • Selected hardmetal compositions described here can maintain high material strength and hardness at high temperatures at or above 1500° C.
  • certain high-power engines operate at such high temperatures such as various jet and/or rocket engines used in various flying devices and vehicles. More specifically, jet and/or rocket nozzles, including non-erosive nozzle throats and low-erosive nozzle throats, in these and other engines may be partially or entirely made of the selected hardmetal materials described in this application.
  • hardmetals based on one or more of (1) one or more carbides, (2) one or more nitrides, (3) one or more borides and (4) a combination of two or more of (1), (2) and (3) with a binder material which is either pure Re or a composite binder material with Re as one component.
  • the melting points of various carbides, nitrides, and borides in this application are above 2400° C.
  • suitable carbides for the present high-temperature hardmetal materials include TaC, HfC, NbC, ZrC, TiC, WC, VC, Al 4 C 3 , ThC 2 , Mo 2 C, SiC and B 4 C.
  • suitable nitrides for the present high-temperature hardmetal materials include HfN, TaN, BN, ZrN, and TiN.
  • suitable borides for the present high-temperature hardmetal materials include HfB 2 , ZrB 2 , TaB 2 , TiB 2 , NbB 2 , and WB.
  • Two examples of the composite binder material with Re as one component are (1) W and Re and (2) Ta and Re.

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.

Description

  • This application claims the benefit of U.S. Provisional Application No. 60/710,016 entitled “HARDMETAL MATERIALS FOR HIGH-TEMPERATURE APPLICATIONS” and filed on Aug. 19, 2005, which is incorporated by reference as part of the specification of this application.
  • This application is a continuation-in-part application of and claims the benefit of U.S. patent application Ser. No. 11/081,928 entitled “High-Performance Hardmetal Materials” and filed on Mar. 15, 2005, which is published as U.S. Publication No. US 2005-0191482-A1.
  • The U.S. patent application Ser. No. 11/081,928 claims the benefit of the following U.S. Patent Applications:
  • No. 60/554,205 entitled “HARDMETAL COATING ON A METAL SURFACE BY THERMAL SPRAY” and filed Mar. 17, 2004; and
  • No. 60/584,593 entitled “HIGH-PERFORMANCE HARDMETAL COMPOSITIONS AND FABRICATION” and filed Jun. 30, 2004.
  • In addition, the U.S. patent application Ser. No. 11/081,928 claims the benefit of and is a continuation-in-part application of U.S. application Ser. No. 10/453,085 entitled “COMPOSITIONS AND FABRICATION METHODS FOR HARDMETALS” and filed Jun. 2, 2003 which further claims benefits of two U.S. Provisional Applications, No. 60/439,838 entitled “HARDMETAL COMPOSITIONS WITH NOVEL BINDER COMPOSITIONS” and filed Jan. 13, 2003, and No. 60/449,305 of the same title filed Feb. 20, 2003. The U.S. application Ser. No. 10/453,085 was published under a publication No. 20040134309 on Jul. 15, 2004.
  • Furthermore, the U.S. patent application Ser. No. 11/081,928 claims the benefit of and is a continuation-in-part application of U.S. application Ser. No. 10/941,967 entitled “Fabrication of Hardmetals Having Binders with Rhenium or Ni-based Superalloy” and filed Sep. 14, 2004.
  • The entire disclosures of the above referenced U.S. patent applications are considered and are incorporated by reference as part of the specification of this application.
    • BACKGROUND
  • This application relates to hardmetal compositions, their fabrication techniques, and associated applications.
  • Hardmetals include various composite materials and are specially designed to be hard and refractory, and exhibit strong resistance to wear. Examples of widely-used hardmetals include sintered or cemented carbides or carbonitrides, or a combination of such materials. Some hardmetals, called cermets, have compositions that may include processed ceramic particles (e.g., TiC) bonded with binder metal particles. Certain compositions of hardmetals have been documented in the technical literature. For example, a comprehensive compilation of hardmetal compositions is published in Brookes' World Dictionary and Handbook of Hardmetals, sixth edition, International Carbide Data, United Kingdom (1996).
  • Hardmetals may be used in a variety of applications. Exemplary applications include cutting tools for cutting metals, stones, and other hard materials, wire-drawing dies, knives, mining tools for cutting coals and various ores and rocks, and drilling tools for oil and other drilling applications. In addition, such hardmetals also may be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.
  • Many hardmetals may be formed by first dispersing hard, refractory particles of carbides or carbonitrides in a binder matrix and then pressing and sintering the mixture. The sintering process allows the binder matrix to bind the particles and to condense the mixture to form the resulting hardmetals. The hard particles primarily contribute to the hard and refractory properties of the resulting hardmetals.
    • SUMMARY
  • The hardmetal materials described below include materials comprising hard particles having a first material, and a binder matrix having a second, different material. The hard particles are spatially dispersed in the binder matrix in a substantially uniform manner. The first material for the hard particles may include, for example, materials based on tungsten carbide, materials based on titanium carbide, materials based on a mixture of tungsten carbide and titanium carbide, other carbides, nitrides, borides, silicides, and combinations of these materials. The second material for the binder matrix may include, among others, rhenium, a mixture of rhenium and cobalt, a nickel-based superalloy, a mixture of a nickel-based superalloy and rhenium, a mixture of a nickel-based superalloy, rhenium and cobalt, and these materials mixed with other materials. Tungsten may also be used as a binder matrix material in hardmetal materials. The nickel-based superalloy may be in the γ-γ′ metallurgic phase.
  • In various implementations, for example, the volume of the second material may be from about 3% to about 40% of a total volume of the material. For some applications, the binder matrix may comprise rhenium in an amount at or greater than 25% of a total weight of the binder matrix of the final material. For other applications, the second material may include a Ni-based superalloy. The Ni-based superalloy may include Ni and other elements such as Re for certain applications.
  • Fabrication of the hardmetal materials of this application may be carried out by, according to one implementation, sintering the material mixture under a vacuum condition and performing a solid-phase sintering under a pressure applied through a gas medium. Such hardmetals may also be coated on surfaces using thermal spray methods to form either hardmetal coatings and hardmetal structures.
  • Advantages arising from various implementations of the described hardmetal materials may include one or more of the following: superior hardness in general, enhanced hardness at high temperatures, and improved resistance to corrosion and oxidation.
  • Additional material compositions and their application are disclosed. For example, a material can include hard particles comprising at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al4C3, ThC2, MO2C, SiC and B4C; and a binder matrix that binds the hard particles and comprises rhenium. For another example, a material can include hard particles comprising at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN; and a binder matrix that binds the hard particles and comprises rhenium. As yet another example, a material can include hard particles comprising at least one boride selected from at least one of HfB2, ZrB2, TaB2, TiB2, NbB2, and WB; and a binder matrix that binds the hard particles and comprises rhenium. These and other materials can be used to construct a jet nozzle or a non-erosive nozzle throat for various applications.
  • These and other features, implementations, and advantages are now described in details with respect to the drawings, the detailed description, and the claims.
    • DRAWING DESCRIPTION
  • FIG. 1 shows one exemplary fabrication flow in making a hardmetal according to one implementation.
  • FIG. 2 shows an exemplary two-step sintering process for processing hardmetals in a solid state.
  • FIGS. 3, 4, 5, 6, 7, and 8 show various measured properties of selected exemplary hardmetals.
  • FIGS. 9 and 10 illustrate examples of the thermal spray methods.
    • DETAILED DESCRIPTION
  • Compositions of hardmetals are important in that they directly affect the technical performance of the hardmetals in their intended applications, and processing conditions and equipment used during fabrication of such hardmetals. The hardmetal compositions also can directly affect the cost of the raw materials for the hardmetals, and the costs associated with the fabrication processes. For these and other reasons, extensive efforts have been made in the hardmetal industry to develop technically superior and economically feasible compositions for hardmetals. This application describes, among other features, material compositions for hardmetals with selected binder matrix materials that, together, provide performance advantages.
  • Material compositions for hardmetals of interest include various hard particles and various binder matrix materials. In general, the hard particles may be formed from carbides of the metals in columns IVB (e.g., TiC, ZrC, HfC), VB (e.g., VC, NbC, TaC), and VIB (e.g., Cr3C2, MO2C, WC) in the Periodic Table of Elements. In addition, nitrides formed by metals elements in columns IVB (e.g., TiN, ZrN, HfN) and VB (e.g., VN, NbN, and TaN) in the Periodic Table of Elements may also be used. For example, one material composition for hard particles that is widely used for many hardmetals is a tungsten carbide, e.g., the mono tungsten carbide (WC). Various nitrides may be mixed with carbides to form the hard particles. Two or more of the above and other carbides and nitrides may be combined to form WC-based hardmetals or WC-free hardmetals. Examples of mixtures of different carbides include but are not limited to a mixture of WC and TiC, and a mixture of WC, TiC, and TaC. In addition to various carbides, nitrides, carbonitrides, borides, and silicides may also be used as hard particles for hardmetals. Examples of various suitable hard particles are described in this application.
  • The material composition of the binder matrix, in addition to providing a matrix for bonding the hard particles together, can significantly affect the hard and refractory properties of the resulting hardmetals. In general, the binder matrix may include one or more transition metals in the eighth column of the Periodic Table of Elements, such as cobalt (Co), nickel (Ni), and iron (Fe), and the metals in the 6B column such as molybdenum (Mo) and chromium (Cr). Two or more of such and other binder metals may be mixed together to form desired binder matrices for bonding suitable hard particles. Some binder matrices, for example, use combinations of Co, Ni, and Mo with different relative weights.
  • The hardmetal compositions described here were developed in part based on a recognition that the material composition of the binder matrix may be specially configured and tailored to provide high-performance hardmetals to meet specific needs of various applications. In particular, the material composition of the binder matrix has significant effects on other material properties of the resulting hardmetals, such as the elasticity, the rigidity, and the strength parameters (including the transverse rupture strength, the tensile strength, and the impact strength). Hence, the inventor recognized that it was desirable to provide the proper material composition for the binder matrix to better match the material composition of the hard particles and other components of the hardmetals in order to enhance the material properties and the performance of the resulting hardmetals.
  • More specifically, these hardmetal compositions use binder matrices that include rhenium, a nickel-based superalloy or a combination of at least one nickel-based superalloy and other binder materials. Other suitable binder materials may include, among others, rhenium (Re) or cobalt. A Ni-based superalloy exhibits a high material strength at a relatively high temperature. The resulting hardmetal formed with such a binder material can benefit from the high material strength at high temperatures of rhenium and Ni-superalloy and exhibit enhanced performance at high temperatures. In addition, a Ni-based superalloy also exhibits superior resistance to corrosion and oxidation, and thus, when used as a binder material, can improve the corresponding resistance of the hardmetals.
  • The compositions of the hardmetals described in this application may include the binder matrix material from about 3% to about 40% by volume of the total materials in the hardmetals so that the corresponding volume percentage of the hard particles is about from 97% to about 60%, respectively. Within the above volume percentage range, the binder matrix material in certain implementations may be from about 4% to about 35% by volume out of the volume of the total hardmetal materials. More preferably, some compositions of the hardmetals may have from about 5% to about 30% of the binder matrix material by volume out of the volume of the total hardmetal materials. The weight percentage of the binder matrix material in the total weight of the resulting hardmetals may be derived from the specific compositions of the hardmetals.
  • In various implementations, the binder matrices may be formed primarily by a nickel-based superalloy, and by various combinations of the nickel-based superalloy with other elements such as Re, Co, Ni, Fe, Mo, and Cr. A Ni-based superalloy of interest may comprise, in addition to Ni, elements Co, Cr, Al, Ti, Mo, W, and other elements such as Ta, Nb, B, Zr and C. For example, Ni-based superalloys may include the following constituent metals in weight percentage of the total weight of the superalloy: Ni from about 30% to about 70%, Cr from about 10% to about 30%, Co from about 0% to about 25%, a total of Al and Ti from about 4% to about 12%, Mo from about 0% to about 10%, W from about 0% to about 10%, Ta from about 0% to about 10%, Nb from about 0% to about 5%, and Hf from about 0% to about 5%. Ni-based superalloys may also include either or both of Re and Hf, e.g., Re from 0% to about 10%, and Hf from 0% to about 5%. Ni-based superalloy with Re may be used in applications under high temperatures. A Ni-based super alloy may further include other elements, such as B, Zr, and C, in small amounts.
  • Compounds TaC and NbC have similar properties to a certain extent and may be used to partially or completely substitute or replace each other in hardmetal compositions in some implementations. Either one or both of HfC and NbC also may be used to substitute or replace a part or all of TaC in hardmetal designs. Compounds WC, TiC, TaC may be produced individually and then mixed to form a mixture or may be produced in a form of a solid solution. When a mixture is used, the mixture may be selected from at least one from a group consisting of (1) a mixture of WC, TiC, and TaC, (2) a mixture of WC, TiC, and NbC, (3) a mixture of WC, TiC, and at least one of TaC and NbC, and (4) a mixture of WC, TiC, and at least one of HfC and NbC. A solid solution of multiple carbides may exhibit better properties and performances than a mixture of several carbides. Hence, hard particles may be selected from at least one from a group consisting of (1) a solid solution of WC, TiC, and TaC, (2) a solid solution of WC, TiC, and NbC, (3) a solid solution of WC, TiC, and at least one of TaC and NbC, and (4) a solid solution of WC, TiC, and at least one of HfC and NbC.
  • The nickel-based superalloy as a binder material may be in a γ-γ′ phase where the γ′ phase with a FCC structure mixes with the γ phase. The strength increases with temperature within a certain extent. Another desirable property of such a Ni-based superalloy is its high resistance to oxidation and corrosion. The nickel-based superalloy may be used to either partially or entirely replace Co in various Co-based binder compositions. As demonstrated by examples disclosed in this application, the inclusion of both of rhenium and a nickel-based superalloy in a binder matrix of a hardmetal can significantly improve the performance of the resulting hardmetal by benefiting from the superior performance at high temperatures from presence of Re while utilizing the relatively low-sintering temperature of the Ni-based superalloy to maintain a reasonably low sintering temperature for ease of fabrication. In addition, the relatively low content of Re in such binder compositions allows for reduced cost of the binder materials so that such materials be economically feasible.
  • Such a nickel-based superalloy may have a percentage weight from several percent to 100% with respect to the total weight of all material components in the binder matrix based on the specific composition of the binder matrix. A typical nickel-based superalloy may primarily comprise nickel and other metal components in a γ-γ′ phase strengthened state so that it exhibits an enhanced strength which increases as temperature rises.
  • Various nickel-based superalloys may have a melting point lower than the common binder material cobalt, such as alloys under the trade names Rene-95, Udimet-700, Udimet-720 from Special Metals which comprise primarily Ni in combination with Co, Cr, Al, Ti, Mo, Nb, W, B, and Zr. Hence, using such a nickel-based superalloy alone as a binder material may not increase the melting point of the resulting hardmetals in comparison with hardmetals using binders with Co.
  • However, in one implementation, the nickel-based superalloy can be used in the binder to provide a high material strength and to improve the material hardness of the resulting hardmetals, at high temperatures near or above 500° C. Tests of some fabricated samples have demonstrated that the material hardness and strength for hardmetals with a Ni-based superalloy in the binder can improve significantly, e.g., by at least 10%, at low operating temperatures in comparison with similar material compositions without Ni-based superalloy in the binder. The following table show measured hardness parameters of samples P65 and P46A with Ni-based superalloy in the binder in comparison with samples P49 and P47A with pure Co as the binder, where the compositions of the samples are listed in Table 4.
    Effects of Ni-based Superalloy (NS) in Binder
    Sample Hv at Room Ksc at room
    Code Co or NS Temperature temperature
    Name Binder (Kg/mm2) (×106 Pa · m1/2) Comparison
    P49 Co: 10 2186 6.5
    volume %
    P65 NS: 10 2532 6.7 Hv is about 16%
    volume % greater than that
    of P49
    P47A Co: 15 2160 6.4
    volume %
    P46A NS: 15 2364 6.4 Hv is about 10%
    volume % greater than that
    of P47A
  • Notably, at high operating temperatures above 500° C., hardmetal samples with Ni-based superalloy in the binder can exhibit a material hardness that is significantly higher than that of similar hardmetal samples without having a Ni-based superalloy in the binder. In addition, Ni-based superalloy as a binder material can also improve the resistance to corrosion of the resulting hardmetals or cermets in comparison with hardmetals or cermets using the conventional cobalt as the binder.
  • A nickel-based superalloy may be used alone or in combination with other elements to form a desired binder matrix. Other elements that may be combined with the nickel-based superalloy to form a binder matrix include but are not limited to, another nickel-based superalloy, other non-nickel-based alloys, Re, Co, Ni, Fe, Mo, and Cr.
  • Rhenium as a binder material may be used to provide strong bonding of hard particles and in particular can produce a high melting point for the resulting hardmetal material. The melting point of rhenium is about 3180° C., much higher than the melting point of 1495° C. of the commonly-used cobalt as a binder material. This feature of rhenium partially contributes to the enhanced performance of hardmetals with binders using Re, e.g., the enhanced hardness and strength of the resulting hardmetals at high temperatures. Re also has other desired properties as a binder material. For example, the hardness, the transverse rapture strength, the fracture toughness, and the melting point of the hardmetals with Re in their binder matrices can be increased significantly in comparison with similar hardmetals without Re in the binder matrices. A hardness Hv over 2600 Kg/mm2 has been achieved in exemplary WC-based hardmetals with Re in the binder matrices. The melting point of some exemplary WC-based hardmetals, i.e., the sintering temperature, has shown to be greater than 2200° C. In comparison, the sintering temperature for WC-based hardmetals with Co in the binders in Table 2.1 in the cited Brookes is below 1500° C. A hardmetal with a high sintering temperature allows the material to operate at a high temperature below the sintering temperature. For example, tools based on such Re-containing hardmetal materials may operate at high speeds to reduce the processing time and the overall throughput of the processing.
  • The use of Re as a binder material in hardmetals, however, may present limitations in practice. For example, the desirable high-temperature property of Re generally leads to a high sintering temperature for fabrication. Thus, the oven or furnace for the conventional sintering process needs to operate at or above the high sintering temperature. Ovens or furnaces capable of operating at such high temperatures, e.g., above 2200° C., can be expensive and may not be widely available for commercial use. U.S. Pat. No. 5,476,531 discloses a use of a rapid omnidirectional compaction (ROC) method to reduce the processing temperature in manufacturing WC-based hardmetals with pure Re as the binder material from 6% to 18% of the total weight of each hardmetal. This ROC process, however, is still expensive and is generally not suitable for commercial fabrication.
  • One potential advantage of the hardmetal compositions and the composition methods described here is that they may provide or allow for a more practical fabrication process for fabricating hardmetals with either Re or mixtures of Re with other binder materials in the binder matrices. In particular, this two-step process makes it possible to fabricate hardmetals where Re is at or more than 25% of the total weight of the binder matrix of the resulting hardmetal. Such hardmetals with Re at or more than 25% may be used to achieve a high hardness and a high material strength at high temperatures.
  • Another limitation of using pure Re as a binder material for hardmetals is that Re oxidizes severely in air at or above about 350° C. This poor oxidation resistance may dramatically reduce the use of pure Re as binder for any application above about 300° C. Since Ni-based superalloy has exceptionally strength and oxidation resistance under 1000° C., a mixture of a Ni-based superalloy and Re where Re is the dominant material in the binder may be used to improve the strength and oxidation resistance of the resulting hardmetal using such a mixture as the binder. On the other hand, the addition of Re into a binder primarily comprised of a Ni-based superalloy can increase the melting range of the resulting hardmetal, and improve the high temperature strength and creep resistance of the Ni-based superalloy binder.
  • In general, the percentage weight of the rhenium in the binder matrix should be between a several percent to essentially 100% of the total weight of the binder matrix in a hardmetal. Preferably, the percentage weight of rhenium in the binder matrix should be at or above 5%. In particular, the percentage weight of rhenium in the binder matrix may be at or above 10% of the binder matrix. In some implementations, the percentage weight of rhenium in the binder matrix may be at or above 25% of the total weight of the binder matrix of the resulting hardmetal. Hardmetals with such a high concentration of Re may be fabricated at relatively low temperatures with a two-step process described in this application.
  • Since rhenium is generally more expensive than other materials used in hardmetals, cost should be considered in designing binder matrices that include rhenium. Some of the examples given below reflect this consideration. In general, according to one implementation, a hardmetal composition includes dispersed hard particles having a first material, and a binder matrix having a second, different material that includes rhenium, where the hard particles are spatially dispersed in the binder matrix in a substantially uniform manner. The binder matrix may be a mixture of Re and other binder materials to reduce the total content of Re to in part reduce the overall cost of the raw materials and in part to explore the presence of other binder materials to enhance the performance of the binder matrix. Examples of binder matrices having mixtures of Re and other binder materials include, mixtures of Re and at least one Ni-based superalloy, mixtures of Re, Co and at least one Ni-based superalloy, mixtures of Re and Co, and others.
  • TABLE 1 lists some examples of hardmetal compositions of interest. In this table, WC-based compositions are referred to as “hardmetals” and the TiC-based compositions are referred to as “cermets.” Traditionally, TiC particles bound by a mixture of Ni and Mo or a mixture of Ni and Mo2C are cermets. Cermets as described here further include hard particles formed by mixtures of TiC and TiN, of TiC, TiN, WC, TaC, and NbC with the binder matrices formed by the mixture of Ni and Mo or the mixture of Ni and Mo2C. For each hardmetal composition, three different weight percentage ranges for the given binder material in the are listed. As an example, the binder may be a mixture of a Ni-based superalloy and cobalt, and the hard particles may a mixture of WC, TiC, TaC, and NbC. In this composition, the binder may be from about 2% to about 40% of the total weight of the hardmetal. This range may be set to from about 3% to about 35% in some applications and may be further limited to a smaller range from about 4% to about 30% in other applications.
    TABLE 1
    (NS: Ni-based superalloy)
    1st Binder
    Binder Composition for Wt. % 2nd Binder 3rd Binder Wt. %
    Composition Hard Particles Range Wt. % Range Range
    Hardmetals Re WC 4 to 40 5 to 35 6 to 30
    WC—TiC—TaC—NbC 4 to 40 5 to 35 6 to 30
    NS WC 2 to 30 3 to 25 4 to 20
    WC—TiC—TaC—NbC 2 to 30 3 to 25 4 to 20
    NS—Re WC 2 to 40 3 to 35 4 to 30
    WC—TiC—TaC—NbC 2 to 40 3 to 35 4 to 30
    Re—Co WC 2 to 40 3 to 35 4 to 30
    WC—TiC—TaC—NbC 2 to 40 3 to 35 4 to 30
    NS—Re—Co WC 2 to 40 3 to 35 4 to 30
    WC—TiC—TaC—NbC 2 to 40 3 to 35 4 to 30
    Cermets NS Mo2C—TiC 5 to 40 6 to 35 8 to 40
    Mo2C—TiC—TiN—WC—TaC—NbC 5 to 40 6 to 35 8 to 40
    Re Mo2C—TiC 10 to 55  12 to 50  15 to 45 
    Mo2C—TiC—TiN—WC—TaC—NbC 10 to 55  12 to 50  15 to 45 
    NS—Re Mo2C—TiC 5 to 55 6 to 50 8 to 45
    Mo2C—TiC—TiN—WC—TaC—NbC 5 to 55 6 to 50 8 to 45
  • Fabrication of hardmetals with Re or a nickel-based superalloy in binder matrices may be carried out as follows. First, a powder with desired hard particles such as one or more carbides or carbonitrides is prepared. This powder may include a mixture of different carbides or a mixture of carbides and nitrides. The powder is mixed with a suitable binder matrix material that includes Re or a nickel-based superalloy. In addition, a pressing lubricant, e.g., a wax, may be added to the mixture.
  • The mixture of the hard particles, the binder matrix material, and the lubricant is mixed through a milling or attriting process by milling or attriting over a desired period, e.g., hours, to fully mix the materials so that each hard particle is coated with the binder matrix material to facilitate the binding of the hard particles in the subsequent processes. The hard particles should also be coated with the lubricant material to lubricate the materials to facilitate the mixing process and to reduce or eliminate oxidation of the hard particles. Next, pressing, pre-sintering, shaping, and final sintering are subsequently performed to the milled mixture to form the resulting hardmetal. The sintering process is a process for converting a powder material into a continuous mass by heating to a temperature that is below the melting temperature of the hard particles and may be performed after preliminary compacting by pressure. During this process, the binder material is densified to form a continuous binder matrix to bind hard particles therein. One or more additional coatings may be further formed on a surface of the resulting hardmetal to enhance the performance of the hardmetal. FIG. 1 is a flowchart for this implementation of the fabrication process.
  • In one implementation, the manufacture process for cemented carbides includes wet milling in solvent, vacuum drying, pressing, and liquid-phase sintering in vacuum. The temperature of the liquid-phase sintering is between melting point of the binder material (e.g., Co at 1495° C.) and the eutectic temperature of the mixture of hardmetal (e.g., WC-Co at 1320° C.). In general, the sintering temperature of cemented carbide is in a range of 1360 to 1480° C. For new materials with low-concentration of Re or a Ni-based superalloy in binder alloy, manufacture process is same as conventional cemented carbide process. The principle of liquid phase sintering in vacuum is applied in here. The sintering temperature is slightly higher than the eutectic temperature of binder alloy and carbide. For example, the sintering condition of P17 (25% of Re in binder alloy, by weight) is at 1700° C. for one hour in vacuum.
  • FIG. 2 shows a two-step fabrication process based on a solid-state phase sintering for fabricating various hardmetals described in this application. Examples of hardmetals that can be fabricated with this two-step sintering method include hardmetals with a high concentration of Re in the binder matrix that would otherwise require the liquid-phase sintering at high temperatures. This two-step process may be implemented at relatively low temperatures, e.g., under 2200° C., to utilize commercially feasible ovens and to produce the hardmetals at reasonably low costs. The liquid phase sintering is eliminated in this two-step process because the liquid phase sintering may not be practical due to the generally high eutectic temperatures of the binder alloy and carbide. As discussed above, sintering at such high temperatures requires ovens operating at high temperatures which may not be commercially feasible.
  • The first step of this two-step process is a vacuum sintering where the mixture materials for the binder matrix and the hard particles are sintered in vacuum. The mixture is initially processed by, e.g., wet milling, drying, and pressing, as performed in conventional processes for fabricating cemented carbides. This first step of sintering is performed at a temperature below the eutectic temperature of the binder alloy and the hard particle materials to remove or eliminate the interconnected porosity. The second step is a solid phase sintering at a temperature below the eutectic temperature and under a pressured condition to remove and eliminate the remaining porosities and voids left in the sintered mixture after the first step. A hot isostatic pressing (HIP) process may be used as this second step sintering. Both heat and pressure are applied to the material during the sintering to reduce the processing temperature which would otherwise be higher in absence of the pressure. A gas medium such as an inert gas may be used to apply and transmit the pressure to the sintered mixture. The pressure may be at or over 1000 bar. Application of pressure in the HIP process lowers the required processing temperature and allows for use of conventional ovens or furnaces. The temperatures of solid phase sintering and HIPping for achieving fully condensed materials are generally significantly lower than the temperatures for liquid phase sintering. For example, the sample P62 which uses pure Re as the binder may be fully densified by vacuum sintering at 2200° C. for one to two hours and then HIPping at about 2000° C. under a pressure of 30,000 PSI in the inert gas such as Ar for about one hour. Notably, the use of ultra fine hard particles with a particulate dimension less than 0.5 micron can reduce the sintering temperature for fully densifying the hardmetals (fine particles are several microns in size). For example, in making the samples P62 and P63, the use of such ultra fine WC allows for sintering temperatures to be low, e.g., around 2000° C. This two-step process is less expensive than the ROC method and may be used to commercial production.
  • The following sections describe exemplary hardmetal compositions and their properties based on various binder matrix materials that include at least rhenium or a nickel-based superalloy.
  • TABLE 2 provides a list of code names (lot numbers) for some of the constituent materials used to form the exemplary hardmetals, where H1 represents rhenium, and L1, L2, and L3 represent three exemplary commercial nickel-based superalloys. TABLE 3 further lists compositions of the above three exemplary nickel-based superalloys, Udimet720(U720), Rene'95(R-95), and Udimet700(U700), respectively. TABLE 4 lists compositions of exemplary hardmetals, both with and without rhenium or a nickel-based superalloy in the binder matrices. For example, the material composition for Lot P17 primarily includes 88 grams of T32 (WC), 3 grams of 132 (TiC), 3 grams of A31 (TaC), 1.5 grams of H1 (Re) and 4.5 grams of L2 (R-95) as binder, and 2 grams of a wax as lubricant. Lot P58 represents a hardmetal with a nickel-based superalloy L2 as the only binder material without Re. These hardmetals were fabricated and tested to illustrate the effects of either or both of rhenium and a nickel-based superalloy as binder materials on various properties of the resulting hardmetals. TABLES 5-8 further provide summary information of compositions and properties of different sample lots as defined above.
  • FIGS. 3 through 8 show measurements of selected hardmetal samples of this application. FIGS. 3 and 4 show measured toughness and hardness parameters of some exemplary hardmetals for the steel cutting grades. FIGS. 5 and 6 show measured toughness and hardness parameters of some exemplary hardmetals for the non-ferrous cutting grades. Measurements were performed before and after the solid-phase sintering HIP process and the data suggests that the HIP process significantly improves both the toughness and the hardness of the materials. FIG. 7 shows measurements of the hardness as a function of temperature for some samples. As a comparison, FIGS. 7 and 8 also show measurements of commercial C2 and C6 carbides under the same testing conditions, where FIG. 7 shows the measured hardness and FIG. 8 shows measured change in hardness from the value at the room temperature (RT). Clearly, the hardmetal samples based on the compositions described here outperform the commercial grade materials in terms of the hardness at high temperatures. These results demonstrate that the superior performance of binder matrices with either or both of Re and a nickel-based superalloy as binder materials in comparison with Co-based binder matrix materials.
    TABLE 2
    Powder
    Code Composition Note
    T32 WC Particle size 1.5 μm, from Alldyne
    T35 WC Particle size 15 μm, from Alldyne
    Y20 Mo Particle size 1.7-2.2 μm, from Alldyne
    L3 U-700 −325 Mesh, special metal Udimet 700
    L1 U-720 −325 Mesh, Special Metal, Udimet 720
    L2 Re-95 −325 Mesh, Special Metal, Rene 95
    H1 Re −325 Mesh, Rhenium Alloy Inc.
    I32 TiC from AEE, Ti-302
    I21 TiB2 from AEE, Ti-201, 1-5 μm
    A31 TaC from AEE, TA-301
    Y31 Mo2C from AEE, MO-301
    D31 VC from AEE, VA-301
    B1 Co from AEE, CO-101
    K1 Ni from AEE, Ni-101
    K2 Ni from AEE, Ni-102
    I13 TiN from Cerac, T-1153
    C21 ZrB2 from Cerac, Z-1031
    Y6 Mo from AEE Mo + 100, 1-2 μm
    L6 Al from AEE Al-100, 1-5 μm
    R31 B4C from AEE Bo-301, 3 μm
    T3.8 WC Particle size 0.8 μm, Alldyne
    T3.4 WC Particle size 0.4 μm, OMG
    T3.2 WC Particle size 0.2 μm, OMG
  • TABLE 3
    Ni Co Cr Al Ti Mo Nb W Zr B C V
    R95 61.982 8.04 13.16 3.54 2.53 3.55 3.55 3.54 0.049 0.059
    U700 54.331 17.34 15.35 4.04 3.65 5.17 .028 .008 .04 .019 .019 .005
    U720 56.334 15.32 16.38 3.06 5.04 3.06 0.01 1.30 .035 .015 .012 .004
  • TABLE 4
    Lot No Composition (units in grams)
    P17 H1 = 1.5, L2 = 4.5, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P18 H1 = 3, L2 = 3, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P19 H1 = 1.5, L3 = 4.5, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P20 H1 = 3, L3 = 3, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P25 H1 = 3.75, L2 = 2.25, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P25A H1 = 3.75, L2 = 2.25, I32 = 3, A31 = 3, T32 = 88, Wax = 2
    P31 H1 = 3.44, B1 = 4.4, T32 = 92.16, Wax = 2
    P32 H1 = 6.75, B1 = 2.88, T32 = 90.37, Wax = 2
    P33 H1 = 9.93, B1 = 1.41, T32 = 88.66, Wax = 2
    P34 L2 = 14.47, I32 = 69.44, Y31 = 16.09
    P35 H1 = 8.77, L2 = 10.27, I32 = 65.73, Y31 = 15.23
    P36 H1 = 16.66, L2 = 6.50, I32 = 62.4, Y31 = 14.56
    P37 H1 = 23.80, L2 = 3.09, I32 = 59.38, Y31 = 13.76
    P38 K1 = 15.51, I32 = 68.60, Y31 = 15.89
    P39 K2 = 15.51, I32 = 68.60, Y31 = 15.89
    P40 H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T32 = 78.92, Wax = 2
    P40A H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T32 = 78.92, Wax = 2
    P41 H1 = 11.1, L2 = 1.45, I32 = 5.20, A31 = 5.11, T32 = 77.14, Wax = 2
    P41A H1 = 11.1, L2 = 1.45, I32 = 5.20, A31 = 5.11, T32 = 77.14, Wax = 2
    P42 H1 = 9.32, L2 = 3.64, I32 = 6.55, A31 = 6.44, I21 = 0.40, R31 = 4.25, T32 = 69.40, Wax = 2
    P43 H1 = 9.04, L2 = 3.53, I32 = 6.35, A31 = 6.24, I21 = 7.39, R31 = 0.22, T32 = 67.24, Wax = 2
    P44 H1 = 8.96, L2 = 3.50, I32 = 14.69, A31 = 6.19, T32 = 66.67, Wax = 2
    P45 H1 = 9.37, L2 = 3.66, I32 = 15.37, A31 = 6.47, Y31 = 6.51, T32 = 58.61, Wax = 2
    P46 H1 = 11.40, L2 = 4.45, I32 = 5.34, A31 = 5.25, T32 = 73.55, Wax = 2
    P46A H1 = 11.40, L2 = 4.45, I32 = 5.34, A31 = 5.25, T32 = 73.55, Wax = 2
    P47 H1 = 11.35, B1 = 4.88, I32 = 5.32, A31 = 5.23, T32 = 73.22, Wax = 2
    P47A H1 = 11.35, B1 = 4.88, I32 = 5.32, A31 = 5.23, T32 = 73.22, Wax = 2
    P48 H1 = 3.75, L2 = 2.25, I32 = 5, A31 = 5, T32 = 84, Wax = 2
    P49 H1 = 7.55, B1 = 3.25, I32 = 5.31, A31 = 5.21, T32 = 78.68, Wax = 2
    P50 H1 = 4.83, L2 = 1.89, I32 = 5.31, A31 = 5.22, T32 = 82.75, Wax = 2
    P51 H1 = 7.15, L2 = 0.93, I32 = 5.23, A31 = 5.14, T32 = 81.55, Wax = 2
    P52 B1 = 8, D31 = 0.6, T3.8 = 91.4, Wax = 2
    P53 B1 = 8, D31 = 0.6, T3.4 = 91.4, Wax = 2
    P54 B1 = 8, D31 = 0.6, T3.2 = 91.4, Wax = 2
    P55 H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.4 = 90.4, Wax = 2
    P56 H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.2 = 90.4, Wax = 2
    P56A H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.2 = 90.4, Wax = 2
    P57 H1 = 1.8, B1 = 7.2, T3.2 = 91, Wax = 2
    P58 L2 = 7.5, D31 = 0.6, T3.2 = 91.9, Wax = 2
    P59 H1 = 0.4, B1 = 3, L2 = 4.5, D31 = 0.6, T3.2 = 91.5, Wax = 2
    P62 H1 = 14.48, I32 = 5.09, A31 = 5.00, T3.2 = 75.43, Wax = 2
    P62A H1 = 14.48, I32 = 5.09, A31 = 5.00, T3.2 = 75.43, Wax = 2
    P63 H1 = 12.47, L2 = 0.86, I32 = 5.16, A31 = 5.07, T3.2 = 76.45, Wax = 2
    P65 H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T3.2 = 78.92, Wax = 2
    P65A H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T3.2 = 78.92, Wax = 2
    P66 H1 = 27.92, I32 = 4.91, A31 = 4.82, T3.2 = 62.35, Wax = 2
    P67 H1 = 24.37, L3 = 1.62, I32 = 5.04, A31 = 4.95, T32 = 32.01, T33 = 32.01, Wax = 2
    P69 L2 = 7.5, D31 = 0.4, T3.2 = 92.1, Wax = 2
    P70 L1 = 7.4, D31 = 0.3, T3.2 = 92.3, Wax = 2
    P71 L3 = 7.2, D31 = 0.3, T3.2 = 92.5, Wax = 2
    P72 H1 = 1.8, B1 = 7.2, D31 = 0.3, T3.2 = 90.7, Wax = 2
    P73 H1 = 1.8, B1 = 4.8, L2 = 2.7, D31 = 0.3, T3.2 = 90.4, Wax = 2
    P74 H1 = 1.8, B1 = 3, L2 = 4.5, D31 = 0.3, T3.2 = 90.4, Wax = 2
    P75 H1 = 0.8, B1 = 3, L2 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2
    P76 H1 = 0.8, B1 = 3, L1 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2
    P77 H1 = 0.8, B1 = 3, L3 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2
    P78 H1 = 0.8, B1 = 4.5, L1 = 3, D31 = 0.3, T3.2 = 91.4, Wax = 2
    P79 H1 = 0.8, B1 = 4.5, L3 = 3.1, D31 = 0.3, T3.2 = 91.3, Wax = 2
  • Several exemplary categories of hardmetal compositions are described below to illustrate the above general designs of the various hardmetal compositions to include either of Re and Nickel-based superalloy, or both. The exemplary categories of hardmetal compositions are defined based on the compositions of the binder matrices for the resulting hardmetals or cermets. The first category uses a binder matrix having pure Re, the second category uses a binder matrix having a Re—Co alloy, the third category uses a binder matrix having a Ni-based superalloy, and the fourth category uses a binder matrix having an alloy having a Ni-based superalloy in combination with of Re with or without Co.
  • In general, hard and refractory particles used in hardmetals of interest may include, but are not limited to, carbides, nitrides, carbonitrides, borides, and silicides. Some examples of Carbides include WC, TiC, TaC, HfC, NbC, Mo2C, Cr2C3, VC, ZrC, B4C, and SiC. Examples of Nitrides include TiN, ZrN, HfN, VN, NbN, TaN, and BN. Examples of Carbonitrides include Ti(C,N), Ta(C,N), Nb(C,N), Hf(C,N), Zr(C,N), and V(C,N). Examples of Borides include TiB2, ZrB2, HfB2, TaB2, VB2, MoB2, WB, and W2B. In addition, examples of Silicides are TaSi2, Wsi2, NbSi2, and MoSi2. The above-identified four categories of hardmetals or cermets can also use these and other hard and refractory particles.
  • In the first category of hardmetals based on the pure Re alloy binder matrix, the Re may be approximately from 5% to 40% by volume of all material compositions used in a hardmetal or cermet. For example, the sample with a lot No. P62 in TABLE 4 has 10% of pure Re, 70% of WC, 15% of TiC, and 5% of TaC by volume. This composition approximately corresponds to 14.48% of Re, 75.43% of WC, 5.09% of TiC and 5.0% of TaC by weight. In fabrication, the Specimen P62-4 was vacuum sintered at 2100° C. for about one hour and 2158° C. for about one hour. The density of this material is about 14.51 g/cc, where the calculated density is 14.50 g/cc. The average hardness Hv is 2627±35 Kg/mm2 for 10 measurements taken at the room temperature under a load of 10 Kg. The measured surface fracture toughness Ksc is about 7.4×106 Pa m1/2 estimated by Palmvist crack length at a load of 10 Kg.
  • Another example under this category is P66 in TABLE 4. This sample has about 20% of Re, 60% of WC, 15% of TiC, and 5% of TaC by volume in composition. In the weight percentage, this sample has about 27.92% of Re, 62.35% of WC, 4.91% of TiC, and 4.82% of TaC. The Specimen P66-4 was first processed with a vacuum sintering process at about 2200° C. for one hour and was then sintered in the solid-phase with a HIP process to remove porosities and voids. The density of the resulting hardmetal is about 14.40 g/cc compared to the calculated density of 15.04 g/cc. The average hardness Hv is about 2402±44 Kg/mm2 for 7 different measurements taken at the room temperature under a load of 10 Kg. The surface fracture toughness Ksc is about 8.1×106 Pa m1/2. The sample P66 and other compositions described here with a high concentration of Re with a weight percentage greater than 25%, as the sole binder material or one of two or more different binder materials in the binder, may be used for various applications at high operating temperatures and may be manufactured by using the two-step process based on solid-phase sintering.
  • The microstructures and properties of Re bound multiples types of hard refractory particles, such as carbides, nitrides, carbon nitrides, silicides, and borides, may provide advantages over Re-bound WC material. For example, Re bound WC—TiC—TaC may have better crater resistance in steel cutting than Re bound WC material. Another example is materials formed by refractory particles of MO2C and TiC bound in a Re binder.
  • For the second category with a Re—Co alloy as the binder matrix, the Re—Co alloy may be about from 5 to 40 Vol % of all material compositions used in the composition. In some implementations, the Re-to-Co ratio in the binder may vary from 0.01 to 0.99 approximately. Inclusion of Re can improve the mechanical properties of the resulting hardmetals, such as hardness, strength and toughness special at high temperature compared to Co bounded hardmetal. The higher Re content is the better high temperature properties are for most materials using such a binder matrix.
  • The sample P31 in TABLE 4 is one example within this category with 2.5% of Re, 7.5% of Co, and 90% of WC by volume, and 3.44% of Re, 4.40% of Co and 92.12% of WC by weight. In fabrication, the Specimen P31-1 was vacuum sintered at 1725C for about one hour. slight under sintering with some porosities and voids. The density of the resulting hardmetal is about 15.16 g/cc (calculated density at 15.27 g/cc). The average hardness Hv is about 1889±18 Kg/mm2 at the room temperature under 10 Kg and the surface facture toughness Ksc is about 7.7×106 Pa·m1/2. In addition, the Specimen P31-1 was treated with a hot isostatic press (HIP) process at about 1600C/15 Ksi for about one hour after sintering. The HIP reduces or substantially eliminates the porosities and voids in the compound to increase the material density. After HIP, the measured density is about 15.25 g/cc (calculated density at 15.27 g/cc). The measured hardness Hv is about 1887±12 Kg/mm2 at the room temperature under 10 Kg. The surface fracture toughness Ksc is about 7.6×106 Pa·m1/2.
  • Another example in this category is P32 in TABLE 4 with 5.0% of Re, 5.0% of Co, and 90% of WC in volume (6.75% of Re, 2.88% of Co and 90.38% of WC in weight). The Specimen P32-4 was vacuum sintered at 1800C for about one hour. The measured density is about 15.58 g/cc in comparison with the calculated density at 15.57 g/cc. The measured hardness Hv is about 2065 Kg/mm2 at the room temperature under 10 Kg. The surface fracture toughness Ksc is about 5.9×106 Pa·m1/2. The Specimen P32-4 was also HIP at 1600C/15 Ksi for about one hour after Sintering. The measured density is about 15.57 g/cc (calculated density at 15.57 g/cc). The average hardness Hv is about 2010±12 Kg/mm2 at the room temperature under 10 Kg. The surface fracture toughness Ksc is about 5.8×106 Pa·m1/2.
  • The third example is P33 in TABLE 4 which has 7.5% of Re, 2.5% of Co, and 90% of WC by volume and 9.93% of Re, 1.41% of Co and 88.66% of WC by weight. In fabrication, the Specimen P33-7 was vacuum sintered at 1950C for about one hour and was under sintering with porosities and voids. The measured density is about 15.38 g/cc (calculated density at 15.87 g/cc). The measured hardness Hv is about 2081 Kg/mm2 at the room temperature under a force of 10 Kg. The surface fracture toughness Ksc is about 5.6×106 Pa·m1/2. The Specimen P33-7 was HIP at 1600C/15Ksi for about one hour after Sintering. The measured density is about 15.82 g/cc (calculated density=15.87 g/cc). The average hardness Hv is measured at about 2039±18 Kg/mm2 at the room temperature under 10 Kg. The surface fracture toughness Ksc is about 6.5×106 Pa m1/2.
    TABLE 5
    Re—Co alloy bound hardmetals
    Temperature Density
    ° C. g/cc Hv Ksc Grain
    Sinter HIP Calculated Measured kg/mm2 ×106 Pa · m1/2 size
    P55-1 1350 1300 14.77 14.79 2047 8.6 Ultra-fine
    P56-5 1360 1300 14.77 14.72 2133 8.6 Ultra-fine
    P56A-4 1350 1300 14.77 14.71 2108 8.5 Ultra-fine
    P57-1 1350 1300 14.91 14.93 1747 12.3 Fine
  • The samples P55, P56, P56A, and P57 in TABLE 4 are also examples for the category with a Re—Co alloy as the binder matrix. These samples have about 1.8% of Re, 7.2% of Co, 0.6% of VC except that P57 has no VC, and finally WC in balance. These different compositions are made to study the effects of hardmetal grain size on Hv and Ksc. TABLE 5 lists the results.
    TABLE 6
    Properties of Ni-based superalloys, Ni, Re, and Co
    Test
    ° Temp. C. R-95 U-700 U720 Nickel Rhenium Cobalt
    Density (g/c.c.) 21 8.2 7.9 8.1 8.9 21 8.9
    Melting Point (° C.) 1255 1205 1210 1450 3180 1495
    Elastic Modulus 21 30.3 32.4 32.2 207 460 211
    (Gpa)
    Ultimate Tensile 21 1620 1410 1570 317 1069 234
    Strength 760 1170 1035 1455
    (Mpa) 800 620
    870 690 1150
    1200 414
    0.2% 21 1310 965 1195 60
    Yield 760 1100 825 1050
    Strength 800
    (Mpa) 870 635
    1200
    Tensile 21 15 17 13 30 >15
    Elongation 760 15 20 9
    (%) 800 5
    870 27
    1200 2
    Oxidation Resistance Excellent Excellent Excellent Good Poor Good
  • The third category is based on binder matrices with Ni-based superalloys from 5 to 40% in volume of all materials in the resulting hardmetal. Ni-based superalloys are a family of high temperature alloys with γ′ strengthening. Three different strength alloys, Rene′95, Udimet 720, and Udimet 700 are used as examples to demonstrate the effects of the binder strength on mechanical properties of the final hardmetals. The Ni-based superalloys have a high strength specially at elevated temperatures. Also, these alloys have good environmental resistance such as resistance to corrosion and oxidation at elevated temperature. Therefore, Ni-based superalloys can be used to increase the hardness of Ni-based superalloy bound hardmetals when compared to Cobalt bound hardmetals. Notably, the tensile strengths of the Ni-based superalloys are much stronger than the common binder material cobalt as shown by TABLE 6. This further shows that Ni-based superalloys are good binder materials for hardmetals.
  • One example for this category is P58 in TABLE 4 which has 7.5% of Rene′95, 0.6% of VC, and 91.9% of WC in weight and compares to cobalt bound P54 in TABLE 4 (8% of Co, 0.6% of VC, and 91.4% of WC). The hardness of P58 is significant higher than P54 as shown in TABLE 7.
    TABLE 7
    Comparison of P54 and P58
    Hv, Ksc
    Sintering HIP Kg/mm2 ×106 Pa · m1/2
    P54-1 1350 C./1 hr 1305° C. 2094 8.8
    P54-2 1380 C./1 hr 15 KSI under 2071 7.8
    P54-3 1420 C./1 hr Ar 1 hour 2107 8.5
    P58-1 1350, 1380, 1400, 2322 7.0
    1420, 1450, 1475
    for 1 hour at each
    temperature
    P58-3 1450 C./1 hr 2272 7.4
    P58-5 1500 C./1 hr 2259 7.2
    P58-7 1550 C./1 hr 2246 7.3
  • The fourth category is Ni-based superalloy plus Re as binder, e.g., approximately from 5% to 40% by volume of all materials in the resulting hardmetal or cermet. Because addition of Re increases the melting point of binder alloy of Ni-based superalloy plus Re, the processing temperature of hardmetal with Ni-based superalloy plus Re binder increases as the Re content increases. Several hardmetals with different Re concentrations are listed in TABLE 8. TABLE 9 further shows the measured properties of the hardmetals in TABLE 8.
    TABLE 8
    Hardmetal with a binder comprising Ni-based superalloy and Re
    Sintering
    Composition, weight % Temperature
    Re Rene95 U-700 U-720 WC TiC TaC Re to Binder Ratio ° C.
    P17 1.5 4.5 88 3 3   25% 1600˜1750
    P18 3 3.0 88 3 3   50% 1600˜1775
    P25 3.75 2.25 88 3 3 62.5% 1650˜1825
    P48 3.75 2.25 84 5 5 62.5% 1650˜1825
    P50 4.83 1.89 82.75 5.31 5.22 71.9% 1675˜1850
    P40 7.57 2.96 78.92 5.32 5.23 71.9% 1675˜1850
    P46 11.40 4.45 73.55 5.34 5.24 71.9% 1675˜1850
    P51 7.15 0.93 81.55 5.23 5.14 88.5% 1700˜1900
    P41 11.10 1.45 77.14 5.20 5.11 88.5% 1700˜1900
    P63 12.47 0.86 76.45 5.16 5.07 93.6% 1850˜2100
    P19 1.5 4.5 88 3 3   25% 1600˜1750
    P20 3 3 88 3 3   50% 1600˜1775
    P67 24.37 1.62 64.02 5.04 4.95 93.6% 1950˜2300
  • TABLE 9
    Properties of hardmetals bound by Ni-based superalloy and Re
    Temperature,
    C. Density, g/cc Hv Ksc
    Sinter HIP Calculated Measured Kg/mm2 ×106 Pa · m1/2
    P17 1700 14.15 14.18 2120 6.8
    P17 1700 1600 14.15 14.21 2092 7.2
    P18 1700 14.38 14.47 2168 5.9
    P18 1700 1600 14.38 14.42 2142 6.1
    P25 1750 14.49 14.41 2271 6.1
    P25 1750 1600 14.49 14.48 2193 6.5
    P48 1800 1600 13.91 13.99 2208 6.3
    P50 1800 1600 13.9 13.78 2321 6.5
    P40 1800 13.86 13.82 2343
    P40 1800 1600 13.86 13.86 2321 6.3
    P46 1800 13.81 13.88 2282 7.1
    P46 1800 1725 13.81 13.82 2326 6.7
    P51 1800 1600 14.11 13.97 2309 6.6
    P41 1800 1600 14.18 14.63 2321 6.5
    P63 2000 14.31 14.37 2557 7.9
    P19 1700 14.11 14.11 2059 7.6
    P19 1700 1600 14.11 2012 8.0
    P20 1725 14.35 14.52 2221 6.4
    P20 1725 1600 14.35 14.35 2151 7.0
    P67 2200 14.65 14.21 2113 8.1
    P67 2200 1725 14.65 14.34 2210 7.1
  • Another example under the fourth category uses a Ni-based superalloy plus Re and Co as binder which is also about 5% to 40% by volume. Exemplary compositions of hardmetals bound by Ni-based superalloy plus Re and Co are list in TABLE 10.
    TABLE 10
    Composition of hardmetals bound by Ni-based
    superalloy plus Re and Co
    Composition, weight %
    Re Co Rene95 U-720 U-700 WC VC
    P73 1.8 4.8 2.7 90.4 0.3
    P74 1.8 3 4.5 90.4 0.3
    P75 0.8 3 4.5 91.4 0.3
    P76 0.8 3 4.5 91.4 0.3
    P77 0.8 3 4.5 91.4 0.3
    P78 0.8 4.5 3 91.4 0.3
    P79 0.8 4.5 3.1 91.3 0.3
  • Measurements on selected samples have been performed to study properties of the binder matrices with Ni-based superalloys. In general, Ni-based superalloys not only exhibit excellent strengths at elevated temperatures but also possess outstanding resistances to oxidation and corrosion at high temperatures. Ni-based superalloys have complex microstructures and strengthening mechanisms. In general, the strengthening of Ni-based superalloys is primarily due to precipitation strengthening of γ-γ′ and solid-solution strengthening. The measurements the selected samples demonstrate that Ni-based superalloys can be used as a high-performance binder materials for hardmetals.
  • TABLE 11 lists compositions of selected samples by their weight percentages of the total weight of the hardmetals. The WC particles in the samples are 0.2 μm in size. TABLE 12 lists the conditions for the two-step process performed and measured densities, hardness parameters, and toughness parameters of the samples. The Palmqvist fracture toughness Ksc is calculated from the total crack length of Palmqvist crack which is produced by the Vicker Indentor: Ksc=0.087*(Hv*W)1/2 See, e.g., Warren and H. Matzke, Proceedings Of the International Conference On the Science of Hard Materials, Jackson, Wyo., Aug. 23-28, 1981. Hardness Hv and Crack Length are measured at a load of 10 Kg for 15 seconds. During each measurement, eight indentations were made on each specimen and the average value was used in computation of the listed data.
    TABLE 11
    Weight %
    Re in Vol %
    Re Co R-95 WC VC Binder Binder
    P54
    0 8 0 91.4 0.6 0 13.13
    P58 0 0 7.5 91.9 0.6 0 13.25
    P56 1.8 7.2 0 90.4 0.6 20 13.20
    P72 1.8 7.2 0 90.7 0.3 20 13.18
    P73 1.8 4.8 2.7 90.4 0.3 20 14.00
    P74 1.8 3 4.5 90.4 0.3 20 14.24
  • TABLE 12
    Palmqvist
    Cal. Measu. Toughness
    Sample Sinter HIP Density Density Hardness, Hv Ksc,
    Code Condition Condition g/c.c. g/c.c. kg/mm2 ×106 Pa · m1/2
    P54-5 1360° C./1 hr 14.63 14.58 2062 ± 35 8.9 ± 0.2
    1360° C./1 hr 1305° C./15KSI/1 hr 14.55 2090 ± 22 8.5 ± 0.2
    P58-7 1550° C./1 hr 14.50 14.40 2064 ± 12 7.9 ± 0.2
    1550° C./1 hr 1305° C./15KSI/1 hr 14.49 2246 ± 23 7.3 ± 0.1
    P56-5 1360° C./1 hr 14.77 14.71 2064 ± 23 8.2 ± 0.1
    1360° C./1 hr 1305° C./15KSI/1 hr 14.72 2133 ± 34 8.6 ± 0.2
    P72-6 1475° C./1 hr 14.83 14.77 2036 ± 34 8.5 ± 0.6
    1475° C./1 hr 1305° C./15KSI/1 hr 14.91 2041 ± 30 9.1 ± 0.4
    P73-6 1475° C./1 hr 14.73 14.70 2195 ± 23 7.7 ± 0.1
    1475° C./1 hr 1305° C./15KSI/1 hr 14.72 2217 ± 25 8.1 ± 0.2
    P74-5 1500° C./1 hr 14.69 14.69 2173 ± 30 7.4 ± 0.3
    and 1520° C./1 hr
    1500° C./1 hr 1305° C./15KSI/1 hr 14.74 2223 ± 34 7.7 ± 0.1
    and 1520° C./1 hr
  • Among the tested samples, the sample P54 uses the conventional binder consisting of Co. The Ni-superalloy R-95 is used in the sample P58 to replace Co as the binder in the sample P54. As a result, the Hv increases from 2090 of P54 to 2246 of P58. In the sample P56, the mixture of Re and Co is used to replace Co as binder and the corresponding Hv increases from 2090 of P54 to 2133 of P56. The samples P72, P73, P74 have the same Re content but different amounts of Co and R95. The mixtures of Re, Co, and R95 are used in samples P73 and P74 to replace the binder having a mixture of Re and Co as the binder in the sample 72. The hardness Hv increases from 2041(P72) to 2217 (P73) and 2223(P74).
    TABLE 13
    Weight %
    WC WC Vol.
    R- (2 (0.2 Re in % Bi-
    Re 95 Co TiC TaC μm) μm) Binder nder
    P17 1.5 4.5 0 3 3 88 0 25 8.78
    P18 3 3 0 3 3 88 0 50 7.31
    P25 3.75 2.25 0 3 3 88 0 62.5 6.57
    P48 3.75 2.25 0 5 5 84 0 62.5 6.3
    P50 4.83 1.89 0 5.31 5.22 82.75 0 71.9 6.4
    P51 7.15 0.93 0 5.23 5.14 81.55 0 88.5 6.4
    P49 7.55 0 3.25 5.31 5.21 78.68 0 69.9 10
    P40A 7.57 2.96 0 5.32 5.23 78.92 0 71.9 10
    P63 12.47 0.86 0 5.16 5.07 0 76.45 93.6 10
    P62A 14.48 0 0 5.09 5.00 0 75.43 100 10
    P66 27.92 0 0 4.91 4.82 0 62.35 100 20
  • Measurements on selected samples have also been performed to further study properties of the binder matrices with Re in the binder matrices. TABLE 13 lists the tested samples. The WC particles with two different particle sizes of 2 μm and 0.2 μm were used. TABLE 14 lists the conditions for the two-step process performed and the measured densities, hardness parameters, and toughness parameters of the selected samples.
    TABLE 14
    Cal. Measu. Palmqvist
    Sample Sinter HIP Density Density Hardness, Hv Toughness**
    Code Condition Condition g/c.c. g/c.c. Kg/mm2 Ksc, MPam0.5
    P17-5 1800° C./1 hr 1600° C./15 KSI/1 hr 14.15 14.21 2092 ± 3  7.2 ± 0.1
    P18-3 1800° C./1 hr 1600° C./15 KSI/1 hr 14.38 14.59 2028 ± 88 6.8 ± 0.3
    P25-3 1750° C./1 hr 1600° C./15 KSI/1 hr 14.49 14.48 2193 ± 8  6.5 ± 0.1
    P48-1 1800° C./1 hr 1600° C./15 KSI/1 hr 13.91 13.99 2208 ± 12 6.3 ± 0.4
    P50-4 1800° C./1 hr 1600° C./15 KSI/1 hr 13.9 13.8 2294 ± 20 6.3 ± 0.1
    P51-1 1800° C./1 hr 1600° C./15 KSI/1 hr 14.11 13.97 2309 ± 6  6.6 ± 0.1
    P40A-1 1800° C./1 hr 1600° C./15 KSI/1 hr 13.86 13.86 2321 ± 10 6.3 ± 0.1
    P49-1 1800° C./1 hr 1600° C./15 KSI/1 hr 13.91 13.92 2186 ± 29 6.5 ± 0.2
    P62A-6 2200° C./1 hr 1725° C./30 KSI/1 hr 14.5 14.41 2688 ± 22 6.7 ± 0.1
    P63-5 2200° C./1 hr 1725° C./30 KSI/1 hr 14.31 14.37 2562 ± 31 6.7 ± 0.2
    P66-4 2200° C./1 hr 15.04 14.40 2402 ± 44 8.2 ± 0.4
    P66-4 2200° C./1 hr 1725° C./30 KSI/1 hr 15.04 14.52
    P66-4 2200° C./1 hr 1725° C./30 KSI/1 hr + 15.04 14.53 2438 ± 47 6.9 ± 0.2
    1950° C./30 KSI/1 hr
    P66-5 2200° C./1 hr 15.04 14.33 2092 ± 23 7.3 ± 0.3
    P66-5 2200° C./1 hr 1725° C./30 KSI/1 hr 15.04 14.63
    P66-5 2200° C./1 hr 1725° C./30 KSI/1 hr + 15.04 14.66 2207 ± 17 7.1 ± 0.2
    1850° C./30 KSI/1 hr
  • TABLE 15 further shows measured hardness parameters under various temperatures for the selected samples, where the Knoop hardness Hk were measured under a load of 1 Kg for 15 seconds on a Nikon QM hot hardness tester and R is a ratio of Hk at an elevated testing temperature over Hk at 25° C. The hot hardness specimens of C2 and C6 carbides were prepared from inserts SNU434 which were purchased from MSC Co. (Melville, N.Y.).
    TABLE 15
    (each measured value at a given temperature is an averaged value of
    3 different measurements)
    Testing Temperature, ° C.
    Lot No. 25 400 500 600 700 800 900 Hv @25°
    P17-5 Hk, Kg/mm2 1880 ± 10 1720 ± 17 1653 ± 25 1553 ± 29 1527 ± 6  2092 ± 3 
    R, % 100 91 88 83 81
    P18-3 Hk, Kg/mm2 1773 ± 32 1513 ± 12 1467 ± 21 1440 ± 10 1340 ± 16 2028 ± 88
    R, % 100 85 83 81 76
    P-25-3 Hk, Kg/mm2 1968 ± 45 1813 ± 12 1710 ± 0  1593 ± 5 2193 ± 8 
    R, % 100 92 87 81
    P40A-1 Hk, Kg/mm2 2000 ± 35 1700 ± 17 1663 ± 12 1583 ± 21 1540 ± 35 2321 ± 10
    R, % 100 85 83 79 77
    P48-1 Hk, Kg/mm2 1925 ± 25 1613 ± 15 1533 ± 29 1477 ± 6  1377 ± 15 2208 ± 12
    R, % 100 84 80 77 72
    P49-1 Hk, Kg/mm2 2023 ± 32 1750 ± 0  1633 ± 6  1600 ± 17 2186 ± 29
    R, % 100 87 81 79
    P50-4 Hk, Kg/mm2 2057 ± 25 1857 ± 15 1780 ± 20 1713 ± 6  1627 ± 40 2294 ± 20
    R, % 100 90 87 83 79
    P51-1 Hk, Kg/mm2 2050 ± 26 1797 ± 6  1743 ± 35 1693 ± 15 1607 ± 15 2309 ± 6 
    R, % 100 88 85 83 78
    P62A-6 Hk, Kg/mm2 2228 ± 29 2063 ± 25 1960 ± 76 1750 ± 0 2688 ± 22
    R, % 100 93 88 79
    P63-5 Hk, Kg/mm2 1887 ± 6  1707 ± 35 1667 ± 15 1633 ± 6  1603 ± 25 2562 ± 31
    R, % 100
    C2 Carbide Hk, Kg/mm2 1503 ± 38 988 ± 9 711 ± 0   584 ± 27 1685 ± 16
    R, % 100 66 47 39
    C6 Carbide Hk, Kg/mm2 1423 ± 23 1127 ± 25 1090 ± 10 1033 ± 23  928 ± 18 1576 ± 11
    R, % 100 79 77 73 65
  • Inclusion of Re in the binder matrices of the hardmetals increases the melting point of binder alloys that include Co—Re, Ni superalloy-Re, Ni superalloy-Re—Co. For example, the melting point of the sample P63 is much higher than the temperature of 2200° C. used for the solid-phase sintering process. Hot hardness values of such hardmetals with Re in the binders (e.g., P17 to P63) are much higher than conventional Co bound hardmetals(C2 and C6 carbides). In particular, the above measurements reveal that an increase in the concentration of Re in the binder increases the hardness at high temperatures. Among the tested samples, the sample P62A with pure Re as the binder has the highest hardness. The sample P63 with a binder composition of 94% of Re and 6% of the Ni-based superalloy R95 has the second highest hardness. The samples P40A(71.9% Re-29.1% R95), P49(69.9% Re-30.1% R95), P51(88.5% Re-11.5% R95), and P50(71.9% Re-28.1% R95) are the next group in their hardness. The sample P48 with 62.5% of Re and 37.5% of R95 in its binder has the lowest hardness at high temperatures among the tested materials in part because its Re content is the lowest.
  • In yet another category, a hardmetal or cermet may include TiC and TiN bonded in a binder matrix having Ni and Mo or MO2C. The binder Ni of cermet can be fully or partially replaced by Re, by Re plus Co, by Ni-based superalloy, by Re plus Ni-based superalloy, and by Re plus Co and Ni-based superalloy. Samples P38 and P39 are examples of Ni-bound cermets. The sample P34 is an example of Rene95-bound Cermet. The P35, P36, P37, and P45 are Re plus Rene95 bound cermet. Compositions of P34, 35, 36, 37, 38, 39, and 45 are listed in TABLE 16.
    TABLE 16
    Composition of P34 to P39
    Weight %
    Re Rene95 Ni 1 Ni 2 TiC Mo2C WC TaC
    P34 14.47 69.44 16.09
    P35 8.77 10.27 65.37 15.23
    P36 16.6 6.50 62.40 14.46
    P37 23.8 3.09 59.38 13.76
    P38 15.51 68.60 15.89
    P39 15.51 68.60 15.89
    P45 9.37 3.66 15.37 6.51 58.6 6.47
  • TABLES 17-29 list additional compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications.
    TABLE 17
    Compositions that use pure Re as a binder for binding a
    carbide from carbides of IVb, Vb, & VIb columns of the Periodic
    Table or a nitride from nitrides of IVb & Vb columns
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re Bound Re 7.25 to 25 to 74 7.25 to 25 to 70 7.25 to 25 to 3000 to
    TiC 40 35 30 65 3200
    TiC 60 to 26 to 75 65 to 30 to 75 70 to 35 to
    92.75 92.75 92.75 75
    Re Bound Re 3 to 40 9 to 68 4 to 35 12 to 63 5 to 30 14 to 3000 to
    ZrC 58 3200
    ZrC 60 to 97 32 to 93 65 to 37 to 88 70 to 42 to
    96 95 86
    Re Bound Re 16.75 to 25 to 52 16.75 25 to 47 16.75 25 to 3000 to
    HfC 40 to 35 to 30 42 3200
    HfC 60 to 48 to 75 65 to 53 to 75 70 to 58 to
    83.25 83.25 83.25 75
    Re Bound Re 3 to 40 11 to 72 4 to 35 14 to 67 5 to 30 17 to 2700 to
    VC 62 3100
    VC 60 to 97 28 to 89 65 to 33 to 86 70 to 38 to
    96 95 83
    Re Bound Re 3 to 40 8 to 64 4 to 35 10 to 59 5 to 30 12 to 3000 to
    NbC 54 3200
    NbC 60 to 97 36 to 92 65 to 41 to 90 70 to 46 to
    96 95 88
    Re Bound Re 3 to 40 4 to 49 4 to 35 6 to 44 5 to 30 7 to 38 3000 to
    TaC TaC 60 to 97 51 to 96 65 to 56 to 94 70 to 62 to 3200
    96 95 93
    Re Bound Re 3 to 40 9 to 68 4 to 35 12 to 63 5 to 30 14 to 1700 to
    Cr2C3 57 1900
    Cr2C3 60 to 97 32 to 91 65 to 37 to 88 70 to 43 to
    96 95 86
    Re Bound Re 3 to 40 7 to 61 4 to 35 9 to 55 5 to 30 11 to 2300 to
    Mo2C 50 2600
    Mo2C 60 to 97 39 to 93 65 to 45 to 91 70 to 50 to
    96 95 89
    Re Bound Re 20 to 40 25 to 47 20 to 25 to 42 20 to 25 to 2700 to
    WC 35 30 37 2900
    WC 60 to 80 53 to 75 65 to 58 to 75 70 to 63 to
    80 80 75
    Re Bound Re 3 to 40 11 to 72 4 to 35 14 to 68 5 to 30 17 to 2900 to
    TiN 62 3100
    TiN 60 to 97 28 to 89 65 to 32 to 86 70 to 38 to
    96 95 83
    Re Bound Re 3 to 40 8 to 66 4 to 35 11 to 61 5 to 30 13 to 2900 to
    ZrN 55 3100
    ZrN 60 to 97 34 to 92 65 to 39 to 89 70 to 45 to
    96 95 87
    Re Bound Re 3 to 40 4 to 50 4 to 35 6 to 45 5 to 30 7 to 39 3000 to
    HfN HfN 60 to 97 50 to 96 65 to 55 to 94 70 to 61 to 3200
    96 95 93
    Re Bound Re 3 to 40 9 to 70 4 to 35 13 to 65 5 to 30 16 to 2100 to
    VN 62 2300
    VN 60 to 97 30 to 91 65 to 35 to 87 70 to 38 to
    96 95 84
    Re Bound Re 3 to 40 8 to 66 4 to 35 11 to 61 5 to 30 13 to 2300 to
    NbN 55 2500
    NbN 60 to 97 34 to 92 65 to 39 to 89 70 to 45 to
    96 95 87
    Re Bound Re 3 to 40 4 to 49 4 to 35 6 to 44 5 to 30 7 to 39 3000 to
    TaN TaN 60 to 97 51 to 96 65 to 56 to 94 70 to 61 to 3200
    96 95 93
  • TABLE 18
    Compositions that use Ni-based superalloy(NBSA) in a
    binder for binding a nitride from nitrides of IVb &Vb columns of the
    Periodic Table.
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Volume % Weight % Volume % Weight % Volume % Weight %
    NBSA - NBSA 3 to 40 4 to 50 4 to 35 6 to 44 5 to 30 7 to 39
    TiN TiN 60 to 97 50 to 96 65 to 96 56 to 94 70 to 95 61 to 93
    NBSA - NBSA 3 to 40 3 to 42 4 to 35 4 to 37 5 to 30 5 to 32
    ZrN ZrN 60 to 97 58 to 97 65 to 96 63 to 96 70 to 95 68 to 95
    NBSA - NBSA 3 to 40 1.8 to 28 4 to 35 2.4 to 24 5 to 30 3 to 19
    HfN HfN 60 to 97 72 to 98.2 65 to 96 76 to 97.6 70 to 95 81 to 97
    NBSA - NBSA 3 to 40 4 to 47 4 to 35 5 to 42 5 to 30 7 to 36
    VN VN 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 64 to 93
    NBSA - NBSA 3 to 40 3 to 42 4 to 35 4 to 37 5 to 30 5 to 32
    NbN NbN 60 to 97 52 to 97 65 to 96 33 to 96 70 to 95 68 to 95
    NBSA - NBSA 3 to 40 1.7 to 27 4 to 35 2.3 to 23 5 to 30 3 to 19
    TaN TaN 60 to 97 73 to 98.3 65 to 96 77 to 97.7 70 to 95 81 to 97
  • TABLE 19
    Compositions that use Re and Ni-based superalloy
    (Re + NBSA) in a binder for binding a carbide from carbides of IVb,
    Vb, & VIb or a nitride from nitrides of IVb & Vb. The range of
    the binder is from 1% Re + 99% superalloy to 99% Re + 1%
    superalloy.
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA) - Re 0.03 to 0.13 to 0.04 to 0.17 to 0.05 to 0.21 to
    TiC 39.6 73.6 34.7 69.3 29.7 64.3
    NBSA 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to
    39.6 51.1 34.7 45.9 29.7 40.4
    TiC 60 to 97 26.1 to 65 to 96 30.5 to 70 to 95 35.5 to 92
    95.1 93.6
    (Re + NBSA) - Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to
    ZrC 39.6 67.7 34.7 62.9 29.7 57.5
    NBSA 0.03 to 0.03 to 0.04 to 0.05 to 0.05 to 0.06 to
    39.6 44.1 34.7 39.0 29.7 33.8
    ZrC 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 42 to 94
    (Re + NBSA) - Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to
    HfC 39.6 52.1 34.7 46.8 29.7 41.2
    NBSA 0.03 to 0.02 to 0.04 to 0.025 to 0.05 to 0.03 to 21
    39.6 29.2 34.7 25 29.7
    HfC 60 to 97 47.7 to 65 to 96 53 to 70 to 95 58.6 to
    98.1 97.4 96.7
    (Re + NBSA) - Re 0.03 to 0.11 to 0.04 to 0.15 to 0.05 to 0.19 to
    VC 39.6 71.5 34.7 67.0 29.7 61.8
    NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    39.6 48.4 34.7 43.3 29.7 37.9
    VC 60 to 97 28.3 to 65 to 96 32.8 to 70 to 95 38 to 92.8
    95.6 94.2
    (Re + NBSA) - Re 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.13 to
    NbC 39.6 63.8 34.7 58.7 29.7 53.1
    NBSA 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 30
    39.6 39.9 34.7 35 29.7
    NbC 60 to 97 36 to 96.9 65 to 96 41 to 70 to 95 46.6 to
    95.8 94.8
    (Re + NBSA) - Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 38
    TaC 39.6 48.8 34.7 43.5 29.7
    NBSA 0.03 to 0.016 to 0.04 to 0.02 to 0.05 to 0.03 to
    39.6 26.5 34.7 22.6 29.7 18.9
    TaC 60 to 97 51 to 98.3 65 to 96 56.3 to 70 to 95 61.8 to
    97.7 97.1
    (Re + NBSA) - Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.16 to
    Cr2C3 39.6 67.3 34.7 62.5 29.7 57.0
    NBSA 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    39.6 43.6 34.7 38.6 29.7 33.4
    Cr2C3 60 to 97 32.4 to 65 to 96 37.3 to 70 to 95 42.8 to
    96.4 95.2 94.0
    (Re + NBSA) - Re 0.03 to 0.07 to 0.04 to 0.1 to 55 0.05 to 0.12 to
    Mo2C 39.6 60.2 34.7 29.7 49.3
    NBSA 0.03 to 0.025 to 0.04 to 0.03 to 0.05 to 0.04 to
    39.6 36.3 34.7 31.6 29.7 26.9
    Mo2C 60 to 97 39.6 to 65 to 96 44.8 to 70 to 95 50.5 to
    97.3 96.4 95.5
    (Re + NBSA) - Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to
    WC 39.6 46.9 34.7 41.7 29.7 36.3
    NBSA 0.03 to 0.015 to 25 0.04 to 0.02 to 0.05 to 0.025 to
    39.6 34.7 21.3 29.7 17.8
    WC 60 to 97 52.9 to 65 to 96 58.2 to 70 to 95 63.6 to
    98.4 97.9 97.3
    (Re + NBSA) - Re 0.03 to 0.1 to 71.7 0.04 to 0.15 to 0.05 to 0.19 to 62
    TiN 39.6 34.7 67.2 29.7
    NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 38
    39.6 48.7 34.7 43.5 29.7
    TiN 60 to 97 28 to 95.6 65 to 96 32.6 to 70 to 95 37.8 to
    94.1 92.7
    (Re + NBSA) - Re 0.03 to 0.09 to 0.04 to 0.1 to 0.05 to 0.14 to
    ZrN 39.6 65.3 34.7 60.3 29.7 54.8
    NBSA 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    39.6 41.4 34.7 36.5 29.7 31.4
    ZrN 60 to 97 34.5 to 65 to 96 39.4 to 70 to 95 45 to 94.5
    96.7 95.6
    (Re + NBSA) - Re 0.03 to 0.05 to 50 0.04 to 0.06 to 0.05 to 0.08 to
    HfN 39.6 34.7 44.7 29.7 39.2
    NBSA 0.03 to 0.017 to 0.04 to 0.02 to 0.05 to 0.03 to
    39.6 27.5 34.7 23.5 29.7 19.6
    HfN 60 to 97 49.8 to 65 to 96 55.1 to 70 to 95 60.7 to 97
    98.2 97.6
    (Re + NBSA) - Re 0.03 to 0.1 to 69.6 0.04 to 0.14 to 0.05 to 0.17 to
    VN 39.6 34.7 65 29.7 59.6
    NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    39.6 46.2 34.7 41.1 29.7 35.8
    VN 60 to 97 30 to 96 65 to 96 35 to 70 to 95 40 to 93.3
    94.7
    (Re + NBSA) - Re 0.03 to 0.09 to 0.04 to 0.1 to 0.05 to 0.14 to
    NbN 39.6 65.3 34.7 60.4 29.7 54.9
    NBSA 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    39.6 41.5 34.7 36.5 29.7 31.5
    NbN 60 to 97 34.4 to 65 to 96 39.4 to 70 to 95 45 to 94.5
    96.7 95.6
    (Re + NBSA) - Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.08 to
    TaN 39.6 49.1 34.7 43.8 29.7 38.3
    NBSA 0.03 to 0.017 to 0.04 to 0.02 to 0.05 to 0.027 to 19
    39.6 26.8 34.7 22.8 29.7
    TaN 60 to 97 50.7 to 65 to 96 56 to 70 to 95 61.5 to 97
    98.3 97.7
  • TABLE 20
    Compositions that use Re and Co (Re + Co) in a binder for
    binding a carbide from carbides of IVb, Vb, & VIb or a nitride
    from nitrides of IVb & Vb. The range of Binder is from 1% Re + 99%
    Co to 99% Re + 1% Co.
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Co) - Re 0.03 to 0.13 to 0.04 to 0.17 to 0.05 to 0.20 to
    TiC 39.6 73.6 34.7 69.3 29.7 64.3
    Co 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to
    39.6 54.1 34.7 48.9 29.7 43.3
    TiC 60 to 26.1 65 to 96 30.4 to 70 to 95 35.5 to 91
    97 to94.6 92.8
    (Re + Co) - Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to
    ZrC 39.6 67.7 34.7 62.9 29.7 57.5
    Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    39.6 47.1 34.7 42.0 29.7 36.6
    ZrC 60 to 32 to 96 65 to 96 37 to 95 70 to 95 42 to 93
    97
    (Re + Co) - Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to
    HfC 39.6 52.1 34.7 46.8 29.7 41.2
    Co 0.03 to 0.02 to 0.04 to 0.028 to 0.05 to 0.035 to 23
    39.6 31.8 34.7 27 29.7
    HfC 60 to 47.6 to 65 to 96 53 to 70 to 95 58.6 to
    97 97.8 97.1 96.3
    (Re + Co) - Re 0.03 to 0.11 to 0.04 to 0.15 to 0.05 to 0.19 to
    VC 39.6 71.4 34.7 67.0 29.7 61.8
    Co 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.07 to
    39.6 51.5 34.7 46.3 29.7 40.8
    VC 60 to 28.3 to 65 to 96 32.8 to 70 to 95 38 to 92
    97 95.1 93.5
    (Re + Co) - Re 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.13 to
    NbC 39.6 63.8 34.7 58.7 29.7 53.1
    Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    39.6 42.8 34.7 37.8 29.7 32.6
    NbC 60 to 36 to 65 to 96 41 to 70 to 95 46.6 to
    97 96.5 95.4 94.2
    (Re + Co) - Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 38
    TaC 39.6 48.8 34.7 43.5 29.7
    Co 0.03 to 0.018 to 0.04 to 0.024 to 0.05 to 0.03 to
    39.6 28.9 34.7 24.8 29.7 20.8
    TaC 60 to 51 to 98 65 to 96 56.3 to 70 to 95 61.8 to
    97 97.4 96.8
    (Re + Co) - Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to
    Cr2C3 39.6 67.3 34.7 62.5 29.7 57.0
    Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    39.6 46.6 34.7 41.5 29.7 36.1
    Cr2C3 60 to 32.4 to 65 to 96 37.3 to 70 to 95 42.7 to
    97 96 94.6 93.3
    (Re + Co) - Re 0.03 to 0.07 to 0.04 to 0.1 to 55 0.05 to 0.12 to
    Mo2C 39.6 60.2 34.7 29.7 49.3
    Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    39.6 39.2 34.7 34.3 29.7 29.4
    Mo2C 60 to 39.6 to 65 to 96 44.8 to 70 to 95 50.5 to 95
    97 97 96
    (Re + Co) - Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to
    WC 39.6 46.9 34.7 41.7 29.7 36.3
    Co 0.03 to 0.017 to 0.04 to 0.023 to 0.05 to 0.028 to
    39.6 27.4 34.7 23.4 29.7 19.6
    WC 60 to 52.9 65 to 96 58.2 to 70 to 95 63.6 to 97
    97 to98.2 97
    (Re + Co) - Re 0.03 to 0.1 to 0.04 to 0.15 to 0.05 to 0.19 to 62
    TiN 39.6 71.6 34.7 67.1 29.7
    Co 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.07 to 41
    39.6 51.7 34.7 46.5 29.7
    TiN 60 to 28 to 95 65 to 96 32.6 to 70 to 95 37.8 to 92
    97 93.4
    (Re + Co) - Re 0.03 to 0.09 to 0.04 to 0.11 to 0.05 to 0.14 to
    ZrN 39.6 65.3 34.7 60.3 29.7 54.8
    Co 0.03 to 0.035 to 0.04 to 0.046 to 0.05 to 0.056 to 34
    39.6 44.4 34.7 39.3 29.7
    ZrN 60 to 34.5 to 65 to 96 39.4 to 70 to 95 45 to 93.8
    97 96.3 95
    (Re + Co) - Re 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.08 to
    HfN 39.6 50 34.7 44.7 29.7 39.2
    Co 0.03 to 0.02 to 0.04 to 0.026 to 0.05 to 0.03 to
    39.6 30 34.7 25.7 29.7 21.6
    HfN 60 to 49.8 to 65 to 96 55.1 to 70 to 95 60.7 to
    97 98 97.3 96.6
    (Re + Co) - Re 0.03 to 0.1 to 0.04 to 0.14 to 0.05 to 0.17 to
    VN 39.6 69.6 34.7 65 29.7 59.6
    Co 0.03 to 0.04 to 0.04 to 0.055 to 0.05 to 0.067 to
    39.6 49.3 34.7 44 29.7 38.6
    VN 60 to 30 to 65 to 96 35 to 94 70 to 95 40 to 92.6
    97 95.5
    (Re + Co) - Re 0.03 to 0.09 to 0.04 to 0.11 to 0.05 to 0.14 to
    NbN 39.6 65.3 34.7 60.4 29.7 54.8
    Co 0.03 to 0.035 to 0.04 to 0.046 to 0.05 to 0.057 to
    39.6 44.5 34.7 39.4 29.7 34.1
    NbN 60 to 34.4 to 65 to 96 39.4 to 70 to 95 45 to 93.8
    97 96.3 95
    (Re + Co) - Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.075 to
    TaN 39.6 49.1 34.7 43.8 29.7 38.3
    Co 0.03 to 0.019 to 0.04 to 0.025 to 0.05 to 0.03 to 21
    39.6 29.2 34.7 25 29.7
    TaN 60 to 50.7 to 65 to 96 56 to 70 to 95 61.5 to
    97 98 97.4 96.7
  • TABLE 21
    Compositions that use Ni-based superalloy (NBSA) and Co
    in a binder for binding a carbide from carbides of IVb, Vb, & VIb
    or a nitride from nitrides of IVb & Vb. The range of Binder is
    from 1% NBSA + 99% Co to 99% NBSA + 1% Co.
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (NBSA + Co) - NBSA 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 29.7 0.08 to
    TiC 39.6 51.5 34.7 46.2 40.6
    Co 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 29.7 0.09 to
    39.6 54.5 34.7 49.2 43.6
    TiC 60 to 97 45 to 95 65 to 96 50 to 93.6 70 to 95 56 to 92
    (NBSA + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 29.7 0.06 to
    ZrC 39.6 44.4 34.7 39.2 57.5
    Co 0.03 to 0.04 to 0.04 to 0.05 to 42 0.05 to 29.7 0.07 to
    39.6 47.4 34.7 34
    ZrC 60 to 97 52 to 96 65 to 96 57 to 95 70 to 95 63 to 94
    (NBSA + Co) - NBSA 0.03 to 0.02 to 0.04 to 0.026 to 0.05 to 29.7 0.03 to
    HfC 39.6 29 34.7 25 21
    Co 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 29.7 0.036 to
    39.6 32 34.7 27.5 23
    HfC 60 to 97 68 to 98 65 to 96 72 to 97.4 70 to 95 77 to
    96.8
    (NBSA + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.06 to 44 0.05 to 29.7 0.07 to
    VC 39.6 49 34.7 38
    Co 0.03 to 0.05 to 0.04 to 0.06 to 47 0.05 to 29.7 0.08 to
    39.6 52 34.7 41
    VC 60 to 97 48 to 96 65 to 96 53 to 93.5 70 to 95 59 to 93
    (NBSA + Co) - NBSA 0.03 to 0.03 to 0.04 to 0.04 to 35 0.05 to 29.7 0.05 to
    NbC 39.6 40 34.7 30
    Co 0.03 to 0.035 to 0.04 to 0.046 to 0.05 to 29.7 0.06 to
    39.6 43 34.7 38 33
    NbC 60 to 97 57 to 97 65 to 96 62 to 96 70 to 95 67 to 95
    (NBSA + Co) - NBSA 0.03 to 0.017 to 0.04 to 0.022 to 0.05 to 29.7 0.03 to
    TaC 39.6 27 34.7 23 19
    Co 0.03 to 0.02 to 0.04 to 0.025 to 0.05 to 29.7 0.03 to
    39.6 29 34.7 25 21
    TaC 60 to 97 71 to 98 65 to 96 75 to 97.8 70 to 95 79 to 97
    (NBSA + Co) - NBSA 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 29.7 0.15 to
    Cr2C3 39.6 67.3 34.7 62.5 57.0
    Co 0.03 to 0.04 to 0.04 to 0.05 to 39 0.05 to 29.7 0.06 to
    39.6 44 34.7 34
    Cr2C3 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 63 to 94
    (NBSA + Co) - NBSA 0.03 to 0.026 to 0.04 to 0.035 to 0.05 to 29.7 0.044 to
    Mo2C 39.6 36.5 34.7 32 27
    Co 0.03 to 0.03 to 0.04 to 0.04 to 34 0.05 to 29.7 0.05 to
    39.6 39 34.7 30
    Mo2C 60 to 97 60 to 97 65 to 96 65 to 96 70 to 95 70 to
    95.6
    (NBSA + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 29.7 0.07 to
    WC 39.6 46.9 34.7 41.7 36.3
    Co 0.03 to 0.018 to 0.04 to 0.024 to 0.05 to 29.7 0.03 to
    39.6 27.5 34.7 23.5 19.7
    WC 60 to 97 72 to98 65 to 96 76 to 98 70 to 95 80 to 97
    (NBSA + Co) - NBSA 0.03 to 0.4 to 49 0.04 to 0.06 to 44 0.05 to 29.7 0.07 to
    TiN 39.6 34.7 38
    Co 0.03 to 0.05 to 0.04 to 0.065 to 0.05 to 29.7 0.08 to
    39.6 52 34.7 47 41
    TiN 60 to 97 47 to 96 65 to 96 53 to 94 70 to 95 58 to 93
    (NBSA + Co) - NBSA 0.03 to 0.03 to 0.04 to 0.04 to 37 0.05 to 29.7 0.05 to
    ZrN 39.6 42 34.7 32
    Co 0.03 to 0.04 to 0.04 to 0.05 to 40 0.05 to 29.7 0.06 to
    39.6 45 34.7 34
    ZrN 60 to 97 55 to 97 65 to 96 60 to 96 70 to 95 65 to 95
    (NBSA + Co) - NBSA 0.03 to 0.02 to 0.04 to 0.027 to 0.05 to 29.7 0.03 to
    HfN 39.6 31 34.7 27 22
    Co 0.03 to 0.02 to 0.04 to 0.024 to 0.05 to 29.7 0.03 to
    39.6 27 34.7 23 20
    HfN 60 to 97 70 to 98 65 to 96 74 to 97.6 70 to 95 78 to 97
    (NBSA + Co) - NBSA 0.03 to 0.045 to 0.04 to 0.06 to 47 0.05 to 29.7 0.07 to
    VN 39.6 53 34.7 41
    Co 0.03 to 0.04 to 0.04 to 0.055 to 0.05 to 29.7 0.066 to
    39.6 44 34.7 40 34
    VN 60 to 97 50 to 96 65 to 96 55 to 95 70 to 95 61 to 93
    (NBSA + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.05 to 41 0.05 to 29.7 0.06 to
    NbN 39.6 47 34.7 36
    Co 0.03 to 0.03 to 0.04 to 0.04 to 35 0.05 to 29.7 0.05 to
    39.6 40 34.7 30
    NbN 60 to 97 55 to 97 65 to 96 60 to 96 70 to 95 65 to 95
    (Re + Co) - NBSA 0.03 to 0.02 to 0.04 to 0.026 to 0.05 to 29.7 0.032 to
    TaN 39.6 30 34.7 26 22
    Co 0.03 to 0.017 to 0.04 to 0.023 to 0.05 to 29.7 0.03 to
    39.6 26 34.7 23 19
    TaN 60 to 97 70 to 98 65 to 96 75 to 97.7 70 to 95 79 to 97
  • TABLE 22
    Compositions that use Re, Ni-based superalloy (NBSA),
    and Co in a binder for binding a carbide from carbides of IVb, Vb,
    & VIb or a nitride from nitrides of IVb & Vb. The range of Binder
    is from 0.5% Re + 0.5% Co + 99% superalloy to 99% Re + 0.5% Co + 0.5%
    Superalloy to 0.5% Re + 99% Co + 0.5% Superalloy
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Co + NBSA) - Re 0.015 to 0.06 to 0.02 to 0.08 to 0.025 to 0.1 to 64.3
    TiC 39.6 73.6 34.65 69.3 29.7
    NBSA 0.015 to 0.02 to 0.02 to 0.03 to 0.025 to 0.035 to
    39.6 51.3 34.65 46.0 29.7 40.5
    Co 0.015 to 0.03 to 0.02 to 0.036 to 0.025 to 0.045 to
    39.6 54.3 34.65 49.0 29.7 43.5
    TiC 60 to 97 26 to 95 65 to 96 30 to 94 70 to 95 35 to 92
    (Re + Co + NBSA) - Re 0.015 to 0.05 to 0.02 to 0.06 to 0.025 to 0.08 to
    ZrC 39.6 67.7 34.65 62.9 29.7 57.5
    NBSA 0.015 to 0.017 to 0.02 to 0.022 to 0.025 to 0.028 to
    39.6 44.2 34.65 39.1 29.7 33.9
    Co 0.015 to 0.02 to 0.02 to 0.027 to 0.025 to 0.034 to
    39.6 47.2 34.65 42.0 29.7 36.7
    ZrC 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 43 to 94
    (Re + Co + NBSA) - Re 0.015 to 0.025 to 0.02 to 0.034 to 0.025 to 0.042 to
    HfC 39.6 52.1 34.65 46.8 29.7 41.2
    NBSA 0.015 to 0.009 to 0.02 to 0.012 to 0.025 to 0.015 to 21
    39.6 29.3 34.65 25.1 29.7
    Co 0.015 to 0.01 to 0.02 to 0.014 to 0.025 to 0.018 to
    39.6 31.8 34.65 27.4 29.7 23.1
    HfC 60 to 97 48 to 98 65 to 96 53 to 70 to 95 59 to 96.8
    97.4
    (Re + Co + NBSA) - Re 0.015 to 0.06 to 0.02 to 0.08 to 0.025 to 0.09 to
    VC 39.6 71.5 34.65 67 29.7 61.8
    NBSA 0.015 to 0.02 to 0.02 to 0.026 to 0.025 to 0.032 to 38
    39.6 48.6 34.65 43.4 29.7
    Co 0.015 to 0.024 to 0.02 to 0.032 to 0.025 to 0.04 to
    39.6 51.7 34.65 46.4 29.7 40.9
    VC 60 to 97 28 to 96 65 to 96 33 to 94 70 to 95 38 to 93
    (Re + Co + NBSA) - Re 0.015 to 0.04 to 0.02 to 0.05 to 0.025 to 0.07 to
    NbC 39.6 63.8 34.65 58.7 29.7 53.1
    NBSA 0.015 to 0.015 to 0.02 to 0.02 to 0.025 to 0.024 to 30
    39.6 40 34.65 35 29.7
    Co 0.015 to 0.017 to 0.02 to 0.023 to 0.025 to 0.03 to
    39.6 43 34.65 37.9 29.7 32.7
    NbC 60 to 97 36 to 97 65 to 96 41 to 96 70 to 95 47 to 95
    (Re + Co + NBSA) - Re 0.015 to 0.02 to 0.02 to 0.03 to 0.025 to 0.04 to 38
    TaC 39.6 48.8 34.65 43.5 29.7
    NBSA 0.015 to 0.008 to 0.02 to 0.011 to 0.025 to 0.013 to
    39.6 26.6 34.65 22.6 29.7 18.9
    Co 0.015 to 0.01 to 0.02 to 0.013 to 0.025 to 0.016 to
    39.6 29 34.65 24.8 29.7 20.8
    TaC 60 to 97 51 to 65 to 96 56 to 70 to 95 61.8 to
    98.3 97.7 97.2
    (Re + Co + NBSA) - Re 0.015 to 0.05 to 0.02 to 0.06 to 0.025 to 0.08 to 57
    Cr2C3 39.6 67.3 34.65 62.5 29.7
    NBSA 0.015 to 0.017 to 0.02 to 0.022 to 0.025 to 0.027 to
    39.6 43.8 34.65 38.7 29.7 33.5
    Co 0.015 to 0.02 to 0.02 to 0.027 to 0.025 to 0.033 to
    39.6 46.8 34.65 41.6 29.7 36.2
    Cr2C3 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 43 to 94
    (Re + Co + NBSA) - Re 0.015 to 0.03 to 0.02 to 0.05 to 0.025 to 0.06 to 49
    Mo2C 39.6 60.2 34.65 55 29.7
    NBSA 0.015 to 0.013 to 0.02 to 0.017 to 0.025 to 0.02 to 27
    39.6 36.4 34.65 31.7 29.7
    Co 0.015 to 0.015 to 0.02 to 0.02 to 0.025 to 0.025 to 29
    39.6 39.3 34.65 34 29.7
    Mo2C 60 to 97 39 to 97 65 to 96 45 to 96 70 to 95 50 to 95.6
    (Re + Co + NBSA) - Re 0.015 to 0.02 to 0.02 to 0.027 to 0.025 to 0.034 to
    WC 39.6 46.9 34.65 41.7 29.7 36.3
    NBSA 0.015 to 0.008 to 0.02 to 0.01 to 0.025 to 0.013 to
    39.6 25.1 34.65 21.3 29.7 17.8
    Co 0.015 to 0.009 to 0.02 to 0.012 to 0.025 to 0.015 to
    39.6 27.5 34.65 23.5 29.7 19.6
    WC 60 to 97 53 to 98 65 to 96 58 to 70 to 95 64 to 97.4
    97.8
    (Re + Co + NBSA) - Re 0.015 to 0.06 to 0.02 to 0.08 to 0.025 to 0.1 to 62
    TiN 39.6 71.6 34.65 67.2 29.7
    NBSA 0.015 to 0.02 to 0.02 to 0.027 to 0.025 to 0.032 to
    39.6 48.8 34.65 43.6 29.7 38.2
    Co 0.015 to 0.025 to 0.02 to 0.03 to 0.025 to 0.04 to
    39.6 51.9 34.65 46.6 29.7 41
    TiN 60 to 97 28 to 96 65 to 96 33 to 94 70 to 95 38 to 93
    (Re + Co + NBSA) - Re 0.015 to 0.04 to 0.02 to 0.06 to 0.025 to 0.07 to
    ZrN 39.6 65.3 34.65 60.3 29.7 54.8
    NBSA 0.015 to 0.016 to 0.02 to 0.02 to 0.025 to 0.025 to
    39.6 41.6 34.65 36.6 29.7 31.5
    Co 0.015 to 0.02 to 0.02 to 0.025 to 0.025 to 0.03 to
    39.6 44.6 34.65 40 29.7 34
    ZrN 60 to 97 34 to 97 65 to 96 39 to 96 70 to 95 45 to 95
    Re + Co + NBSA - Re 0.015 to 0.02 to 0.02 to 0.03 to 45 0.025 to 0.04 to
    HfN 39.6 50 34.65 29.7 39
    NBSA 0.015 to 0.009 to 0.02 to 0.011 to 0.025 to 0.014 to
    39.6 27.5 34.65 23.5 29.7 20
    Co 0.015 to 0.01 to 0.02 to 0.013 to 0.025 to 0.017 to
    39.6 30 34.65 25.8 29.7 22
    HfN 60 to 97 50 to 98 65 to 96 55 to 97.6 70 to 95 61 to 97
    Re + Co + NBSA - Re 0.015 to 0.05 to 0.02 to 0.07 to 65 0.025 to 0.09 to
    VN 39.6 60 34.65 29.7 60
    NBSA 0.015 to 0.02 to 0.02 to 0.024to 0.025 to 0.03 to
    39.6 46.4 34.65 41.2 29.7 36
    Co 0.015 to 0.02 to 0.02 to 0.03 to 44 0.025 to 0.04 to
    39.6 49 34.65 29.7 39
    VN 60 to 97 30 to 96 65 to 96 35 to 95 70 to 95 40 to 93
    Re + Co + NBSA - Re 0.015 to 0.04 to 0.02 to 0.06 to 60 0.025 to 0.07 to
    NbN 39.6 65 34.65 29.7 55
    NBSA 0.015 to 0.016to 0.02 to 0.02 to 37 0.025 to 0.025 to
    39.6 42 34.65 29.7 32
    Co 0.015 to 0.02 to 0.02 to 0.025 to 0.025 to 0.03 to
    39.6 45 34.65 39.5 29.7 34
    NbN 60 to 97 34 to 97 65 to 96 39 to 96 70 to 95 45 to 95
    Re + Co + NBSA - Re 0.015 to 0.02 to 0.02 to 0.03 to 44 0.025 to 0.04 to
    TaN 39.6 49 34.65 29.7 38
    NBSA 0.015 to 0.008 to 0.02 to 0.011 to 0.025 to 0.014 to
    39.6 27 34.65 23 29.7 19
    Co 0.015 to 0.01 to 0.02 to 0.013 to 0.025 to 0.016 to
    39.6 29 34.65 25 29.7 21
    TaN 60 to 97 51 to 65 to 96 56 to 97.7 70 to 95 61.5 to
    98.3 97.1
  • TABLE 23
    Compositions that use Re for binding WC + TiC or WC + TaC or
    WC + TiC + TaC
    Composition Composition Composition
    Range
    1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    Re - Re 3 to 40 4 to 54 4 to 35 5 to 49 5 to 30 7 to 43
    WC + TiC WC 40 to 96 40 to 96 43 to 94.5 44 to 94 45 to 93 48 to 93
    TiC 1 to 48 0.3 to 21 1.5 to 43 0.5 to 19 2 to 45 0.6 to 18
    Re - Re 3 to 40 4 to 48 4 to 35 5 to 42 5 to 30 7 to 37
    WC + TaC WC 50 to 96.5 44 to 96 55 to 95 49 to 94 60 to 93.5 55 to 92
    TaC 0.5 to 24 0.5 to 21 1 to 22 1 to 19 1.5 to 18 1.5 to18
    Re - Re 3 to 40 4 to 48 4 to 35 5 to 43 5 to 30 7 to 38
    WC + TiC + TaC WC 40 to 95.5 36 to 95 45 to 93 41 to 93 50 to 90 48 to 90
    TiC 1 to 48 0.3 to 22 2 to 45 0.6 to 20 3 to 42 0.9 to 18
    TaC 0.5 to 20 0.5 to 25 1 to 18 0.8 to 22 2 to 15 2 to 17
  • TABLE 24
    Compositions that use Ni-based superalloy (NBSA) for
    binding WC + TiC or WC + TaC or WC + TiC + TaC
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    NBSA - NBSA   3 to 40 1.5 to 31   4 to 35   2 to 26   5 to 30   3 to 23
    WC + TiC WC  40 to 96  60 to 98  43 to 94.5  63 to 97  45 to 93  66 to 96.5
    TiC   1 to 48 0.3 to 25 1.5 to 43 0.5 to 22   2 to 45 0.6 to 20
    NBSA - NBSA   3 to 40 1.5 to 26   4 to 35   2 to 22   5 to 30   13 to 18
    WC + TaC WC  50 to 96.5  63 to 98  55 to 95  67 to 97  60 to 93.5  71 to 96
    TaC 0.5 to 24 0.5 to 26   1 to 22   1 to 23 1.5 to 18 1.5 to 21
    NBSA - NBSA   3 to 40 1.5 to 26   4 to 35   2 to 22   5 to 30   3 to 19
    WC + TiC + TaC WC  40 to 95.5  51 to 98  45 to 93  56 to 96  50 to 90  61 to 94
    TiC   1 to 48 0.4 to 23   2 to 45 0.8 to 21   3 to 42   1 to 19
    TaC 0.5 to 20 0.6 to 26   1 to 18   1 to 23   2 to 15   2 to 18
  • TABLE 25
    Compositions that use Re and Ni-based superalloy (NBSA)
    in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA) - Re 0.03 to 39.6 0.04 to 52    0.04 to 34.65 0.06 to 48   0.05 to 29.7 0.07 to 45  
    WC + TiC NBSA 0.03 to 39.6 0.015 to 29    0.04 to 34.65 0.02 to 26   0.05 to 29.7 0.026 to 23  
    WC 40 to 96 40 to 98   43 to 94.5 44 to 97 45 to 93   48 to 96.6
    TiC  1 to 48 0.3 to 24  1.5 to 45  0.5 to 22   2 to 42 0.6 to 21 
    (Re + NBSA) - Re 0.03 to 39.6 0.04 to 47    0.04 to 34.65 0.055 to 42   0.05 to 29.7 0.07 to 37  
    WC + TaC NBSA 0.03 to 39.6 0.015 to 25    0.04 to 34.65 0.02 to 22   0.05 to 29.7 0.025 to 18  
    WC   50 to 96.5 44 to 98 55 to 95 50 to 97 60 to 93   55 to 95.5
    TaC 0.5 to 22  0.5 to 24   1 to 20   1 to 21.5  2 to 18  2 to 19
    (Re + NBSA) - Re 0.03 to 39.6 0.04 to 53    0.04 to 34.65 0.06 to 47   0.05 to 29.7 0.07 to 41  
    WC + TiC + TaC NBSA 0.03 to 39.6 0.015 to 30    0.04 to 34.65 0.02 to 25   0.05 to 29.7 0.026 to 21  
    WC   40 to 95.5 40 to 98 45 to 93 46 to 96 50 to 90 51 to 94
    TiC  1 to 48 0.3 to 23   2 to 45 0.6 to 21   3 to 42 0.9 to 19 
    TaC 0.5 to 20  0.4 to 26   1 to 18 0.8 to 23   2 to 15  2 to 18
  • TABLE 26
    Compositions that use Re and Co in a binder for binding
    WC + TiC or WC + TaC or WC + TiC + TaC
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Co) - Re 0.03 to 39.6 0.04 to 53    0.04 to 34.65 0.055 to 48   0.05 to 29.7 0.07 to 43  
    WC + TiC Co 0.03 to 39.6 0.017 to 31    0.04 to 34.65 0.023 to 28   0.05 to 29.7 0.03 to 26  
    WC 40 to 96 40 to 98   43 to 94.5 44 to 97 45 to 93 48 to 96
    TiC  1 to 48 0.3 to 23  1.5 to 45  0.5 to 22   2 to 42 0.6 to 21 
    (Re + Co) - Re 0.03 to 39.6 0.04 to 47    0.04 to 34.65 0.055 to 42   0.05 to 29.7 0.07 to 37  
    WC + TaC CO 0.03 to 39.6 0.017 to 28    0.04 to 34.65 0.023 to 24   0.05 to 29.7 0.03 to 20  
    WC   50 to 96.5 44 to 98 55 to 95 50 to 97 60 to 93 55 to 95
    TaC 0.5 to 22  0.5 to 24   1 to 20  1 to 21  2 to 18  2 to 19
    (Re + Co) - Re 0.03 to 39.6 0.04 to 53    0.04 to 34.65 0.06 to 47   0.05 to 29.7 0.07 to 4  
    WC + TiC + TaC Co 0.03 to 39.6 0.017 to 33    0.04 to 34.65 0.023 to 28   0.05 to 29.7 0.03 to 23  
    WC   40 to 95.5 40 to 98 45 to 93 46 to 96 50 to 90 51 to 94
    TiC  1 to 48 0.3 to 23   2 to 45 0.6 to 21   3 to 42 0.9 to 19 
    TaC 0.5 to 20  0.4 to 26   1 to 18 0.8 to 23   2 to 15  2 to 18
  • TABLE 27
    Compositions that use Co and Ni-based superalloy (NBSA)
    in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Co + NBSA) - Co 0.03 to 39.6 0.018 to 33    0.04 to 34.65 0.024 to 29   0.05 to 29.7 0.03 to 25  
    WC + TiC NBSA 0.03 to 39.6 0.015 to 29    0.04 to 34.65 0.02 to 26   0.05 to 29.7 0.03 to 23  
    WC 40 to 96 58 to 98   43 to 94.5 61 to 97 45 to 93   64 to 96.7
    TiC  1 to 48 0.3 to 24  1.5 to 45  0.5 to 22   2 to 42 0.7 to 21 
    (Co + NBSA) - Co 0.03 to 39.6 0.018 to 28    0.04 to 34.65 0.024 to 24   0.05 to 29.7 0.03 to 20  
    WC + TaC NBSA 0.03 to 39.6 0.015 to 25    0.04 to 34.65 0.02 to 22   0.05 to 29.7 0.025 to 18  
    WC   50 to 96.5 61 to 98 55 to 95 65 to 97 60 to 93 69 to 95
    TaC 0.5 to 22  0.5 to 24   1 to 20   1 to 21.5  2 to 18  2 to 19
    (Co + NBSA) - Co 0.03 to 39.6 0.018 to 33    0.04 to 34.65 0.024 to 28   0.05 to 29.7 0.03 to 23  
    WC + TiC + TaC NBSA 0.03 to 39.6 0.015 to 30    0.04 to 34.65 0.02 to 25   0.05 to 29.7 0.026 to 21  
    WC   40 to 95.5 57 to 98 45 to 93 62 to 96 50 to 90 67 to 94
    TiC  1 to 48 0.4 to 23   2 to 45 0.7 to 21   3 to 42  1 to 19
    TaC 0.5 to 20  0.6 to 26   1 to 18  1 to 23  2 to 15  2 to 18
  • TABLE 28
    Compositions that use Re, Ni-based superalloy (NBSA),
    and Co in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC.
    The range of Binder is from 0.5% Re + 99.5% superalloy to 99.5% Re + 0.5%
    Superalloy to 0.5% Re + 0.5% Superalloy + 99% Co.
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Co Re 0.015 to 39.8  0.02 to 54   0.02 to 34.8 0.027 to 48   0.025 to 29.9  0.035 to 43  
    NBSA) - NBSA 0.015 to 39.8  0.008 to 29   0.02 to 34.8 0.01 to 26   0.025 to 29.9  0.13 to 24  
    WC + TiC Co   0 to 39.6  0 to 32   0 to 34.7  0 to 29   0 to 29.8  0 to 26
    WC 40 to 96 40 to 98   43 to 94.5 44 to 97 45 to 93 48 to 96
    TiC  1 to 48 0.3 to 24  1.5 to 45  0.5 to 22   2 to 42 0.6 to 21 
    (Re + Co + NBSA) - Re 0.015 to 39.8  0.02 to 47   0.02 to 34.8 0.027 to 42   0.025 to 29.9  0.034 to 37  
    WC + TaC NBSA 0.015 to 39.8  0.008 to 26   0.02 to 34.8 0.01 to 22   0.025 to 29.9  0.13 to 18  
    Co   0 to 39.6  0 to 28   0 to 34.7  0 to 24   0 to 29.8  0 to 20
    WC   50 to 96.5 45 to 98 55 to 95 50 to 97 60 to 93 55 to 95
    TaC 0.5 to 22  0.5 to 24   1 to 20 0.9 to 21   2 to 18 1.8 to19 
    (Re + NBSA + Co) - Re 0.015 to 39.8  0.02 to 65   0.02 to 34.8 0.027 to 58  0.025 to 29.9  0.034 to 51  
    WC + TiC + TaC NBSA 0.015 to 39.8  0.008 to 41   0.02 to 34.8 0.01 to 34   0.025 to 29.9  0.13 to 28  
    Co   0 to 39.6  0 to 44   0 to 34.7  0 to 37   0 to 29.8  0 to 31
    WC 35 to 85 35 to 93 40 to 80 41 to 88 40 to 75 47 to83
    TiC  1 to 50 0.3 to 25   2 to 45 0.6 to 22   3 to 40 0.9 to 18 
    TaC 0.5 to 25  0.4 to 26   1 to 22 0.8 to 24   2 to 20 1.6 to 21 
  • TABLE 29
    Additional Material Samples and Their Compositions
    Lot No. Re R95 Co U700 U720 Ni WC TiC TaC VC Mo2C TiN
    Composition in Weight %
    P80 0 0 14.28 74.15 5.835 5.733
    P81 0.736 0 13.904 73.84 5.811 5.709
    P82 0.707 6.026 7.3694 74.31 5.847 5.744
    P83 0.679 12.82 0 74.83 5.889 5.785
    P84 1.45 5.903 7.1237 73.98 5.822 5.719
    P85 3.06 5.532 6.7027 73.27 5.766 5.665
    P86 1.45 5.903 7.1237 36.99 5.822 5.719
    P87 1.063 4.126 5.4174 78.14 5.676 5.576
    P88 1.861 7.57 9.1372 69.59 5.974 5.869
    P89 1.368 5.572 6.7242 80.31 3.004 3.023
    P99 0 0 5.5 15 29 10 9.5 20
    P100 4.8 4.65 14.5 28.1 9.7 9.5 19.4
    P101 4.8 4.65 14.5 28.1 9.7 9.5 19.4
    P102 4.8 10 14.5 28.1 9.7 9.5 19.4
    P103 9.6 20 11.25 21.65 7.5 7.1 14.9
    P104 7.2 15 12.8 25 8.6 8.1 17.3
    P105 15 7.5 13.6 26.35 9.05 8.9 18.1
    P106 14.49 0 0 74.415 5.092 6.003
    P107 15.101 0 0 66.875 7.076 10.95
    P108 11.796 0.7485 0.437 75.727 5.182 6.109
    P109 12.303 0.7807 0.456 68.105 7.206 11.15
    P110 9.5724 1.4017 0.761 76.812 5.256 6.196
    P111 9.9896 1.4628 0.794 69.124 7.314 11.32
    P112 6.9929 2.1369 1.16 78.07 5.342 6.298
    P113 14.131 4.3182 2.343 67.447 5.398 6.363
    P114 21.418 6.545 3.552 56.602 5.454 6.43
    P115 3.8745 3.0258 1.642 79.591 5.446 6.421
    P116 7.988 6.2383 3.385 70.155 5.614 6.619
    P117 12.363 9.6552 5.24 60.119 5.793 6.829
    P118 1.8824 3.5833 1.961 80.561 5.513 6.499
    P119 2.8849 5.4917 3.006 76.345 5.632 6.64
    P120 5.0264 9.5681 5.237 67.339 5.888 6.941
    P121 13.157 0.5708 0 75.078 5.138 6.057
    P122 5.294 2.0672 0 81.057 5.316 6.266
    Weight %
    P123 19.908 5.9798 1.976 60.41 5.382 6.344
    P124 20.68 9.9386 2.736 54.464 5.59 6.59
    P125 1.5492 3.0246 0.833 82.731 5.444 6.418
    P126 8.4621 13.217 3.639 61.723 5.948 7.011
    P127 12.191 13.964 3.844 61.702 3.808 4.49
    P128 11.906 0.5166 0 86.99 0.604
    P129 1.6752 2.0169 1.9524 93.77 0.599
    P130 11.97 8.0334 8.085 71.33 0.6
    P131 1.4372 3.8162 3.7765 90.39 0.596
    P132 6.6223 1.3705 1.3191 90.1 0.605
    P133 5.505 1.7196 1.6331 90.55 0.609
    P134 11.43 5.0212 4.8443 78.11 0.613
    P135 1.644 2.3344 2.571 79.98 3.151 10.32
    P136 3.6545 5.1371 5.657 73.439 0 12.11
    P137 4.4642 6.3916 7.039 69.776 0 12.33
    P138 4.899 6.5757 7.241 69.279 1.435 10.57
    P139 6.5381 7.902 8.702 64.651 1.459 10.75
    P140 3.0601 5.5324 6.703 73.274 5.766 5.665
    P141 2.9261 5.2902 6.409 71.233 3.308 10.83
    P142 5.0649 6.1371 7.419 67.113 3.337 10.93
    A 13.853 0.2847 0.314 74.887 5.125 5.538
    B 2.7327 5.0305 0 81.358 5.488 5.391
    C 3.0601 5.5324 6.703 73.274 5.766 5.665
    D 1.8803 3.5793 1.988 81.637 5.507 5.41
    E 7.7737 9.4819 0 71.578 5.633 5.534
    P144 0.6786 12.821 0 74.827 5.889 5.785
    P145 0.6437 5.663 0 80.041 3.194 10.46
    P146 1.8837 5.3941 0 81.786 5.517 5.42
    P147 2.3479 5.1953 0 81.552 5.501 5.404
    P148 1.5479 8.462 0 76.038 3.264 10.69
    P149 1.6376 15.347 0 68.255 3.453 11.31
    J 25.75 2.5 14.5 24.1 8.5 8 16.65
    K 11.671 0.4143 0.3935 0 0 86.92 0.605
    L 2.6826 5.5683 0 0 0 91.32 0.43
    M 3.5669 0 14.235 0 0 81.75 0.452
    N 0 7.5039 0 0 0 92.06 0.44
    O 12.515 0 0 0 0.2541 86.63 0.601
    P 1.7969 0 0 6.9309 90.68 0.597
    Q 0 0 0 7.4214 91.98 0.602
    S 8.371 0 0 5.3814 85.67 0.579
    T 1.6967 0 4.681 0 92.98 0.645
    U 3.9002 0 0 3.8684 91.6 0.636
    P150 0 0 14.847 84.68 0.469
    P151 0 3.2554 11.851 84.38 0.51
    P152 1.5219 3.225 11.153 83.59 0.505
    P153 12.451 1.2899 4.6957 81.09 0.478
    P154 2.6486 2.9933 7.6052 54.464 0.509
    P155 0 0 11.55 82.731 0.414
    P156 1.1019 3.5804 6.2338 61.723 0.671
    P157 0 3.761 6.5607 86.24 0.675
    P158 0 0 9.9898 88.04 0.512
    P159 0.9437 3.0766 5.5161 88.41 0.502
    P160 0 3.0946 5.9144 89 0.505
    P161 0 0 8.7552 89.5 0.506
    P162 2.967 5.6892 0.6379 0.654 89.817 0.2346
    P163 0.581 8.1942 0.9297 0.8972 89.156 0.2413
    P164 2.16 7.569 0.8669 0.8333 88.331 0.2391
    P165 2.801 6.7279 1.976 2.026 86.226 0.2422
    P166 2.797 8.3834 1.2603 1.2361 86.082 0.2418
    P167 2.789 11.13 0 0 85.84 0.2411
  • The following TABLES 30-41 list exemplary cermet compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications.
    TABLE 30
    Compositions that use Re as a binder for binding TiC + Mo2C,
    or TiN + Mo2C, or TiC + TiN + Mo2C, or TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    Re - Re  3 to 30 9.5 to 65   4 to 27 13 to 60  5 to 25 15 to 58
    TiC + Mo2C TiC 43 to 97 19 to 88 48 to 92 23 to 79 51 to 90 25 to 75
    Mo2C  0 to 27  0 to 38  0 to 26  0 to 36  0 to 24  0 to 33
    Re - Re  3 to 30  9 to 63  4 to 27 12 to 58  5 to 25 15 to 56
    TiN + Mo2C TiN 43 to 97 21 to 89 48 to 92 25 to 81 51 to 90 27 to 76
    Mo2C  0 to 27  0 to 36  0 to 26  0 to 34  0 to 24  0 to 31
    Re - Re  3 to 30  9 to 64  4 to 27 12 to 60  5 to 25 15 to 58
    TiC + TiN + Mo2C TiC  0.3 to 93.7 0.2 to 84   0.4 to 91.6 0.3 to 79   0.5 to 89.5 0.35 to 74  
    TiN  0.3 to 93.7 0.3 to 85   0.4 to 91.6 0.4 to 80   0.5 to 89.5 0.5 to 76 
    Mo2C  0 to 27  0 to 36  0 to 26  0 to 34  0 to 24  0 to 31
    Re - Re  3 to 30  6 to 65  4 to 27  9 to 61  5 to 25 11 to 65
    TiC + TiN + TiC  0.3 to 93.5 0.1 to 83   0.4 to 91.3 0.2 to 78   0.5 to 89.1 0.3 to 74 
    Mo2C + WC + TiN  0.3 to 93.5 0.15 to 85    0.4 to 91.3 0.2 to 80   0.5 to 89.1 0.3 to 76 
    TaC + VC + Cr2C3 Mo2C  0 to 28  0 to 25  0 to 26  0 to 25  0 to 24  0 to 24
    WC 0.1 to 20  0.15 to 39   0.15 to 15   0.25 to 32   0.2 to 12  0.35 to 28  
    TaC 0.1 to 15  0.15 to 30   0.15 to 12   0.25 to 25   0.2 to 10  0.3 to 22 
    VC  0 to 15  0 to 11  0 to 12  0 to 10  0 to 10 0 to 9
    Cr2C3  0 to 15  0 to 16  0 to 12  0 to 14  0 to 10  0 to 12
  • TABLE 31
    Compositions that use Ni-based superalloy (NBSA) as a
    binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    NBSA - NBSA 3 to 30 4 to 41 4 to 27 5 to 37 5 to 25 6 to 34
    TiC + Mo2C TiC 43 to 94  30 to 90  48 to 92  35 to 87  51 to 90  37 to 84 
    Mo2C 3 to 27 4 to 40 4 to 26 6 to 39 5 to 24 8 to 36
    NBSA - NBSA 3 to 30 4 to 38 4 to 27 5 to 34 5 to 25 6 to 32
    TiN + Mo2C TiN 43 to 94  32 to 91  48 to 92  37 to 88  51 to 90  40 to 85 
    Mo2C 3 to 27 4 to 38 4 to 26 6 to 37 5 to 24 7 to 34
    NBSA - NBSA 3 to 30 4 to 40 4 to 27 5 to 36 5 to 25 6 to 34
    TiC + TiN + Mo2C TiC 0.3 to 93.7 0.2 to 90   0.4 to 91.6 0.3 to 86   0.5 to 89.5 0.4 to 83  
    TiN 0.3 to 93.7 0.3 to 91   0.4 to 91.6 0.4 to 88   0.5 to 89.5 0.5 to 85  
    Mo2C 3 to 27 4 to 38 4 to 26 6 to 37 5 to 24 8 to 34
    NBSA - NBSA 3 to 30 2 to 40 4 to 27 4 to 36 5 to 25 5 to 34
    TiC + TiN + TiC 0.3 to 93.3 0.15 to 90   0.4 to 91.3 0.2 to 86   0.5 to 89.3 0.3 to 83  
    Mo2C + WC + TaC + TiN 0.3 to 93.3 0.25 to 90   0.4 to 91.3 0.35 to 87   0.5 to 89.3 0.45 to 84  
    VC + Cr2C3 Mo2C 3 to 27 4 to 25 4 to 26 6 to 26 5 to 24   8 to 25.5
    WC 0.1 to 20   0.25 to 42   0.15 to 15   0.4 to 34   0.2 to 12   0.5 to 29  
    TaC 0.1 to 15   0.25 to 36   0.15 to 12   0.4 to 30   0.2 to 10   0.5 to 26  
    VC 0 to 15 0 to 14 0 to 12 0 to 12 0 to 10 0 to 10
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 32
    Compositions that use Re and Ni-based superalloy (NBSA) in
    a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA) - Re 0.03 to 29.7  0.1 to 64   0.04 to 26.73 0.13 to 60   0.05 to 24.75 0.16 to 57  
    TiC + TiN + Mo2C NBSA 0.03 to 29.7  0.03 to 40   0.04 to 26.73 0.05 to 36   0.05 to 24.75 0.06 to 34  
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + NBSA) - Re 0.03 to 29.7  0.06 to 64   0.04 to 26.73 0.1 to 60   0.05 to 24.75 0.12 to 57  
    TiC + TiN + NBSA 0.03 to 29.7  0.02 to 40   0.04 to 26.73 0.03 to 36   0.05 to 24.75 0.04 to 34  
    Mo2C + WC + TaC + TiC 0.3 to 93.5 0.15 to 89   .40 to 91.3 0.2 to 86   0.5 to 89.1 0.3 to 83  
    VC + Cr2C3 TiN 0.3 to 93.5 0.15 to 90   .40 to 91.3 0.2 to 87   0.5 to 89.1 0.3 to 84  
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24   5 to 25.5
    WC 0.1 to 20   0.15 to 42   0.15 to 15   0.25 to 35   0.2 to 12   0.35 to 29  
    TaC 0.1 to 15   0.15 to 33   0.15 to 12   0.25 to 28   0.2 to 10   0.3 to 24  
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 33
    Compositions that use Re and Ni in a binder for binding
    TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Range 1 Composition Range 2 Composition Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Ni) - Re 0.03 to 29.7  0.1 to 64   0.04 to 26.73 0.13 to 60   0.05 to 24.75 0.16 to 57  
    TiC + TiN + Mo2C Ni 0.03 to 29.7  0.04 to 42   0.04 to 26.73 0.05 to 38   0.05 to 24.75 0.06 to 36  
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 83
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + Ni) - Re 0.03 to 29.7  0.06 to 64   0.04 to 26.73 0.1 to 60   0.05 to 24.75 0.12 to 57  
    TiC + TiN + Ni 0.03 to 29.7  0.03 to 42   0.04 to 26.73 0.04 to 39   0.05 to 24.75 0.05 to 36  
    Mo2C + WC + TaC + TiC 0.3 to 93.5 0.15 to 89   .40 to 91.3 0.2 to 85   0.5 to 89.1 0.3 to 82  
    VC + Cr2C3 TiN 0.3 to 93.5 0.15 to 90   .40 to 91.3 0.2 to 87   0.5 to 89.1 0.3 to 83  
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24   5 to 25.5
    WC 0.1 to 20   0.15 to 42   0.15 to 15   0.25 to 35   0.2 to 12   0.35 to 29  
    TaC 0.1 to 15   0.15 to 33   0.15 to 12   0.25 to 28   0.2 to 10   0.3 to 24  
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 34
    Compositions that use Re and Co in a binder for binding
    TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    Re + Co - Re 0.03 to 0.1 to 64 0.04 to 0.13 to 0.05 to 0.16 to
    TiC + TiN + Mo2C 29.7 26.73 60 24.75 57
    Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    29.7 43 26.73 39 24.75 36
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 83
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    Re + Co - Re 0.03 to 0.06 to 0.04 to 0.1 to 60 0.05 to 0.12 to
    TiC + TiN + Mo2C + 29.7 64 26.73 24.75 57
    WC + TaC + VC + Cr2C3 Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.7 43 26.73 39 24.75 36
    TiC 0.3 to 0.15 to .40 to 0.2 to 85 0.5 to 0.3 to 82
    93.5 89 91.3 89.1
    TiN 0.3 to 0.15 to .40 to 0.2 to 87 0.5 to 0.3 to 83
    93.5 90 91.3 89.1
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24 5 to 25.5
    WC 0.1 to 0.15 to 0.15 to 0.25 to 0.2 to 12 0.35 to
    20 42 15 34 29
    TaC 0.1 to 0.15 to 0.15 to 0.25 to 0.2 to 10 0.3 to 24
    15 32 12 27
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to13
  • TABLE 35
    Compositions that use Ni-based superalloy (NBSA) and Co in
    a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (NBSA + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    TiC + TiN + Mo2C 29.7 40 26.73 37 24.75 34
    Co 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to
    29.7 43 26.73 39 24.75 37
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 86
    Mo2C 3 to 27 4 to 38 4 to 26 6 to 37 5 to 24 7 to 34
    (NBSA + Co) - NBSA 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 0.05 to
    TiC + TiN + Mo2C + 29.7 40 26.73 36 24.75 34
    WC + TaC + VC + Cr2C3 Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.7 43 26.73 39 24.75 36
    TiC 0.3 to 0.15 to .40 to 0.2 to 0.5 to 0.3 to
    93.5 89 91.3 86 89.1 83
    TiN 0.3 to 0.25 to .40 to 0.35 to 0.5 to 0.45 to
    93.5 90 91.3 87 89.1 84
    Mo2C 3 to 28 4 to 26 4 to 26 6 to 26 5 to 24 7 to
    25.5
    WC 0.1 to 20 0.25 to 0.15 to 0.38 to 0.2 to 12 0.5 to
    42 15 35 29
    TaC 0.1 to 15 0.23 to 0.15 to 0.35 to 0.2 to 10 0.47 to
    33 12 28 24
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to13
  • TABLE 36
    Compositions that use Ni-based superalloy (NBSA) and Ni in
    a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (NBSA + Ni) - NBSA 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    TiC + TiN + Mo2C 29.7 40 26.73 37 24.75 34
    Ni 0.03 to 0.04 to 0.04 to 0.055 to 0.05 to 0.07 to
    29.7 43 26.73 39 24.75 36
    TiC 0 to 94 0 to 90 0 to 92 0 to 88 0 to 90 0 to 85
    TiN 0 to 94 0 to 91 0 to 92 0 to 89 0 to 90 0 to 86
    Mo2C 3 to 27 4 to 38 4 to 26 6 to 37 5 to 24 7 to 34
    (NBSA + Ni) - NBSA 0.03 to 0.02 to 0.04 to 0.035 to 0.05 to 0.05 to
    TiC + TiN + Mo2C + 29.7 40 26.73 36 24.75 34
    WC + TaC + VC + Cr2C3 Ni 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.7 43 26.73 39 24.75 36
    TiC 0.3 to 0.15 to .40 to 0.2 to 86 0.5 to 0.3 to 83
    93.5 89 91.3 89.1
    TiN 0.3 to 0.25 to .40 to 0.35 to 0.5 to 0.45 to
    93.5 90 91.3 87 89.1 84
    Mo2C 3 to 28 4 to 26 4 to 26 6 to 26 5 to 24 7 to 25.5
    WC 0.1 to 20 0.25 to 0.15 to 0.38 to 0.2 to 12 0.5 to 29
    42 15 35
    TaC 0.1 to 15 0.23 to 0.15 to 0.35 to 0.2 to 10 0.47 to
    33 12 28 24
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to13
  • TABLE 37
    Compositions that use Re, Co, and Ni-based superalloy
    (NBSA) in a binder for binding TiC and Mo2C, or TiN and Mo2C, or TiC,
    TiN, and Mo2C, or TiC, TiN, Mo2C, WC, TaC, VC, and Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA + Co) - Re 0.03 to 0.1 to 64 0.04 to 0.13 to 60 0.05 to 0.16 to 57
    TiC + TiN + Mo2C 29.4 26.46 24.5
    NBSA 0.03 to 0.035 to 0.04 to 0.045 to 36 0.05 to 0.055 to
    29.4 40 26.46 24.5 34
    Co 0.03 to 0.04 to 0.04 to 0.05 to 39 0.05 to 0.06 to 36
    29.4 42 26.46 24.5
    TiC 0 to 94 0 to 90 0 to 92 0 to 88 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + NBSA + Co) - Re 0.03 to 0.06 to 0.04 to 0.1 to 60 0.05 to 0.13 to 57
    TiC + TiN + Mo2C + 29.4 63 26.46 24.5
    WC + TaC + VC + Cr2C3 NBSA 0.03 to 0.02 to 0.04 to 0.03 to 36 0.05 to 0.04 to 33
    29.4 39 26.46 24.5
    Co 0.03 to 0.03 to 0.04 to 0.04 to 39 0.05 to 0.05 to 36
    29.4 42 26.46 24.5
    TiC 0.3 to 0.15 to 0.4 to 0.2 to 86 0.5 to 0.3 to 83
    93.5 89 91.3 89.1
    TiN 0.3 to 0.15 to 0.4 to 0.2 to 87 0.5 to 0.3 to 84
    93.5 90 91.3 89.1
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24 5 to 25.5
    WC 0.1 to 0.15 to 0.15 to 0.25 to 35 0.2 to 12 0.35 to 29
    20 42 15
    TaC 0.1 to 0.15 to 0.15 to 0.25 to 28 0.2 to 10 0.3 to 24
    15 33 12
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 38
    Compositions that use Re, Ni, and Ni-based superalloy
    (NBSA) in a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C,
    or TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA + Ni) - Re 0.03 to 0.1 to 63 0.04 to 0.13 to 0.05 to 0.16 to
    TiC + TiN + Mo2C 29.4 26.46 60 24.5 57
    NBSA 0.03 to 0.035 to 0.04 to 0.045 to 0.05 to 0.055 to
    29.4 40 26.46 36 24.5 33
    Ni 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    29.4 42 26.46 38 24.5 36
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + NBSA + Ni) - Re 0.03 to 0.06 to 0.04 to 0.1 to 60 0.05 to 0.13 to
    TiC + TiN + Mo2C + WC + 29.4 63 26.46 24.5 57
    TaC + VC + Cr2C3 NBSA 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 0.04 to
    29.4 39 26.46 36 24.5 33
    Ni 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.4 42 26.46 38 24.5 36
    TiC 0.3 to 0.15 to 0.4 to 0.2 to 86 0.5 to 0.3 to 83
    93.5 89 91.3 89.1
    TiN 0.3 to 0.15 to 0.4 to 0.2 to 87 0.5 to 0.3 to 84
    93.5 90 91.3 89.1
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24 5 to 25.5
    WC 0.1 to 20 0.15 to 0.15 to 0.25 to 0.2 to 0.35 to
    42 15 35 12 29
    TaC 0.1 to 15 0.15 to 0.15 to 0.25 to 0.2 to 0.3 to 24
    33 12 28 10
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 39
    Compositions that use Re, Ni, and Co in a binder for
    binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C, or
    TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + Ni + Co) - Re 0.03 to 0.1 to 63 0.04 to 0.13 to 0.05 to 0.16 to
    TiC + TiN + Mo2C 29.4 26.46 60 24.5 57
    Ni 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    29.4 42 26.46 38 24.5 36
    Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    29.4 42 26.46 39 24.5 36
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 83
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + Ni + Co) - Re 0.03 to 0.06 to 0.04 to 0.1 to 60 0.05 to 0.13 to
    TiC + TiN + Mo2C + WC + 29.4 63 26.46 24.5 57
    TaC + VC + Cr2C3 Ni 0.03 to 0.025 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.4 42 26.46 38 24.5 36
    Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to
    29.4 42 26.46 39 24.5 36
    TiC 0.3 to 0.15 to 0.4 to 0.2 to 85 0.5 to 0.3 to 82
    93.5 89 91.3 89.1
    TiN 0.3 to 0.15 to 0.4 to 0.2 to 87 0.5 to 0.3 to 83
    93.5 90 91.3 89.1
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24 5 to 25.5
    WC 0.1 to 0.15 to 0.15 to 0.25 to 0.2 to 12 0.35 to
    20 42 15 35 29
    TaC 0.1 to 0.15 to 0.15 to 0.25 to 0.2 to 10 0.3 to 24
    15 33 12 28
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 40
    Compositions that use Co, Ni, and Ni-based superalloy
    (NBSA) in a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C,
    or TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range
    1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (NBSA + Ni + Co) - NBSA 0.03 to 0.04 to 0.04 to 0.5 to 36 0.05 to 0.06 to 34
    TiC + TiN + Mo2C 29.4 40 26.46 24.5
    Ni 0.03 to 0.04 to 0.04 to 0.055 to 0.05 to 0.07 to 37
    29.4 42 26.46 39 24.5
    Co 0.03 to 0.04 to 0.04 to 0.055 to 0.05 to 0.07 to 36
    29.4 43 26.46 39 24.5
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 4 to 38 4 to 26 5 to 37 5 to 24 7 to 34
    (NBSA + Ni + Co) - NBSA 0.03 to 0.025 to 0.04 to 0.035 to 0.05 to 0.05 to 33
    TiC + TiN + Mo2C + 29.4 40 26.46 36 24.5
    WC + TaC + VC + Cr2C3 Ni 0.03 to 0.025 to 0.04 to 0.04 to 38 0.05 to 0.05 to 36
    29.4 42 26.46 24.5
    Co 0.03 to 0.03 to 0.04 to 0.04 to 39 0.05 to 0.05 to 36
    29.4 42 26.46 24.5
    TiC 0.3 to 0.15 to 0.4 to 0.2 to 86 0.5 to 0.3 to 83
    93.5 89 91.3 89.1
    TiN 0.3 to 0.25 to 0.4 to 0.35 to 87 0.5 to 0.45 to 84
    93.5 90 91.3 89.1
    Mo2C 3 to 28 4 to 26 4 to 26 6 to 26 5 to 24 7 to 25.5
    WC 0.1 to 0.25 to 0.15 to 0.35 to 35 0.2 to 12 0.5 to 29
    20 42 15
    TaC 0.1 to 0.25 to 0.15 to 0.35 to 28 0.2 to 10 0.45 to 24
    15 33 12
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • TABLE 41
    Compositions that use Re, Ni, Co, and Ni-based superalloy
    (NBSA) in a binder for binding TiC + Mo2C, or TiN + Mo2C, or TiC + TiN + Mo2C,
    or TiC + TiN + Mo2C + WC + TaC + VC + Cr2C3
    Composition Composition Composition
    Range 1 Range 2 Range 3
    Material Volume % Weight % Volume % Weight % Volume % Weight %
    (Re + NBSA + Ni + Co) - Re 0.03 to 0.1 to 0.04 to 0.13 to 0.05 to 0.16 to
    TiC + TiN + Mo2C 29.1 63 26.19 59 24.25 57
    NBSA 0.03 to 0.035 to 0.04 to 0.45 to 0.05 to 0.055 to
    29.1 39 26.19 36 24.25 33
    Ni 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to
    29.1 42 26.19 38 24.25 36
    Co 0.03 to 0.04 to 0.04 to 0.5 to 0.05 to 0.06 to
    29.1 42 26.19 38 24.25 36
    TiC 0 to 94 0 to 90 0 to 92 0 to 87 0 to 90 0 to 84
    TiN 0 to 94 0 to 91 0 to 92 0 to 88 0 to 90 0 to 85
    Mo2C 3 to 27 3 to 38 4 to 26 4 to 37 5 to 24 5 to 34
    (Re + NBSA + Ni + Co) - Re 0.03 to 0.06 to 0.04 to 0.1 to 0.05 to 0.12 to
    TiC + TiN + Mo2C + WC + 29.1 63 26.19 59 24.25 56
    TaC + VC + Cr2C3 NBSA 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 0.04 to
    29.1 39 26.19 35 24.25 33
    Ni 0.03 to 0.025 to 0.04 to 0.035 to 0.05 to 0.05 to
    29.1 42 26.19 38 24.25 35
    Co 0.03 to 0.025 to 0.04 to 0.03 to 0.05 to 0.05 to
    29.1 42 26.19 38 24.25 36
    TiC 0.3 to 0.15 to 0.4 to 0.2 to 0.5 to 0.3 to
    93.5 89 91.3 86 89.1 83
    TiN 0.3 to 0.15 to 0.4 to 0.2 to 0.5 to 0.3 to
    93.5 90 91.3 87 89.1 84
    Mo2C 3 to 28 3 to 26 4 to 26 4 to 26 5 to 24 5 to
    25.5
    WC 0.1 to 0.15 to 0.15 to 0.25 to 0.2 to 12 0.3 to
    20 42 15 35 29
    TaC 0.1 to 0.15 to 0.15 to 0.2 to 0.2 to 10 0.3 to
    15 33 12 28 24
    VC 0 to 15 0 to 16 0 to 12 0 to 13 0 to 10 0 to 11
    Cr2C3 0 to 15 0 to 18 0 to 12 0 to 15 0 to 10 0 to 13
  • The following TABLES 42-51 list additional examples of various compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications. Similar to some compositions described above, some compositions in TABLES 42-51 may be particularly useful for applications at high temperatures as indicated in the last row under “estimated melting points.”
  • As described above, binder matrix materials with rhenium, a nickel-based superalloy or a combination of both can enhance material performance at high temperatures. Tungsten is typically used as a constituent element in various hard particles such as carbides, nitrides, carbonitrides, borides, and silicides. When used as a binder matrix material, either alone or in combination with other metals, tungsten can significantly raise the melting point of the final hardmetal materials to the range of about 2500 to about 3500° C. Hence, hardmetals using W-based binder matrix materials can be used in applications at high temperatures that may not be possible with other materials. Notably, certain compositions that use a binder matrix based on tungsten (W) shown in TABLES 43-48 show expected high melting points around 3500° C.
  • For the compositions made of nitrides bound by rhenium and cobalt in TABLE 47, each nitride may be substituted by a combination of a nitride and carbide as the hard particle material. A material under this design includes hard particles comprising at least one nitride from nitrides of IVB and VB columns in the periodic table and 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 and cobalt.
    TABLE 42
    Re bound a Boride from Borides of IVb, Vb, & VIb or a Silicide
    from Silicides of IVb, Vb & VIb
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re Re 3 to 40 12.5 to 4 to 35 16 to 71 5 to 30 20 to 67 2700 to
    Bound 76 3000
    TiB2 TiB2 60 to 97 24 to 65 to 96 29 to 84 70 to 95 33 to 80
    87.5
    Re Re 3 to 40 9.5 to 4 to 35 12.5 to 5 to 30 15 to 60 2800 to
    Bound 70 65 3000
    ZrB2 ZrB2 60 to 97 30 to 65 to 96 35 to 70 to 95 40 to 85
    90.5 87.5
    Re Re 3 to 40 5.5 to 4 to 35 7 to 50 5 to 30 9 to 3000 to
    Bound 55.5 44.5 3200
    HfB2 HfB2 60 to 97 44.5 to 65 to 96 50 to 93 70 to 95 55.5 to
    94.5 91
    Re Re 3 to 40 11 to 73 4 to 35 14.5 to 5 to 30 18 to 64 2000 to
    Bound 69 2500
    VB2 VB2 60 to 97 27 to 89 65 to 96 31 to 70 to 95 36 to 82
    85.5
    Re Re 3 to 40 8 to 66 4 to 35 11 to 61 5 to 30 13 to 2800 to
    Bound 55.5 3100
    NbB2 NbB2 60 to 97 34 to 92 65 to 96 39 to 89 70 to 95 44.5 to
    87
    Re Re 3 to 40 5 to 53 4 to 35 6.5 to 5 to 30 8 to 42 3000 to
    Bound 47 3200
    TaB2 TaB2 60 to 97 47 to 95 65 to 96 53 to 70 to 95 58 to 92
    93.5
    Re Re 3 to 40 9.5 to 4 to 35 12.5 to 5 to 30 15 to 60 1800 to
    Bound 69.5 65 2200
    Cr3B2 Cr3B2 60 to 97 30.5 to 65 to 96 35 to 70 to 95 40 to 85
    90.5 87.5
    Re Re 3 to 40 7.5 to 4 to 35 10 to 59 5 to 30 12.5 to 2000 to
    Bound 64 54 2400
    MoB2 MoB2 60 to 97 36 to 65 to 96 41 to 90 70 to 95 46 to
    92.5 87.5
    Re Re 3 to 40 4 to 47 4 to 35 5 to 41 5 to 30 6.5 to 2700 to
    Bound 36 3000
    WB WB 60 to 97 53 to 96 65 to 96 59 to 95 70 to 95 64 to
    93.5
    Re Re 3 to 40 4 to 47 4 to 35 5 to 41 5 to 30 6.5 to 2600 to
    Bound 36 2900
    W2B W2B 60 to 97 53 to 96 65 to 96 59 to 95 70 to 95 64 to
    93.5
    Re Re 3 to 40 13 to 77 4 to 35 17 to 72 5 to 30 20 to 68 2000 to
    Bound Ti5Si3 60 to 97 23 to 87 65 to 96 28 to 83 70 to 95 32 to 80 2400
    Ti5Si3
    Re Re 3 to 40 10 to 72 4 to 35 14 to 67 5 to 30 17 to 62 2100 to
    Bound Zr6Si5 60 to 97 28 to 90 65 to 96 33 to 86 70 to 95 38 to 83 2500
    Zr6Si5
    Re Re 3 to 40 9 to 69 4 to 35 12 to 64 5 to 30 15 to 59 1800 to
    Bound NbSi2 60 to 97 31 to 91 65 to 96 36 to 88 70 to 95 41 to 85 2200
    NbSi2
    Re Re 3 to 40 7 to 62 4 to 35 9 to 57 5 to 30 12 to 51 2200 to
    Bound TaSi2 60 to 97 38 to 93 65 to 96 43 to 91 70 to 95 49 to 88 2600
    TaSi2
    Re Re 3 to 40 9 to 69 4 to 35 12 to 64 5 to 30 15 to 59 1800 to
    Bound MoSi2 60 to 97 31 to 91 65 to 96 36 to 88 70 to 95 41 to 85 2200
    MoSi2
    Re Re 3 to 40 6 to 60 4 to 35 9 to 55 5 to 30 11 to 49 1800 to
    Bound WSi2 60 to 97 40 to 94 65 to 96 45 to 91 70 to 95 51 to 89 2200
    WSi2
  • TABLE 43
    W bound a carbide from carbides of IVb, Vb, & VIb or a
    nitride from nitrides of IVb & Vb.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    W W
    3 to 40 11 to 72 4 to 35 25.02 to 5 to 30 25.02 to 3000 to
    Bound 70 65 3300
    TiC TiC 60 to 97 28 to 89 65 to 96 30 to 70 to 95 35 to
    74.98 74.98
    W W 3 to 40 8 to 66 4 to 35 11 to 61 5 to 30 13 to 56 3200 to
    Bound ZrC 60 to 97 34 to 92 65 to 96 39 to 89 70 to 95 44 to 87 3500
    ZrC
    W W
    3 to 40 4 to 50 4 to 35 6 to 45 5 to 30 7 to 40 3300 to
    Bound HfC 60 to 97 50 to 96 65 to 96 55 to 64 70 to 95 60 to 93 3500
    HfC
    W W
    3 to 40 10 to 70 4 to 35 13 to 65 5 to 30 16 to 60 2700 to
    Bound VC 60 to 97 30 to 90 65 to 96 35 to 87 70 to 95 40 to 84 3300
    VC
    W W 3 to 40 7 to 62 4 to 35 9 to 57 5 to 30 11 to 51 3000 to
    Bound NbC 60 to 97 38 to 93 65 to 96 43 to 91 70 to 95 49 to 89 3500
    NbC
    W W
    3 to 40 4 to 47 4 to 35 5 to 42 5 to 30 7 to 36 3300 to
    Bound TaC 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 64 to 93 3500
    TaC
    W W
    3 to 40 8 to 66 4 to 35 11 to 61 5 to 30 13 to 55 1700 to
    Bound Cr2C3 60 to 97 34 to 92 65 to 96 39 to 89 70 to 95 45 to 87 2100
    Cr2C3
    W W 3 to 40 6 to 59 4 to 35 8 to 53 5 to 30 10 to 48 2400 to
    Bound Mo2C 60 to 97 41 to 94 65 to 96 47 to 93 70 to 95 52 to 90 2600
    Mo2C
    W W 3 to 40 4 to 45 4 to 35 5 to 40 5 to 30 6 to 35 2800 to
    Bound WC 60 to 97 55 to 96 65 to 96 60 to 95 70 to 95 65 to 94 3000
    WC
    W W
    3 to 40 11 to 72 4 to 35 14 to 68 5 to 30 16 to 60 2800 to
    Bound TiN 60 to 97 28 to 89 65 to 96 32 to 86 70 to 95 40 to 84 3300
    TiN
    W W 3 to 40 8 to 64 4 to 35 10 to 59 5 to 30 12 to 53 2900 to
    Bound ZrN 60 to 97 36 to 92 65 to 96 41 to 90 70 to 95 47 to 88 3300
    ZrN
    W W 3 to 40 4 to 48 4 to 35 6 to 43 5 to 30 7 to 37 3200 to
    Bound HfN 60 to 97 52 to 96 65 to 96 57 to 94 70 to 95 63 to 93 3500
    HfN
    W W
    3 to 40 9 to 68 4 to 35 12 to 63 5 to 30 15 to 58 2000 to
    Bound VN 60 to 97 32 to 91 65 to 96 37 to 88 70 to 95 42 to 85 2400
    VN
    W W
    3 to 40 8 to 64 4 to 35 10 to 59 5 to 30 12 to 53 2200 to
    Bound NbN 60 to 97 36 to 92 65 to 96 41 to 90 70 to 95 47 to 88 2600
    NbN
    W W
    3 to 40 4 to 47 4 to 35 5 to 42 5 to 30 7 to 37 3000 to
    Bound TaN 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 63 to 93 3500
    TaN
  • TABLE 44
    W bound a Boride from Borides of IVb, Vb, & VIb or a
    Silicide from Silicides of IVb, Vb & Vib
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    W W
     3 to 40 12 to 74  4 to 35 15 to 70  5 to 30 18 to 65 2700 to
    Bound TiB 2 60 to 97 26 to 88 65 to 96 30 to 85 70 to 95 35 to 82 3000
    TiB2
    W W  3 to 40  9 to 68  4 to 35 12 to 63  5 to 30 14 to 58 2800 to
    Bound ZrB2 60 to 97 32 to 91 65 to 96 37 to 88 70 to 95 42 to 86 3000
    ZrB2
    W W  3 to 40  5 to 54  4 to 35  7 to 48  5 to 30  8 to 42 3000 to
    Bound HfB2 60 to 97 46 to 95 65 to 96 52 to 93 70 to 95 58 to 92 3400
    HfB2
    W W  3 to 40 10 to 72  4 to 35 14 to 67  5 to 30 17 to 62 2000 to
    Bound VB2 60 to 97 28 to 90 65 to 96 33 to 86 70 to 95 38 to 83 2500
    VB2
    W W  3 to 40  8 to 64  4 to 35 10 to 59  5 to 30 12 to 53 2900 to
    Bound NbB2 60 to 97 36 to 92 65 to 96 41 to 90 70 to 95 47 to 88 3400
    NbB2
    W W  3 to 40  5 to 51  4 to 35  6 to 45  5 to 30  7 to 40 3100 to
    Bound TaB2 60 to 97 49 to 95 65 to 96 55 to 94 70 to 95 60 to 93 3400
    TaB2
    W W  3 to 40  9 to 68  4 to 35 12 to 63  5 to 30 14 to 58 1800 to
    Bound Cr3B2 60 to 97 32 to 91 65 to 96 37 to 88 70 to 95 42 to 86 2200
    Cr3B2
    W W  3 to 40  7 to 62  4 to 35  9 to 57  5 to 30 12 to 52 2000 to
    Bound MoB2 60 to 97 38 to 93 65 to 96 43 to 91 70 to 95 48 to 88 2400
    MoB2
    W W  3 to 40  4 to 45  4 to 35  5 to 39  5 to 30  6 to 34 2700 to
    Bound WB 60 to 97 55 to 96 65 to 96 61 to 95 70 to 95 66 to 94 3000
    WB
    W W  3 to 40  3 to 44  4 to 35  5 to 38  5 to 30  6 to 33 2600 to
    Bound W2B 60 to 97 56 to 97 65 to 96 62 to 95 70 to 95 67 to 94 2900
    W2 B
    W W
     3 to 40 12 to 75  4 to 35 16 to 71  5 to 30 19 to 66 2000 to
    Bound Ti5Si3 60 to 97 25 to 88 65 to 96 29 to 84 70 to 95 34 to 81 2400
    Ti5Si3
    W W  3 to 40 10 to 70  4 to 35 13 to 65  5 to 30 16 to 60 2100 to
    Bound Zr6Si5 60 to 97 30 to 90 65 to 96 35 to 87 70 to 95 40 to 84 2500
    Zr6Si5
    W W  3 to 40  9 to 67  4 to 35 11 to 62  5 to 30 14 to 57 1800 to
    Bound NbSi2 60 to 97 33 to 91 65 to 96 38 to 89 70 to 95 43 to 86 2200
    NbSi2
    W W  3 to 40  7 to 60  4 to 35  9 to 55  5 to 30 11 to 49 2200 to
    Bound TaSi2 60 to 97 40 to 93 65 to 96 45 to 91 70 to 95 51 to 89 2600
    TaSi2
    W W  3 to 40  9 to 67  4 to 35 11 to 62  5 to 30 14 to 57 1800 to
    Bound MoSi2 60 to 97 31 to 91 65 to 96 38 to 89 70 to 95 43 to 86 2200
    MoSi2
    W W  3 to 40  6 to 58  4 to 35  8 to 53  5 to 30 10 to 47 1800 to
    Bound WSi2 60 to 97 42 to 94 65 to 96 47 to 92 70 to 95 43 to 90 2200
    WSi2
  • TABLE 45
    Re and W (Re + W) bound a carbide from carbides of IVb, Vb, &
    VIb or a nitride from nitrides of IVb & Vb. The range of Binder is
    from 1% Re + 99% W to 99% Re + 1% W.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + W Re 0.03 to 0.12 to 0.04 to 0.15 to 0.05 to 0.19 to 2900
    Bound 39.6 73 34.7 69 29.7 64 to
    TiC W 0.03 to 0.1 to 72 0.04 to 0.14 to 0.05 to 0.17 to 3300
    39.6 34.7 67 29.7 62
    TiC 60 to 97 26 to 89 65 to 96 30 to 86 70 to 95 35 to 83
    Re + W Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to 3000
    Bound 39.6 67 34.7 63 29.7 57 to
    ZrC W 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.13 to 3400
    39.6 66 34.7 61 29.7 55
    ZrC 60 to 97 32 to 92 65 to 96 37 to 89 70 to 95 42 to 87
    Re + W Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 3100
    Bound 39.6 52 34.7 47 29.7 41 to
    HfC W 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.07 to 3500
    39.6 50 34.7 45 29.7 39
    HfC 60 to 97 48 to 95 65 to 96 53 to 94 70 to 95 58 to 93
    Re + W Re 0.03 to 0.11 to 0.14 to 0.15 to 0.17 to 0.19 to 2700
    Bound 39.6 71 67 67.0 62 61.8 to
    VC W 0.03 to 0.1 to 69 0.13 to 0.06 to 0.15 to 0.07 to 3000
    39.6 65 46.3 60 40.8
    VC 60 to 97 28 to 90 33 to 87 32.8 to 70 to 95 38 to 84
    93.5
    Re + W Re 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.13 to 3200
    Bound 39.6 64 34.7 59 29.7 53 to
    NbC W 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 3500
    39.6 56 34.7 56 29.7 51
    NbC 60 to 97 36 to 93 65 to 96 41 to 91 70 to 95 47 to 88
    Re + W Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 3100
    Bound 39.6 49 34.7 43 29.7 38 to
    TaC W 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 3500
    39.6 47 34.7 41 29.7 36
    TaC 60 to 97 51 to 96 65 to 96 56 to 95 70 to 95 62 to 93
    Re + W Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.14 to 1700
    Bound 39.6 67 34.7 62 29.7 57 to
    Cr2C3 W 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.13 to 1900
    39.6 65 34.7 60 29.7 55
    Cr2C3 60 to 97 32 to 92 65 to 96 37 to 89 70 to 95 43 to 87
    Re + W Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 2400
    Bound 39.6 60 34.7 55 29.7 49 to
    Mo2C W 0.03 to 0.06 to 0.04 to 0.08 to 0.05 to 0.1 to 47 2600
    39.6 58 34.7 53 29.7
    Mo2C 60 to 97 39 to 94 65 to 96 45 to 92 70 to 95 50 to 90
    Re + W Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 2700
    Bound 39.6 47 34.7 42 29.7 36 to
    WC W 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 2900
    39.6 45 34.7 40 29.7 34
    WC 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 63 to 94
    Re + W Re 0.03 to 0.1 to 71 0.04 to 0.14 to 0.05 to 0.17 to 2900
    Bound 39.6 34.7 67 29.7 62 to
    TiN W 0.03 to 0.1 to 70 0.04 to 0.13 to 0.05 to 0.16 to 3200
    39.6 34.7 65 29.7 60
    TiN 60 to 97 28 to 90 65 to 96 32 to 87 70 to 95 38 to 84
    Re + W Re 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.13 to 2900
    Bound 39.6 65 34.7 60 29.7 55 to
    ZrN W 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.12 to 3200
    39.6 63 34.7 58 29.7 53
    ZrN 60 to 97 34 to 92 65 to 96 39 to 90 70 to 95 45 to 88
    Re + W Re 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.08 to 3100
    Bound 39.6 50 34.7 45 29.7 39 to
    HfN W 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 3400
    39.6 48 34.7 43 29.7 37
    HfN 60 to 97 50 to 96 65 to 96 55 to 95 70 to 95 61 to 93
    Re + W Re 0.03 to 0.1 to 69 0.04 to 0.13 to 0.05 to 0.16 to 2100
    Bound 39.6 34.7 65 29.7 59 to
    VN W 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.14 to 2300
    39.6 67 34.7 63 29.7 57
    VN 60 to 97 30 to 91 65 to 96 35 to 88 70 to 95 40 to 86
    Re + W Re 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.13 to 2300
    Bound 39.6 65 34.7 60 29.7 55 to
    NbN W 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.12 to 2500
    39.6 63 34.7 58 29.7 53
    NbN 60 to 97 35 to 92 65 to 96 39 to 90 70 to 95 45 to 88
    Re + W Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 2900
    Bound 39.6 49 34.7 44 29.7 38 to
    TaN W 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 3400
    39.6 47 34.7 42 29.7 36
    TaN 60 to 97 51 to 96 65 to 96 56 to 95 70 to 95 61 to 93
  • TABLE 46
    Re and W (Re + W) bound a boride from borides of IVb, Vb, &
    VIb or a silicide from silicides of IVb & Vb. The range of
    Binder is from 1% Re + 99% W to 99% Re + 1% W
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + W Re 0.03 to 0.13 to 0.04 to 0.16 to 0.05 to 0.2 to 2900
    Bound 39.6 75 34.7 71 29.7 66 to
    TiB2 W 0.03 to 0.12 to 0.04 to 0.15 to 0.05 to 0.18 to 3100
    39.6 73 34.7 69 29.7 64
    TiB2 60 to 97 24 to 88 65 to 96 29 to 85 70 to 95 33 to 82
    Re + W Re 0.03 to 0.1 to 69 0.04 to 0.13 to 0.05 to 0.16 to 2900
    Bound 39.6 34.7 64 29.7 59 to
    ZrB2 W 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.14 to 3100
    39.6 67 34.7 63 29.7 57
    ZrB2 60 to 97 30 to 91 65 to 96 35 to 88 70 to 95 40 to 86
    Re + W Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.09 to 3100
    Bound 39.6 54 34.7 50 29.7 44 to
    HfB2 W 0.03 to 0.05 to 0.04 to 0.07to 0.05 to 0.08to 3300
    39.6 53 34.7 48 29.7 42
    HfB2 60 to 97 44 to 95 65 to 96 50 to 93 70 to 95 55 to 92
    Re + W Re 0.03 to 0.11 to 0.14 to 0.15 to 0.17 to 0.18 to 2000
    Bound 39.6 73 67 68 62 63 to
    VB2 W 0.03 to 0.1 to 71 0.13 to 0.13 to 0.15 to 0.16 to 2200
    39.6 65 66 60 61
    VB2 60 to 97 27 to 90 33 to 87 31 to 70 to 95 36 to
    86 84
    Re + W Re 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.13 to 2900
    Bound 39.6 65 34.7 61 29.7 55 to
    NbB2 W 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.12 to 3100
    39.6 63 34.7 58 29.7 53
    NbB2 60 to 97 34 to 92 65 to 96 39 to 90 70 to 95 44 to 88
    Re + W Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 3100
    Bound 39.6 52 34.7 47 29.7 41 to
    TaB2 W 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.07 to 3300
    39.6 50 34.7 39 29.7 39
    TaB2 60 to 97 47 to 96 65 to 96 53 to 94 70 to 95 58 to 93
    Re + W Re 0.03 to 0.1 to 69 0.04 to 0.13 to 0.05 to 0.16 to 1900
    Bound 39.6 34.7 64 29.7 59 to
    Cr3B2 W 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.14 to 2100
    39.6 67 34.7 62 29.7 57
    Cr3B2 60 to 97 32 to 91 65 to 96 35 to 88 70 to 95 40 to 86
    Re + W Re 0.03 to 0.08 to 0.04 to 0.1 to 0.05 to 0.13 to 2000
    Bound 39.6 64 34.7 59 29.7 53 to
    MoB2 W 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 2200
    39.6 62 34.7 57 29.7 51
    MoB 2 60 to 97 36 to 93 65 to 96 41 to 91 70 to 95 46 to 88
    Re + W Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 2800
    Bound 39.6 46 34.7 41 29.7 36 to
    WB W 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 2900
    39.6 44 34.7 39 29.7 34
    WB 60 to 97 53 to 96 65 to 96 57 to 95 70 to 95 64 to 94
    Re + W Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 2700
    Bound 39.6 45 34.7 40 29.7 35 to
    W2B W 0.03 to 0.03 to 0.04 to 0.05 to 0.05 to 0.06 to 2900
    39.6 43 34.7 38 29.7 33
    W2B 60 to 97 54 to 97 65 to 96 60 to 95 70 to 95 65 to 94
    Re + W Re 0.03 to 0.13 to 0.04 to 0.17 to 0.05 to 0.21 to 2000
    Bound 39.6 76 34.7 72 29.7 67 to
    Ti5Si3 W 0.03 to 0.12 to 0.04 to 0.16 to 0.05 to 0.19 to 2200
    39.6 74 34.7 70 29.7 65
    Ti5Si3 60 to 97 24 to 88 65 to 96 28 to 84 70 to 95 32 to 81
    Re + W Re 0.03 to 0.11 to 0.04 to 0.14 to 0.05 to 0.17 to 2100
    Bound 39.6 71 34.7 67 29.7 61 to
    Zr6Si5 W 0.03 to 0.1 to 69 0.04 to 0.13 to 0.05 to 0.15 to 2400
    39.6 34.7 65 29.7 59
    Zr6Si5 60 to 97 28 to 90 65 to 96 33 to 87 70 to 95 38 to 84
    Re + W Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to 1900
    Bound 39.6 68 34.7 64 29.7 58 to
    NbSi2 W 0.03 to 0.09 to 0.04 to 0.11 to 0.05 to 0.14 to 2100
    39.6 66 34.7 62 29.7 56
    NbSi2 60 to 97 31 to 91 65 to 96 36 to 89 70 to 95 41 to 86
    Re + W Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.12 to 2300
    Bound 39.6 62 34.7 57 29.7 51 to
    TaSi2 W 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 2500
    39.6 60 34.7 54 29.7 49
    TaSi2 60 to 97 38 to 93 65 to 96 43 to 91 70 to 95 49 to 89
    Re + W Re 0.03 to 0.1 to 69 0.04 to 0.12 to 0.05 to 0.15 to 1900
    Bound 39.6 34.7 64 29.7 58 to
    MoSi2 W 0.03 to 0.09 to 0.04 to 0.11 to 0.05 to 0.14 to 2100
    39.6 67 34.7 62 29.7 56
    MoSi 2 60 to 97 31 to 91 65 to 96 36 to 89 70 to 95 41 to 86
    Re + W Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 1900
    Bound 39.6 60 34.7 54 29.7 49 to
    WSi2 W 0.03 to 0.06 to 0.04 to 0.08 to 0.05 to 0.1 to 2100
    39.6 58 34.7 52 29.7 47
    WSi 2 60 to 97 40 to 94 65 to 96 45 to 92 70 to 95 51 to 90
  • TABLE 47
    Re and Co (Re + Co) bound a carbide from carbides of IVb,
    Vb, & VIb or a nitride from nitrides of IVb & Vb. The range of
    Binder is from 1% Re + 99% Co to 99% Re + 1% Co.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + Co Re 0.03 to 0.12 to 0.04 to 0.17 to 0.05 to 0.2 to 64 1400
    Bound 39.6 74 34.7 69 29.7 to
    TiC Co 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 3200
    39.6 54 34.7 49 29.7 43
    TiC 60 to 97 26 to 95 65 to 96 30 to 93 70 to 95 35 to 91
    Re + Co Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to 1400
    Bound 39.6 68 34.7 63 29.7 57 to
    ZrC Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 3200
    39.6 47 34.7 42 29.7 37
    ZrC 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 42 to 93
    Re + Co Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 1400
    Bound 39.6 52 34.7 47 29.7 41 to
    HfC Co 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 0.04 to 3200
    39.6 32 34.7 27 29.7 23
    HfC 60 to 97 48 to 98 65 to 96 53 to 97 70 to 95 59 to 96
    Re + Co Re 0.03 to 0.11 to 0.14 to 0.15 to 0.17 to 0.19 to 1400
    Bound 39.6 71 67 67.0 62 62 to
    VC Co 0.03 to 0.05 to 0.13 to 0.06 to 0.15 to 0.07 to 2900
    39.6 51 65 46 60 41
    VC 60 to 97 28 to 95 33 to 87 33 to 94 70 to 95 38 to 92
    Re + Co Re 0.03 to 0.08 to 0.04 to 0.1 to 59 0.05 to 0.13 to 1400
    Bound 39.6 64 34.7 29.7 53 to
    NbC Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 3200
    39.6 43 34.7 38 29.7 33
    NbC 60 to 97 36 to 97 65 to 96 41 to 95 70 to 95 47 to 94
    Re + Co Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1400
    Bound 39.6 49 34.7 43 29.7 38 to
    TaC Co 0.03 to 0.02 to 0.04 to 0.024 to 0.05 to 0.03 to 3200
    39.6 29 34.7 25 29.7 21
    TaC 60 to 97 51 to 98 65 to 96 56 to 97 70 to 95 62 to 97
    Re + Co Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to 1400
    Bound 39.6 67 34.7 62 29.7 57 to
    Cr2C3 Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 1900
    39.6 47 34.7 41 29.7 36
    Cr2C3 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 43 to 93
    Re + Co Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 1400
    Bound 39.6 60 34.7 55 29.7 49 to
    Mo2C Co 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 2600
    39.6 39 34.7 34 29.7 29
    Mo2C 60 to 97 40 to 97 65 to 96 45 to 96 70 to 95 50 to 95
    Re + Co Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 1400
    Bound 39.6 47 34.7 42 29.7 36 to
    WC Co 0.03 to 0.017 to 0.04 to 0.023 to 0.05 to 0.028 to 2900
    39.6 27 34.7 23 29.7 20
    WC 60 to 97 53 to 96 65 to 96 58 to 95 70 to 95 63 to 94
    Re + Co Re 0.03 to 0.11 to 0.04 to 0.15 to 0.05 to 0.19 to 1400
    Bound 39.6 71 34.7 67 29.7 62 to
    TiN Co 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.07 to 3200
    39.6 52 34.7 46 29.7 41
    TiN 60 to 97 28 to 95 65 to 96 33 to 93 70 to 95 38 to 92
    Re + Co Re 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.14 to 1400
    Bound 39.6 65 34.7 60 29.7 55 to
    ZrN Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 3200
    39.6 44 34.7 39 29.7 34
    ZrN 60 to 97 34 to 96 65 to 96 39 to 95 70 to 95 45 to 94
    Re + Co Re 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.08 to 1400
    Bound 39.6 50 34.7 45 29.7 39 to
    HfN Co 0.03 to 0.019 to 0.04 to 0.026 to 0.05 to 0.032 to 3200
    39.6 30 34.7 26 29.7 22
    HfN 60 to 97 50 to 98 65 to 96 55 to 97 70 to 95 61 to 97
    Re + Co Re 0.03 to 0.1 to 70 0.04 to 0.14 to 0.05 to 0.17 to 1400
    Bound 39.6 34.7 65 29.7 60 to
    VN Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 2300
    39.6 49 34.7 44 29.7 39
    VN 60 to 97 30 to 96 65 to 96 35 to 94 70 to 95 40 to 93
    Re + Co Re 0.03 to 0.08 to 0.04 to 0.11 to 0.05 to 0.14 to 1400
    Bound 39.6 65 34.7 60 29.7 55 to
    NbN Co 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 2500
    39.6 45 34.7 39 29.7 34
    NbN 60 to 97 34 to 96 65 to 96 39 to 95 70 to 95 45 to 94
    Re + Co Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1400
    Bound 39.6 49 34.7 44 29.7 38 to
    TaN Co 0.03 to 0.02 to 0.04 to 0.025 to 0.05 to 0.03 to 3200
    39.6 29 34.7 25 29.7 21
    TaN 60 to 97 51 to 98 65 to 96 56 to 97 70 to 95 62 to 98
  • TABLE 48
    Re and Co (Re + Co) bound a boride from borides of IVb,
    Vb, & VIb or a silicide from silicides of IVb & Vb. The range of
    Binder is from 1% Re + 99% Co to 99% Re + 1% Co.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + Co Re 0.03 to 0.13 to 0.04 to 0.18 to 71 0.05 to 0.22 to 1400
    Bound 39.6 75 34.7 29.7 66 to
    TiB2 Co 0.03 to 0.05 to 0.04 to 0.07 to 51 0.05 to 0.08 to 3100
    39.6 56 34.7 29.7 45
    TiB2 60 to 97 24 to 34 65 to 96 29 to 92 70 to 95 34 to 90
    Re + Co Re 0.03 to 0.1 to 69 0.04 to 0.13 to 64 0.05 to 0.17 to 1400
    Bound 39.6 34.7 29.7 59 to
    ZrB2 Co 0.03 to 0.04 to 0.05 to 0.05 to 44 0.05 to 0.07 to 3100
    39.6 49 34.7 29.7 38
    ZrB2 60 to 97 30 to 96 65 to 96 35 to 94 70 to 95 40 to 93
    Re + Co Re 0.03 to 0.06 to 0.04 to 0.08 to 50 0.05 to 0.09 to 1400
    Bound 39.6 55 34.7 29.7 44 to
    HfB2 Co 0.03 to 0.2 to 34 0.04 to 0.03 to 30 0.05 to 0.04 to 3200
    39.6 34.7 29.7 25
    HfB2 60 to 97 45 to 98 65 to 96 50 o 97 70 to 95 56 to 96
    Re + Co Re 0.03 to 0.12 to 0.14 to 0.16 to 69 0.17 to 0.2 to 63 1400
    Bound 39.6 73 67 62 to
    VB2 Co 0.03 to 0.05 to 0.13 to 0.06 to 48 0.15 to 0.08 to 2200
    39.6 53 65 60 42
    VB2 60 to 97 27 to 95 33 to 87 31 to 93 70 to 95 36 to 91
    Re + Co Re 0.03 to 0.09 to 0.04 to 0.12 to 61 0.05 to 0.14 to 1400
    Bound 39.6 66 34.7 29.7 55 to
    NbB2 Co 0.03 to 0.04 to 0.04 to 0.05 to 40 0.05 to 0.06 to 3100
    39.6 45 34.7 29.7 34
    NbB2 60 to 97 34 to 96 65 to 96 39 to 95 70 to 95 45 to 94
    Re + Co Re 0.03 to 0.05 to 0.04 to 0.07 to 47 0.05 to 0.08 to 1400
    Bound 39.6 52 34.7 29.7 41 to
    TaB2 Co 0.03 to 0.02 to 0.04 to 0.03 to 27 0.05 to 0.035 to 3300
    39.6 32 34.7 29.7 23
    TaB2 60 to 97 48 to 98 65 to 96 53 to 97 70 to 95 58 to 96
    Re + Co Re 0.03 to 0.1 to 69 0.04 to 0.13 to 65 0.05 to 0.17 to 1400
    Bound 39.6 34.7 29.7 59 to
    Cr3B2 Co 0.03 to 0.04 to 0.04 to 0.05 to 44 0.05 to 0.07 to 2100
    39.6 49 34.7 29.7 38
    Cr3B2 60 to 97 30 to 96 65 to 96 35 to 93 70 to 95 41 to 93
    Re + Co Re 0.03 to 0.08 to 0.04 to 0.1 to 59 0.05 to 0.13 to 1400
    Bound 39.6 64 34.7 29.7 53 to
    MoB2 Co 0.03 to 0.03 to 0.04 to 0.04 to 38 0.05 to 0.05 to 2200
    39.6 43 34.7 29.7 33
    MoB2 60 to 97 36 to 97 65 to 96 41 to 95 70 to 95 46 to 94
    Re + Co Re 0.03 to 0.04 to 0.04 to 0.05 to 41 0.05 to 0.07 to 1400
    Bound 39.6 46 34.7 29.7 36 to
    WB Co 0.03 to 0.017 to 0.04 to 0.022 to 23 0.05 to 0.028 to 2900
    39.6 27 34.7 29.7 19
    WB 60 to 97 53 to 98 65 to 96 59 to 98 70 to 95 64 to 97
    Re + Co Re 0.03 to 0.04 to 0.04 to 0.05 to 40 0.05 to 0.06 to 1400
    Bound 39.6 45 34.7 29.7 35 to
    W2B Co 0.03 to 0.016 to 0.04 to 0.021 to 22 0.05 to 0.027 to 2900
    39.6 26 34.7 29.7 19
    W2B 60 to 97 55 to 98 65 to 96 60 to 98 70 to 95 65 to 97
    Re + Co Re 0.03 to 0.14 to 0.04 to 0.18 to 72 0.05 to 0.23 to 1400
    Bound 39.6 76 34.7 29.7 67 to
    Ti5Si3 Co 0.03 to 0.06 to 0.04 to 0.07 to 52 0.05 to 0.09 to 2200
    39.6 57 34.7 29.7 47
    Ti5Si3 60 to 97 24 to 94 65 to 96 28 to 92 70 to 95 32 to 90
    Re + Co Re 0.03 to 0.11 to 0.04 to 0.15 to 67 0.05 to 0.19 to 1400
    Bound 39.6 71 34.7 29.7 62 to
    Zr6Si5 Co 0.03 to 0.05 to 0.04 to 0.06 to 46 0.05 to 0.07 to 2400
    39.6 51 34.7 29.7 41
    ZrN 60 to 97 28 to 95 65 to 96 33 to 94 70 to 95 38 to 92
    Re + Co Re 0.03 to 0.1 to 69 0.04 to 0.13 to 64 0.05 to 0.16 to 1400
    Bound 39.6 34.7 29.7 58 to
    NbSi2 Co 0.03 to 0.04 to 0.04 to 0.05 to 43 0.05 to 0.06 to 2100
    39.6 48 34.7 29.7 37
    NbSi2 60 to 97 31 to 96 65 to 96 36 to 94 70 to 95 41 to 93
    Re + Co Re 0.03 to 0.07 to 0.04 to 0.1 to 57 0.05 to 0.12 to 1400
    Bound 39.6 62 34.7 29.7 51 to
    TaSi2 Co 0.03 to 0.03 to 0.04 to 0.04 to 36 0.05 to 0.05 to 2500
    39.6 41 34.7 29.7 31
    TaSi2 60 to 97 38 to 97 65 to 96 43 to 96 70 to 95 49 to 95
    Re + Co Re 0.03 to 0.1 to 69 0.04 to 0.13 to 64 0.05 to 0.16 to 1400
    Bound 39.6 34.7 29.7 59 to
    MoSi2 Co 0.03 to 0.04 to 0.04 to 0.05 to 43 0.05 to 0.07 to 2100
    39.6 48 34.7 29.7 38
    MoSi2 60 to 97 31 to 96 65 to 96 36 to 94 70 to 95 41 to 93
    Re + Co Re 0.03 to 0.07 to 0.04 to 0.09 to 55 0.05 to 0.11 to 1400
    Bound 39.6 60 34.7 29.7 49 to
    WSi2 Co 0.03 to 0.03 to 0.04 to 0.04 to 34 0.05 to 0.046 to 2100
    39.6 39 34.7 29.7 29
    WSi 2 60 to 97 40 to 97 65 to 96 45 to 96 70 to 95 51 to 95
  • TABLE 49
    Re and Mo (Re + Mo) bound a carbide from carbides of IVb,
    Vb, & VIb. The range of Binder is from 1% Re + 99% Mo to 99% Re + 1% Mo.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + Mo Re 0.03 to 0.12 to 0.04 to 0.16 to 0.05 to 0.2 to 2600
    Bound 39.6 74 34.7 69 29.7 64 to
    TiC Mo 0.03 to 0.06 to 0.04 to 0.07 to 0.05 to 0.09 to 3200
    39.6 57 34.7 52 29.7 46
    TiC 60 to 97 26 to 94 65 to 96 30 to 92 70 to 95 35 to 90
    Re + Mo Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to 2600
    Bound 39.6 68 34.7 63 29.7 57 to
    ZrC Mo 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 3200
    39.6 50 34.7 45 29.7 39
    ZrC 60 to 97 32 to 95 65 to 96 37 to 94 70 to 95 42 to 92
    Re + Mo Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 2600
    Bound 39.6 52 34.7 47 29.7 41 to
    HfC Mo 0.03 to 0.02 to 0.04 to 0.03 to 0.05 to 0.04 to 3200
    39.6 34 34.7 30 29.7 25
    HfC 60 to 97 48 to 98 65 to 96 53 to 97 70 to 95 59 to 96
    Re + Mo Re 0.03 to 0.11 to 0.14 to 67 0.15 to 0.17 to 0.18 to 2600
    Bound 39.6 71 67.0 62 62 to
    VC Mo 0.03 to 0.05 to 0.13 to 65 0.07 to 0.15 to 0.08 to 2900
    39.6 55 49 60 44
    VC 60 to 97 28 to 95 33 to 87 33 to 93 70 to 95 38 to 91
    Re + Mo Re 0.03 to 0.08 to 0.04 to 0.1 to 59 0.05 to 0.13 to 2600
    Bound 39.6 64 34.7 29.7 53 to
    NbC Mo 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 3200
    39.6 46 34.7 41 29.7 35
    NbC 60 to 97 36 to 96 65 to 96 41 to 95 70 to 95 47 to 94
    Re + Mo Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 2600
    Bound 39.6 49 34.7 43 29.7 38 to
    TaC Mo 0.03 to 0.02 to 0.04 to 0.028 to 0.05 to 0.03 to 3200
    39.6 31 34.7 27 29.7 22
    TaC 60 to 97 51 to 98 65 to 96 56 to 97 70 to 95 62 to 96
    Re + Mo Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to 1700
    Bound 39.6 67 34.7 62 29.7 57 to
    Cr2C3 Mo 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1900
    39.6 50 34.7 45 29.7 39
    Cr2C3 60 to 97 32 to 95 65 to 96 37 to 94 70 to 95 43 to 92
    Re + Mo Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 2500
    Bound 39.6 60 34.7 55 29.7 49 to
    Mo2C Mo 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 2600
    39.6 42 34.7 37 29.7 32
    Mo2C 60 to 97 40 to 97 65 to 96 45 to 96 70 to 95 50 to 95
    Re + Mo Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 2600
    Bound 39.6 47 34.7 42 29.7 36 to
    WC Mo 0.03 to 0.019 to 0.04 to 0.026 to 0.05 to 0.032 to 2900
    39.6 30 34.7 26 29.7 22
    WC 60 to 97 53 to 98 65 to 96 58 to 97 70 to 95 64 to 97
  • TABLE 50
    Re and Ni (Re + Ni) bound a carbide from carbides of IVb,
    Vb, & VIb. The range of Binder is from 1% Re + 99% Ni to 99% Re + 1% Ni.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + Ni Re 0.03 to 0.12 to 0.04 to 0.17 to 0.05 to 0.2 to 64 1400
    Bound 39.6 74 34.7 69 29.7 to
    TiC Ni 0.03 to 0.05 to 0.04 to 0.06 to 0.05 to 0.08 to 3200
    39.6 54 34.7 49 29.7 43
    TiC 60 to 97 26 to 95 65 to 96 30 to 93 70 to 95 35 to 91
    Re + Ni Re 0.03 to 0.09 to 0.04 to 0.13 to 0.05 to 0.16 to 1400
    Bound 39.6 68 34.7 63 29.7 57 to
    ZrC Ni 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 3200
    39.6 47 34.7 42 29.7 36
    ZrC 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 42 to 93
    Re + Ni Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.08 to 1400
    Bound 39.6 52 34.7 47 29.7 41 to
    HfC Co 0.03 to 0.02 to 0.04 to 0.027 to 0.05 to 0.034 to 3200
    39.6 31 34.7 27 29.7 23
    HfC 60 to 97 48 to 98 65 to 96 53 to 97 70 to 95 59 to 96
    Re + Ni Re 0.03 to 0.11 to 0.14 to 0.15 to 0.17 to 0.19 to 1400
    Bound 39.6 71 67 67.0 62 62 to
    VC Ni 0.03 to 0.04 to 0.13 to 0.06 to 0.15 to 0.07 to 2900
    39.6 51 65 46 60 40
    VC 60 to 97 28 to 95 33 to 87 33 to 94 70 to 95 38 to 92
    Re + Ni Re 0.03 to 0.08 to 0.04 to 0.1 to 59 0.05 to 0.13 to 1400
    Bound 39.6 64 34.7 29.7 53 to
    NbC Ni 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 3200
    39.6 43 34.7 37 29.7 32
    NbC 60 to 97 36 to 97 65 to 96 41 to 95 70 to 95 47 to 94
    Re + Ni Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1400
    Bound 39.6 49 34.7 43 29.7 38 to
    TaC Ni 0.03 to 0.018 to 0.04 to 0.024 to 0.05 to 0.03 to 3200
    39.6 29 34.7 25 29.7 21
    TaC 60 to 97 51 to 98 65 to 96 56 to 97 70 to 95 62 to 97
    Re 30 Ni Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.15 to 1400
    Bound 39.6 67 34.7 62 29.7 57 to
    Cr2C3 Ni 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 1900
    39.6 46 34.7 41 29.7 36
    Cr2C3 60 to 97 32 to 96 65 to 96 37 to 95 70 to 95 43 to 93
    Re + Ni Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 1400
    Bound 39.6 60 34.7 55 29.7 49 to
    Mo2C Ni 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 2600
    39.6 39 34.7 34 29.7 29
    Mo2C 60 to 97 40 to 97 65 to 96 45 to 96 70 to 95 50 to 95
    Re + Ni Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1400
    Bound 39.6 47 34.7 42 29.7 36 to
    WC Ni 0.03 to 0.017 to 0.04 to 0.022 to 0.05 to 0.028 to 2900
    39.6 27 34.7 23 29.7 19
    WC 60 to 97 53 to 98 65 to 96 58 to 98 70 to 95 64 to 97
  • TABLE 51
    Re and Cr (Re + Cr) bound a carbide from carbides of IVb,
    Vb, & VIb. The range of Binder is from 1% Re + 99% Cr to 99% Re + 1% Cr.
    Composition Composition Composition Estimated
    Range 1 Range 2 Range 3 Melting
    Volume % Weight % Volume % Weight % Volume % Weight % Point, ° C.
    Re + Cr Re 0.03 to 0.13 to 0.04 to 0.17 to 0.05 to 0.2 to 64 1800
    Bound 39.6 74 34.7 69 29.7 to
    TiC Cr 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.06 to 3200
    39.6 48 34.7 43 29.7 39
    TiC 60 to 97 26 to 96 65 to 96 30 to 94 70 to 95 36 to 93
    Re + Cr Re 0.03 to 0.1 to 68 0.04 to 0.13 to 0.05 to 0.16 to 1800
    Bound 39.6 34.7 63 29.7 57 to
    ZrC Cr 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 3200
    39.6 41 34.7 36 29.7 32
    ZrC 60 to 97 32 to 97 65 to 96 37 to 95 70 to 95 42 to 94
    Re + Cr Re 0.03 to 0.05 to 0.04 to 0.07 to 0.05 to 0.09 to 1800
    Bound 39.6 52 34.7 47 29.7 41 to
    HfC Cr 0.03 to 0.017 to 0.04 to 0.022 to 0.05 to 0.027 to 3200
    39.6 27 34.7 23 29.7 19
    HfC 60 to 97 48 to 98 65 to 96 53 to 98 70 to 95 59 to 97
    Re + Cr Re 0.03 to 0.11 to 0.14 to 0.15 to 0.17 to 0.19 to 1800
    Bound 39.6 71 67 67.0 62 62 to
    VC Cr 0.03 to 0.04 to 0.13 to 0.05 to 0.15 to 0.06 to 2900
    39.6 46 65 41 60 35
    VC 60 to 97 28 to 96 33 to 87 33 to 95 70 to 95 38 to 93
    Re + Cr Re 0.03 to 0.08 to 0.04 to 0.1 to 59 0.05 to 0.13 to 1800
    Bound 39.6 64 34.7 29.7 53 to
    NbC Cr 0.03 to 0.026 to 0.04 to 0.034 to 0.05 to 0.04 to 3200
    39.6 37 34.7 33 29.7 28
    NbC 60 to 97 36 to 97 65 to 96 41 to 96 70 to 95 47 to 95
    Re + Cr Re 0.03 to 0.04 to 0.04 to 0.06 to 0.05 to 0.07 to 1800
    Bound 39.6 49 34.7 43 29.7 38 to
    TaC Cr 0.03 to 0.015 to 0.04 to 0.019 to 0.05 to 0.024 to 3200
    39.6 25 34.7 21 29.7 17
    TaC 60 to 97 51 to 98 65 to 96 56 to 98 70 to 95 62 to 97
    Re + Cr Re 0.03 to 0.09 to 0.04 to 0.12 to 0.05 to 0.16 to 1800
    Bound 39.6 67 34.7 62 29.7 57 to
    Cr2C3 Cr 0.03 to 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 1900
    39.6 41 34.7 36 29.7 31
    Cr2 C 3 60 to 97 32 to 97 65 to 96 37 to 96 70 to 95 43 to 95
    Re + Cr Re 0.03 to 0.07 to 0.04 to 0.09 to 0.05 to 0.11 to 1800
    Bound 39.6 60 34.7 55 29.7 49 to
    Mo2C Cr 0.03 to 0.023 to 0.04 to 0.03 to 0.05 to 0.037 to 2600
    39.6 34 34.7 29 29.7 25
    Mo2C 60 to 97 40 to 98 65 to 96 45 to 97 70 to 95 50 to 96
    Re + Cr Re 0.03 to 0.04 to 0.04 to 0.05 to 0.05 to 0.07 to 1800
    Bound 39.6 47 34.7 42 29.7 36 to
    WC Cr 0.03 to 0.014 to 0.04 to 0.018 to 0.05 to 0.023 to 2900
    39.6 23 34.7 20 29.7 16
    WC 60 to 97 53 to 65 to 96 58 to 98 70 to 95 64 to
    98.6 97.6
  • The above compositions for hardmetals or cermets may be used for a variety of applications. For example, a material as described above may be used to form a wear part in a tool that cuts, grinds, or drills a target object by using the wear part to remove the material of the target object. Such a tool may include a support part made of a different material, such as a steel. The wear part is then engaged to the support part as an insert. The tool may be designed to include multiple inserts engaged to the support part. For example, some mining drills may include multiple button bits made of a hardmetal material. Examples of such a tool includes a drill, a cutter such as a knife, a saw, a grinder, and a drill. Alternatively, hardmetals descried here may be used to form the entire head of a tool as the wear part for cutting, drilling or other machining operations. The hardmetal particles may also be used to form abrasive grits for polishing or grinding various materials. In addition, such hardmetals may also be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.
  • More specifically, the hardmetals described here may be used to manufacture cutting tools for machining metals, alloys, composite materials, plastic materials, wooden materials, and others. The cutting tools may include indexable inserts for turning, milling, boring and drilling, drills, end mills, reamers, taps, hobs and milling cutters. Since the temperature of the cutting edge of such tools may be higher than 500° C. during machining, the hardmetal compositions for high-temperature operating conditions described above may have special advantages when used in such cutting tools, e.g., extended tool life and improved productivity by such tools by increasing the cutting speed.
  • The hardmetals described here may be used to manufacture tools for wire drawing, extrusion, forging and cold heading. Also as mold and Punch for powder process. In addition, such hardmetals may be used as wear-resistant material for rock drilling and mining.
  • The hardmetal materials described in this application may be fabricated in bulk forms or as coatings on metal surfaces. Coatings with such new hardmetal materials may be advantageously used to form a hard layer on a metal surface to achieve desired hardness that would otherwise be difficult to achieve with the underlying metal material. Bulk hardmetal materials based on the compositions in this application may be expensive and hence the use of coatings on less expensive metals with lower hardness may be used to reduce the costs of various components or parts with high hardness.
  • A number of powder processes for producing commercial hardmetals may be used to manufacture the hardmetals of this application. As an example, a binder alloy with Re higher than 85% in weight may be fabricated by the process of solid phase sintering to eliminate open porosities then HIP replaces liquid phase sintering.
  • FIG. 9 shows a flowchart for several fabrication methods for materials or structures from the above hardmetal compositions. As illustrated, alloy powders for the binders and the hard particle powders may be mixed with a milling liquid in a wet mixing process with or without a lubricant (e.g., wax). The fabrication flows on the left hand side of FIG. 9 are for fabricating hardmetals with lubricated wet mixing. The mixture is first dried by vacuum drying or spray drying process to produce lubricated grade powder. Next, the lubricated grade power is shaped into a bulky material via pill pressing, extruding, or cold isostatic press (CIP) and shaping. The CIP is a process to consolidate powder by isostatic pressure. The bulky material is then heated to remove the lubricant and is sintered in a presintering process. Next, the material may be processed via several different processes. For example, the material may be processed via a liquid phase sintering in vacuum or hydrogen and then further processed by a HIP process to form the final hardmetal parts. Alternatively, the material after the presintering may go through a solid phase sintering to eliminate open porosity and then a HIP process to form the final hardmetal parts.
  • When alloy powders for the binders and the hard particle powders are mixed without the lubricant, the unlubricated grade power after the drying process may be processed in two different ways to form the final hardmetal parts. The first way as illustrated simply uses hot pressing to complete the fabrication. The second way uses a thermal spray forming process to form the grade powder on a metal substrate in vacuum. Next, the metal substrate is removed to leave the structure by the thermal spray forming as a free-standing material as the final hardmetal part. In addition, the free-standing material may be further processed by a HIP process to reduce the porosities if needed.
  • In forming a hardmetal coating on a metal surface, a thermal spray process may be used under a vacuum condition to produce large parts coated with hardmetal materials. For example, surfaces of steel parts and tools may be coated to improve their hardness and thus performance. FIG. 10 shows an exemplary flow chart of a thermal spray process.
  • Various thermal spray processes are known for coating metal surfaces. For example, the ASM Handbook Vol. 7 (P408, 1998) describes the thermal spray as a family of particulate/droplet consolidation processes capable of forming metals, ceramics, intermetallics, composites, and polymers into coatings or freestanding structures. During the process, powder, wire, or rods can be injected into combustion or arc-heated jets, where they are heated, melted or softened, accelerated, and directed toward the surface, or substrate, being coated. On impact at the substrate, the particles or droplets rapidly solidify, cool, contract, and incrementally build up to form a deposit on a target surface. The thin “splats” may undergo high cooling rates, e.g., in excess of 106 K/s for metals.
  • A thermal spray process may use chemical (combustion) or electrical (plasma or arc) energy to heat feed materials injected into hot-gas jets to create a stream of molten droplets that are accelerated and directed toward the substrates being coated. Various thermal spray processes are shown in FIGS. 3 and 4 in ASM Handbook Vol. 7, pages 409-410.
  • Various details of thermal spray processes are described in “Spray Forming” by Lawley et al. and “Thermal Spray Forming of Materials” by Knight et al., which are published in ASM Handbook, Volume 7, Powder Metal Technologies and Application (1998), from pages 396 to 407, and pages 408 to 419, respectively.
  • Selected hardmetal compositions described here can maintain high material strength and hardness at high temperatures at or above 1500° C. For example, certain high-power engines operate at such high temperatures such as various jet and/or rocket engines used in various flying devices and vehicles. More specifically, jet and/or rocket nozzles, including non-erosive nozzle throats and low-erosive nozzle throats, in these and other engines may be partially or entirely made of the selected hardmetal materials described in this application.
  • For example, hardmetals based on one or more of (1) one or more carbides, (2) one or more nitrides, (3) one or more borides and (4) a combination of two or more of (1), (2) and (3) with a binder material which is either pure Re or a composite binder material with Re as one component. The melting points of various carbides, nitrides, and borides in this application are above 2400° C. Examples of suitable carbides for the present high-temperature hardmetal materials include TaC, HfC, NbC, ZrC, TiC, WC, VC, Al4C3, ThC2, Mo2C, SiC and B4C. Examples of suitable nitrides for the present high-temperature hardmetal materials include HfN, TaN, BN, ZrN, and TiN. Examples of suitable borides for the present high-temperature hardmetal materials include HfB2, ZrB2, TaB2, TiB2, NbB2, and WB. Two examples of the composite binder material with Re as one component are (1) W and Re and (2) Ta and Re.
  • While this specification contains many specifics, these should not be construed as limitations on the scope of an invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or a variation of a subcombination.
  • Only a few implementations and examples are disclosed. However, it is understood that variations and enhancements may be made.

Claims (24)

1. A material, comprising:
hard particles comprising at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al4C3, ThC2, MO2C, SiC and B4C; and
a binder matrix that binds the hard particles and comprises rhenium.
2. A material as in claim 1, wherein the hard particles are less than 75% of a total weight of the material and rhenium is greater than 25% of the total weight of the material.
3. A material as in claim 1, wherein the hard particles further comprise at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN.
4. A material as in claim 1, wherein the hard particles further comprise at least one boride selected from at least one of HfB2, ZrB2, TaB2, TiB2, NbB2, and WB.
5. A material as in claim 1, wherein the binder matrix further comprises W or Ta.
6. A material as in claim 2, wherein the binder matrix further comprises W or Ta.
7. A material as in claim 3, wherein the binder matrix further comprises W or Ta.
8. A material as in claim 4, wherein the binder matrix further comprises W or Ta.
9. A material, comprising:
hard particles comprising at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN; and
a binder matrix that binds the hard particles and comprises rhenium.
10. A material as in claim 9, wherein the hard particles are less than 75% of a total weight of the material and rhenium is greater than 25% of the total weight of the material.
11. A material as in claim 9, wherein the hard particles further comprise at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al4C3, ThC2, Mo2C, SiC and B4C.
12. A material as in claim 9, wherein the hard particles further comprise at least one boride selected from at least one of HfB2, ZrB2, TaB2, TiB2, NbB2, and WB.
13. A material as in claim 9, wherein the binder matrix further comprises W or Ta.
14. A material as in claim 10, wherein the binder matrix further comprises W or Ta.
15. A material as in claim 11, wherein the binder matrix further comprises W or Ta.
16. A material as in claim 12, wherein the binder matrix further comprises W or Ta.
17. A material, comprising:
hard particles comprising at least one boride selected from at least one of HfB2, ZrB2, TaB2, TiB2, NbB2, and WB; and
a binder matrix that binds the hard particles and comprises rhenium.
18. A material as in claim 17, wherein the hard particles are less than 75% of a total weight of the material and rhenium is greater than 25% of the total weight of the material.
19. A material as in claim 17, wherein the hard particles further comprise at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN.
20. A material as in claim 17, wherein the hard particles further comprise at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al4C3, ThC2, MO2C, SiC and B4C.
21. A material as in claim 17, wherein the binder matrix further comprises W or Ta.
22. A material as in claim 18, wherein the binder matrix further comprises W or Ta.
23. A material as in claim 19, wherein the binder matrix further comprises W or Ta.
24. A material as in claim 20, wherein the binder matrix further comprises W or Ta.
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BRPI0707371-2A BRPI0707371A2 (en) 2006-01-31 2007-01-31 high performance friction stir welding tools
US11/669,791 US7857188B2 (en) 2005-03-15 2007-01-31 High-performance friction stir welding tools
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US58459304P 2004-06-30 2004-06-30
US10/941,967 US7354548B2 (en) 2003-01-13 2004-09-14 Fabrication of hardmetals having binders with rhenium or Ni-based superalloy
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US20170191148A1 (en) * 2014-05-30 2017-07-06 A.L.M.T. Corp. Heat-resistant tungsten alloy, friction stir welding tool, and production method
US10465266B2 (en) * 2014-05-30 2019-11-05 A.L.M.T. Corp. Heat-resistant tungsten alloy, friction stir welding tool, and production method
CN104313444A (en) * 2014-09-30 2015-01-28 苏州博利迈新材料科技有限公司 Cobalt-coated titanium hard alloy material and preparation method thereof
US20190084888A1 (en) * 2017-09-21 2019-03-21 National Tsing Hua University Eutectic cermets
CN107641770A (en) * 2017-09-27 2018-01-30 济南大学 Hard alloy blade material and its manufacturing process
CN112828298A (en) * 2020-12-31 2021-05-25 中国人民解放军空军工程大学 Preparation method of high-temperature molybdenum alloy spherical powder
CN115369270A (en) * 2022-08-15 2022-11-22 金昌镍都矿山实业有限公司 Forming method of electroplating anode nickel ball

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