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Patent 2212197 Summary

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Claims and Abstract availability

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(12) Patent: (11) CA 2212197
(54) English Title: DOUBLE CEMENTED CARBIDE INSERTS
(54) French Title: MISES RAPPORTEES EN CARBURES DOUBLE CEMENTATION
Status: Deemed expired
Bibliographic Data
(51) International Patent Classification (IPC):
  • B24D 3/06 (2006.01)
  • C22C 1/05 (2006.01)
  • C22C 32/00 (2006.01)
  • C23C 30/00 (2006.01)
(72) Inventors :
  • FANG, ZHIGANG (United States of America)
  • SUE, J. ALBERT (United States of America)
(73) Owners :
  • SMITH INTERNATIONAL, INC. (United States of America)
(71) Applicants :
  • SMITH INTERNATIONAL, INC. (United States of America)
(74) Agent: OYEN WIGGS GREEN & MUTALA LLP
(74) Associate agent:
(45) Issued: 2000-10-17
(22) Filed Date: 1997-08-01
(41) Open to Public Inspection: 1998-02-01
Examination requested: 1997-08-01
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
60/023,656 United States of America 1996-08-01
60/041,111 United States of America 1997-03-20

Abstracts

English Abstract





Double cemented carbide composites comprises a plurality of first regions and a second
ductile phase that separate the first regions from each other. Each first region comprises a
composite of grains and a first ductile phase bonding the grains. The grain are selected from
the group of carbides consisting of W, Ti, Mo, Nb, V, Hf, Ta. and Cr carbides. The fist ductile
phase is selected from the group consisting of Co, Ni, Fe, alloys thereof, and alloys with
materials selected from the group consisting of C, B, Cr, Si, and Mn. A preferred first region
comprises tungsten carbide grains that are cemented with a cobalt first binder phase and which
are in the form of substantially spherical pellets. The second ductile phase is selected from the
group consisting of Co, Ni, Fe, W, Mo, Ti, Ta, V, Nb, alloys thereof, and alloys with materials
selected from the group consisting of C, B, Cr, and Mn. A preferred second ductile phase is
cobalt. Additionally, additives such as those selected from the group consisting of carbides,
nitrides, and borides can be added to the second ductile phase to provite improved properties of
wear resistance. The composites are prepared by combining hard phase particles formed from
the grains and first ductile phase, with the second ductile phase material under conditions of
pressure and heat, and have improved properties of fracture toughness and equal or better wear
resistance when compared to conventional cemented tungsten carbide materials.





French Abstract

Cette invention concerne des composites de carbures à double cémentation qui comprennent une pluralité de premières zones et une seconde phase ductile séparant lesdites premières zones les unes des autres. Chacune des premières zones se compose de grains composites et d'une première phase ductile assurant le liaisonnement des grains. Les grains sont choisis dans le groupe des carbures de W, Ti, Mo, Nb, V, Hf, Ta et Cr. La première phase ductile est choisie dans le groupe Co, Ni, Fe, alliages de Co, Ni, Fe, et métaux d'alliage C, B, Cr, Si et Mn. Une première zone privilégiée se compose de grains de carbure de tungstène cémentés par une première phase liante au cobalt et se présentant sous forme de granules essentiellement sphériques. La deuxième phase ductile est choisie dans le groupe Co, Ni, Fe, W, Mo, Ti, Ta, V, Nb et les alliages avec les métaux du groupe C, B, Cr et Mn. Le cobalt est privilégié comme deuxième phase ductile. De plus, des additifs tels que ceux choisis dans le groupe des carbures, nitrures et borures peuvent être ajoutés à la deuxième phase ductile pour obtenir une meilleure résistance à l'usure. Les composites sont élaborés en combinant des particules de métaux durs et la première phase ductile avec la deuxième phase ductile sous pression et chaleur, pour une ténacité supérieure et une résistance à l'usure au moins égale à celle des carbures de tungstène cémentés classiques.

Claims

Note: Claims are shown in the official language in which they were submitted.



WHAT IS CLAIMED IS:
1. A composite cermet material comprising:
a plurality of first regions, each region comprising a composite of grains and a first ductile
phase bonding the grains, wherein the grains are selected from the group of carbides consisting
of W, Ti, Mo, Nb, V, Hf, Ta, and Cr carbides, wherein the first ductile phase is selected from the
group consisting of Co, Ni, Fe, alloys thereof, and alloys with materials selected from the group
consisting of C, B, Cr, Si and Mn;
a second ductile phase separating the first regions from each other, the second ductile
phase being selected from the group consisting of Co, Ni, W, Mo, Ti, Ta, V, Nb, alloys thereof,
and alloys with materials selected from the group consisting of C, B, Cr, and Mn.
2. The composite material as recited in claim 1 comprising in the range of from about
40 to 95 percent by volume first regions, and less than about 60 percent by volume second
ductile phase based on the total volume of the composite.
3. The composite material as recited in claim 2 comprising in the range of from about
60 to 80 percent by volume first regions and in the range of from about 20 to 40 percent by
volume second ductile phase based on the total volume of the composite.
4. The composite material as recited in claim 1 having a Kie fracture toughness of
greater than 20 ksi~in-2, and a wear number of at least 1.5(1,000 rev/cm3).
5. An insert for use in roller cone and percussion drill bits formed from the composite
material of claim 1.
6. A polycrystalline diamond shear cutter substrate formed from the composite
material of claim 1 and layer of polyerystalline diamond on a face of the shear cutter substrate.
7. The composite material as recited in claim 1 wherein the second ductile phase
further comprises an additive selected from the group consisting of carbides, nitrides, borides,
and mixtures thereof.
8. The composite material as recited in claim 7 wherein the additive is selected from
the group consisting of WC, VC, NBC, TIB2, TIC, MoC, Cr3-C7, polycrystalline diamond, and
cBN.


-18-







9. The composite material as recited in claim 7 wherein the additive has an average
particle size of less than about 20 micrometers.

10. The composite material as recited in claim 7 comprising less than about 30 percent
by volume of the additive based on the total volume of the second ductile phase.
11. The composite material as recited in claim 1 wherein the first regions comprise
tungsten carbide grains a cobalt first ductile phase, and wherein the second ductile phase is
cobalt.

12. The composite material as recited in claim 1 wherein the first regions comprise
spherical pellets embedded in the second phase.

13. The composite material as recited in claim 1 wherein in the event that the second
ductile binder is an alloyed steel, the steel comprises less than about 0.8 percent by weight
carbon and has a total alloy content of less than five percent by weight based on the total weight
of the second ductile binder.
14. The composite material as recited in claim 13 having a Kie fracture toughness of
greater than 20 ksi.in-2, and a wear number of at least 1.5 (1,000 rev/cm3).

15. A double cemented carbide composite that is prepared by combining:
hard phase particle comprising a carbide compound and a first binder material, wherein
the carbide compound is selected from the group consisting W, Ti, Mo, Nb, V, Hf, Ta and Cr
carbides and the first binder material is selected from the group consisting of Co, Ni, Fe, alloys
thereof, and alloys with materials selected from the group consisting of C, B, Cr, Si, and Mn,
Wherein the hard phase particles have an average particle size of less than about 500
micrometers; with
a ductile second binder material separating the hard phase particles from each other, the
second ductile material being selected from the group consisting of Co, Fe, Ni, W, Mo, Ti, Ta,
V, Nb, alloys thereof, and alloys with materials selected from the group consisting of C, B, Cr,
and Mn, and sintering the composite at a sufficient temperature for melting the second binder
material;
wherein the composite has a kic fracture toughness of greater than 20 ksi-in-2, and a wear
number of at least 1.5 (1,000 rev/cm3).

-19-






16. The double cemented carbide composite as recited in claim 15 wherein the hard
phase particles are substantially spherical.

17. The double cemented carbide composite as recited in claim 15 comprising in the
range of from about 40 to 95 percent by volume hard phase particles and less than about 60
percent by volume of the ductile second binder material based on the total volume of the
composite.
18. The double cemented carbide composite as recited in claim 15 wherein the ductile
second binder material further comprises an additive ingredient selected from the group
consisting of carbides, nitrides, borides, and mixtures thereof.

19. The double cemented carbide composite as recited in claim 18 wherein the additive
ingredient is selected from the group consisting of WC, VC, NbC, TiB2, TiC, MoC, Cr3C7,
polycrystalline diamond, and cBN.

20. The double cemented carbide composite as recited in claim 19 comprising less than
about 30 percent by volume of the additive ingredient based on the total volume of the ductile
second binder material.

21. The double cemented carbide composite as recited in claim 15 wherein in the event
that the second ductile binder material comprises an alloyed steel it comprises less than 0.8
percent by weight carbon and has a total alloy content of less than five percent by weight based
on the total weight of the second ductile binder material.

22. A double cemented carbide composite comprising:
has particle of tungsten carbide cemented with a first cobalt binder, and
a second cobalt binder surrounding the hard particles.

23. The double cemented carbide composite as recited in claim 22 wherein the hard
particles are substantially spherical.

24. The double cemented carbide composite as recited in claim 22 comprising hardparticles in the range of from 60 to 80 percent by volume of the total composite.

-20-






25. The double cemented carbide composite as recited in claim 22 wherein the hard
particles have an average particle size of less than about 500 micrometers.

26. The double cemented carbide composite as recited in claim 22 wherein the
composite has a Kie fracture toughness of greater than 20 ksi~in2, and a wear number of at least
1.5 (1,000 rev/cm3).

27. The double cemented carbide composite as recited in claim 22 wherein the second
cobalt binder further comprises additives selected from the group consisting of carbides, nitrides,
borides, and mixtures thereof.

28. The double cemented carbide composite as recited in claim 28 wherein the additive
is selected from the group consisting of WC, VC, NbC, TiB2, TiC, MoC, Cr3C7 polycrystalline
diamond, and cBN.

29. A double cemented carbide composite comprising;
hard particles of tungsten carbide cemented with a first cobalt binder, and
a second binder surrounding the hard particles formed from a material having a coefficient
of thermal expansion less than about 8 µm/m-K.

30. A roller cone drill bit comprising:
a body having a number of legs that extend therefrom;
cutting cones rotatably disposed on an end of each leg;
a plurality of cutting inserts disposed in the cutting cones, wherein at least a portion of the
cutting inserts are formed from a double cemented carbide composite comprising;
a plurality of first regions, each region comprising a composite of grains and a first
ductile phase bonding the grains, wherein the grains are selected from the group of
carbides consisting of W, Ti, Mo, Nb, V, Hf, Ta, and Cr carbides, wherein first ductile
phase is selected from the group consisting of Co, Ni, Fe, alloys thereof, and alloys with
materials selected from the group consisting of C, B, Cr, Si, and Mn; and
a second ductile phase separating the first regions from each other, the second
ductile phase being selected from the group consisting of Co, Ni, Fe, W, Mo, Ti, Ta, V,
Nb, alloys thereof, and alloys with materials selected from the group consisting of C, B,
Cr, and Mn.

-21-







31. The roller cone drill bit as recited in claim 31 wherein the event that the second
ductile phase comprises an alloyed steel it comprises less than 0.8 percent by weight carbon and
has a total alloy content of less than five percent by weight based on the total weight of the
second ductile phase.

32. The roller cone drill bit as recited in claim 31 wherein the double cemented carbide
composite comprises in the range of from about 40 to 95 percent by volume first regions, and
less than about 60 percent by volume second ductile phase based on the total volume of the
composite.

33. The roller cone drill bit as recited in claim 31 wherein the double cemented carbide
composite comprises in the range of from about 60 to 80 percent by volume first regions and in
the range of from about 20 to 40 percent by volume second ductile phase based on the total
volume of the composite.

34. The roller cone drill bit as recited in claim 31 wherein the double cemented carbide
composite has a K~~ fracture toughness of greater than 20 ksi*in-2, and a wear number of at least
1.5 (1,000 rev/cm3).

35. The roller cone drill bit as recited in claim 31 wherein the second ductile phase
further comprises an additive selected from the group consisting of carbides, nitrides, borides,
and mixtures thereof.

36. The roller cone drill bit as recited in claim 36 wherein the additive is selected from
the group consisting of WC, VC, NbC, TiB2, TiC, MoC, Cr3C7, polycrystalline diamond, and
cBN.

37. The roller cone drill bit as recited in claim 31 wherein the first regions comprise
substantially spherical pellets of cemented tungsten carbide.

38. The roller cone drill bit as recited in claim 31 wherein the first regions comprise
tungsten carbide grains and a cobalt first ductile phase, and wherein the second ductile phase is
cobalt.




-22-



39. A percussion drill bit comprising:
a body having a head with a surface adapted to engage a subterranean formation during
drilling;
a plurality of inserts disposed in head surface, wherein the inserts are formed from a
double cemented carbide composite comprising:
a plurality of first regions, each region comprising a composite of grain and a first
ductile phase bonding the grains, wherein the grains are selected from the group of
carbides consisting of W, Ti, Mo, Nb, V, Hf, Ta, and Cr carbides, wherein the first ductile
phase is selected from the group consisting of Co, Ni, Fe, alloys thereof, and alloys with
materials selected from the group consisting of C, B, Cr, Si, and Mn; and
a second ductile phase separating the first regions from each other, the second
ductile phase being selected from the group consisting of Co, Ni, Fe, W, Mo, Ti, Ta, V,
Nb, alloys thereof, and alloys with materials selected from the group consisting of C, B,
Cr, and Mn.
40. The percussion drill bit recited in claim 40 wherein the first regions comprise
substantially spherical pellets of cemented tungsten carbide.
41. A drag drill bit comprising:
a body having a head and having a number of blades extending away from a head surface,
the blades being adapted to engage a subterranean formation during drilling;
a plurality of shear cutters disposed in the blades to contact the subterranean formation
during drilling, each shear cutter comprising a substrate and a layer of cutting material disposed
thereon, the substrate being formed from a double cemented carbide composite comprising:
a plurality of first regions, each region comprising a composite of grains and a first
ductile phase bonding the grains, wherein the grains are selected from the group of
carbides consisting of W, Ti, Mo, Nb, V, Hf, Ta and Cr carbides, wherein the first ductile
phase is selected from the group consisting of Co, Ni, Fe, alloys thereof, and alloys with
materials selected from the group consisting of C, B, Cr, Si, and Mn; and
a second ductile phase separating the first regions from each other, the second
ductile phase being selected from the group consisting of Co, Ni, Fe, W, Mo, Ti, Ta, V,
Nb, alloys thereof, and alloys with materials selected from the group consisting of C, B,
Cr, and Mn.



-23-





42. The percussion drill bit recited in claim 40 wherein the first regions comprise
substantially spherical pellets of cemented tungsten carbide.

43. A method for forming a double cemented carbide composite comprising the steps
of:
combining:
a plurality of hard particles, each comprising a composite of grains and a firstductile binder bonding the grains, wherein the grains are selected from the group of
carbides consisting of W, Ti, Mo, Nb, V, Hf, Ta, and Cr carbides, wherein the first ductile
binder is selected from the group consisting of Co, Ni, Fe, alloys thereof, and alloys with
materials selected from the group consisting of C, B, Cr, Si, and Mn; with
a second ductile binder material selected from the group consisting of Co, Ni, Fe,
W, Mo, Ti, Ta, V, Nb, alloys thereof, and alloys with materials selected from the group
consisting of C, B, Cr, and Mn to form a mixture, wherein in the event that the second
ductile binder material is alloyed steel it comprises less than 0.8 percent by weight carbon
and has a total alloy content of less than five percent by weight based on the total weight
of the second ductile binder material; and
consolidating the mixture at an elevated temperature for sufficient time to form a shaped
part.

44. The method as recited in claim 42 wherein the step of consolidating is done by hot
isostatic pressing process.

45. The method as recited in claim 42 wherein the step of consolidating is done by
rapid omnidirectional compaction process.

46. The method as recited in claim 42 wherein the hard particles comprise grains of
tungsten carbide bonded with a cobalt binder, and the second ductile binder is cobalt.

47. The method as recited in claim 42 wherein the hard particles comprise substantially
spherical pellets of cemented tungsten carbide.




-24-



48. A method for forming a double cemented carbide composite comprising the steps
of:
combining:
a plurality of hard particles each comprising carbide grains and a first ductilebinder bonded to the grains; with
a second ductile binder selected from the consisting of metals and metal
alloys to form a mixture;
pressing the mixture to form a shaped part;
placing the shaped part into a high-temperature ceramic container comprising glass
powder disposed therein;
heating the ceramic container to consolidation temperature above a liquefaction
temperature of the glass powder, and
isostatically pressing the ceramic container within a close die a produce a double
cemented carbide composite part.

49. The method as recited in claim 49 wherein the hart particles grains of
tungsten carbide bonded with a cobalt binder, and the second ductile binder is cobalt.
50. The method as recited in claim 49 wherein the hard particle comprise substantially
spherical pellets of cemented tungsten carbide.

- 25 -





Description

Note: Descriptions are shown in the official language in which they were submitted.


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DOUBLE CEMENrED CARBIDE COM~ O~

FIE:LD O~ ~E I~E~l~ON
1;v~lre~ to~ t~l.~4.t~ -carbidem ~ and~- t~-l~ofma~ingthe
same and, more particularly ~is iu~ ,tio~ relatos to double C~---P ~~t~ carbide c~ s that
have improved ~.J~ S of t~J~"t~- -t si without ~ - ing wcar ~ h~ ~ -re whcn CG~I ~p<~,d to
CC~ c~ --o--t~l h~ - CL~

~ACKGROU~D O~ 'rHE INVENnON
~ t~ 4~lc~bi~: suchA~WC-Coiswcllknownforits.~ .u~ s
of 1~.~, 1O-~J--- s~ rear ~ maldng it a populal Tn5~t~Aql of choice for u~e ~n s~ch
;At ~,~ g and drilling Wtl~: its J.~ ~o~os an~ highly desired.
15 ~. c~ of i~s desired ~D}~3, c~m~ed ~ . car~ide has been ~he ~lf~ t ' llsed
as cutt~ng tools for 'L~ d facing, wear inse~, and a~ng inse~ts in rota~y cone rock
bi~s, and sl~kct-at~ bodic:s for dIag bit shear cutte~s. The ~--P~ t~lu~ ie~ g~ t~ h
c ~ t~ n~en carbide and o~her c~nn~t~ iolt~ ~he unique c~mhi--~io-- of }~.c~
t~ ..C~ ~nd wear ~i~nf~ make these lnpt~ more ~ haD ei~her n~e~ or
20 ceramics alone.
Forconv- ~t;~ AI c~~....t" ~ .t~l~b;dr,fi~ctule to~ 'CiS irl~ve~sely~ u~u.tional~o hardness. and w~ar ~ rC iS l ~OPO~UO~I to hahl~.~. Al~oug}i ~he LWL~ tC~ ... cc
of C-~r~t ~t~ 1n~ c~ide has been soll.- .~t i~.,p,~._d over ~e years, it is still a I tinf~
factor ~n ~ Ah~g;n~ ;O~ such as hi~ p.~h ~ lling, whe~ c~ ,
~ t~ ca~bide i~serts often cxhibit gross brittlc li~.lu.~ that leads to cdt~;~hic fiilure.
Traditional metallur~cal m~hn~lc for erlhA-~ ing E;L~ tuu~ , such as ~ain size
r~,rlr~ , cob~lt contellt op~ n-~, and ,~ lh- ~,ing agents, have been ~ A ,I;-ily
ek~ d ~lvith respectto con~ tir~ c~ carbidc. The ~ r~ vpe~lies
of co.~ ial grade c~ .t~ carbide can be varied within a parricular envelope by
adjusting cobal~ meral cotltenl and E~rain sizes. For ~AA ~ IC~ the Rockwell A h ~ s~ of
~ ," ~~t.~ h~ carbide can be var~ed f~om about 85 to 94, ant the Lacl~ i to~-~hn~ss can be
vaIied fiom about 8 to l9 ksi-in~2. ArF~ Ationc of c~ t~ .. carbide are linuted to ~his
envelopo.
Another cl~;s of mAt~ for cutting and wear ~rp?ir~tinrl~ is tool steel. In E~ene~l, the
3~ wear ~ e of steels. inclùding tool steel. is much lower ~ ha~ of cP ~ t~ n~cten
carbide. U.S. Patcnt No. ~ '~90,507 tescribes a material that is fo~ned by i~ u~ti~ a certain
pc.~ ,tage of c~ ,r.'~ d t~ cter~ carl~ide granules into a malrix of tool s~eel binder to in~lc;~ie




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the wear reCisp~ of the ~ool 5teel. Such tool s~el/c~ t~tl~G~ carbide c~
materisls ~clang to the r~t~l ~ of metal m~ t U~ 57 when the bnttlo phase, i.e.,
~_,"..,t~t ~ cs~ide ~ j5 ~e n~nori~ ph~.
A problem Icnown to cxist with tool steeVc - - ' t...~ t~.~ carbide c~ , is that
iro~ (Fe) present in the tool steel biTlder tend~ to ~act wi~ the ~....,.,,1 t ~ carbide t~
fo~m Fe3C, ~hich can be ~~ h:,,,.,t~l to dle ductility and lu.~ c of thc c~ . For this
reason, such tool stee~ t~dt~ t;t~r~ carbite co~ t~ not desired for use in~ ~L~ S~ as tbose ~ d abo~e, where ~.u~ is nK~od. ~A~ ,11y~
the limited ductility of ~he tool steel that is uset to fonn the ~ tP~ car~ide
~v~ also acts to limit thc ove~ o~ r - ~ ofthe cY~ ;~, ~eby ~E, its use.
~t is, lh~rer,.. " .1.~ Ie tha~ a ~ "~ t~ ~ ca~ide ~ lu~d that
has improved l,~ lies of fiacb~e ~v~ t ~ when ~ r ~ ,r~ ~0 COIIV~ l~t ~ cf.r~ ~~t~ d
~ ,n çarbide m~t~ C It is dc~ tle Tlu~ such r- ~-- .~t~ carbide c~ ha~ve
such i~ v._~l fi~e t~U~h~ firi~g we~ ." i.c.... ha~ing cqu;~l o~ bettnr
wear~ thatûfc~ c~ ncarbide ~ iPIC- Itigdesi~dtha~
such ~ u~,~h ~ G~oide c ~ c;1 ~ t~ for use in such P~ppli~ e as rolle~ cone
bits, p_r~ ;on or 1~ r bits and clIag bits, and other ~ppl;~t;~.C such as min~ng ant
20 cor.;~ ion ~ooIs whe~ ~,.opc~u-s of i..,~.v~ _t fiacture t~ is de~e~

~UM~RY OF THE lNVENTION
Dwble ~ bide c- ~ of ~is ~vLlLo~ c- ~l" ;~ a plu~ality ûf fir5t re~ions
and a second duc~ile phase that sc~ ~ the fin;t regions fi~m each other. Each fiIst ~on
~5 comprises a cor-~cit~ of ~ and a fi~st ductilc phase ~ di~ he ~rains. lhe g~ins are
selçct~ fiom the group of c~lJ.~S cr~n~ of W, Ti, Mo, 1~, V, ~If~ Ta, and Cr . &bid ~ ~
llle first ductile phase is s~ t~ ~1 fiom the group co~ of Co, Ni, Fe, a11Oys ~ereo~, and
alloys with ~ ~. Is ~ t ~ fi~m the g~oup cor~ of C, B, Cr, Si ant Mn. A p~ l fi~5t
reg~on c 7 t~ t ~ carbide ~ains that are e ~ with a cobalt fi~n binder phase nle
30 seco~d ducti~c phase is ~1~r~ ~ ~om the ~roup CV~ of Co~ Ni, Fe, W, Mo, r,, Ta, V, N~
alloys t~f; and alloys with nl~e~lc ~lr~ d h~m the ~oup c~ g of C~ B. Cr, and Mrl.
A p,.~.lcd second ducule phase is co~alL Addi~ionally, additiYes such as ~ho~ ret~ ~1 fiom
~he additiYe sel~rcted fi oIn the ~oup con~ of c~ s, nir~ c,and bondc~ can be added
to the scond ducdle phase to pn~de imp~ved p~o~~ ,5 of wear .~
3 5 Double c~ t~ t ~arbidc cG~ ;, of this invention are ~Ic~&~d by com~ining hard
phase panicles (e.~., WC-Co) formed fi~m ~he ~ns and fi~st ductile pl~ase, with The _econd
dllc~ile phase ~P~ der conditi~n~ of plc~c and heat. llle co...~.os;-~ .o.,.~";~s in the




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mnge offnDm about40to 95 percent by voluunc f~ntrer~ and lessth~n ~bout60 percentby
volurne secont ductiie phase based on thetotal volume ofthe co~.rnq;-e and more ~.ef~.a~ly
S ~v~p~i~ 3 in the mnge offhDm about60 to gO percent by volu me f~s¢r~gions and h thc ran~e
offio m about20~o 40 percent by volume secont ductile phase based on ~he tot~l volume of the
~o~ Sil~. C~ "ho~ t~ c~~ ..;c;.~ an add~ve in the secont ducdle binder
~ lessthan about40 pe~cent by volu me ofthe additive based on the total volulne of~hc
second tuct~c b~nder.
Double ~ d c ~ ide c~ it - of ~s i~ Lon have i~ U~_t ~ en~es of
fi~u~Luet~g~h.~ 4hen conn ~ dto uO~ t~d tungsten ca~bide ~ ale, without
~ e wear ~ , i e., ha~ing equ~ orbK~er wearre~sbance dhan ~h~tofconv~
c~ r~u,.c~ carbitc~otL~. ~ mabing t~e ~ 4ell ~ tEt forsuch ~p~ s
nD~ercone biL~ or~ bi~,drag bit~ an~ o~ber~r~ nn~such e mining ~nd
cnr.~ tool5 where ~o~e.~cs of ~ c~ tuuc t~n~ .f~s is desinod. For ~ . 'e,
doublc Cf ~ r~ J carbide c~ , of this ;.~ un have a R~ r ~ tou~hn~ss of g~eater
~han 20 Icsi-i~Z, and a wear number of at least 1.5 (1,000 rev/cm3).

DESCRlPl~ON OF 1~ DRAW~GS
'Ihese an~i o~ feao~es and ~tag~s of the pre~ent invenuon will be~ r appreci~tetas the sE~ne ~ -~ ~f S be~rer u~.d~ ~r~ Qth l~fL.~n~ e s~ rio~, claims and dra~ ;,.
~vherein:
FIG. 1 is a s~ "~t~ h~t~ .v~ph of aportion of COllV~ ;nr~ C.. ~t
~alL:d.,
F~G. ~ is a ~ t~ti-~ of the r~lRt;~ Chir ~t~ the p~ .s of
t~ughn~es,hL~ 3~ and wearlw;~ c fora conv~-.tir~ c ~, ~ dt~ carbide~,.at~.i31
hav~ng the mi..~u.~ ofFIG.l;
FIG.3 is a g~ h'~A~ t~1;nn of~he ~ ;0..-1.;r ~ ~L_~ ~he ~rvF~.lies offRsctlre
~J.~ and wear.~ fora con~ iv~P~IC~ t ~ n~Pn carbide m~ren~l of ~IG. I:
30FIG. 4 is a ~h~ ic photo-~;--vE~h of a por~on of a do~ble .~ .ttd carbide
cn~ s;tP ~e~ l acco~ gto ~ in~irles of~si~vention;
FIG.5 is a ~ h;~ ;oi~ofthe rel~in~hip b.h ~ hc prPpo.lies offracblre
tou~hn~ss and wear l~ Qr~r~ for both co~v~rio..~l cer- ~t~ t~ t~n c ~ ide and double
ce.-- ~.n d carbide CO~ vSitL5 of~invention;
FIG.6is a ~ ~ ~de ~iew ofa doublet~ ~e--carbide co........................ j~s;-~in ~rt;
F~G. 7 is a p~ ~yc~ri~ side ~iew of a ~oller cone c~ill bi~ ,p.;iing a .. ~.IL~. of~he
insens ofPIG.6;




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FIG. 8 is ~ side ~ie~ of 8 ~..;u~ion or 1.7--....-- . bit compnsin~ a number of
i~er s fonned fiom double .~ t~ c~bite co..~ ;h~ of ~ ~vendon;
FIG. 9 is a ~h~ t;r~ Si~ view of a pol~ ,t llhe ~1~A ~d she~ cu~er
CO~ a ~vl, -~-t fom~ed fiom double l~ car~ide r~ as of this ~nv~.lt;on, ant
FIG. 10 is a~ rL ~ide view of a drag bit c~ -;c~ a ~. of the pol~c~ystallinc 1 she~.r Cutteni of FIG. 9.

10 DETAILED DESCI~ION
r~ r . ~ cart~ide is a c~ ~l~ -;~ m~ at is rrlade f~om tvnE~ carbite
(WC) grLuDs ~. a ~ lie binder such as cobalt (Co), thcn:~y f ~ g WC~o. FIG. I
illu.stra~ a c.,..~f .4:0-.~1 . v~t~.u~.lu.~ of ~. c .It i tUIl~ carbide ~e ~ 1~ 10, c~
t~ carbidc gr~ 12 tb.at arc bonded to one ar.othcr by the bindet pha~e ~4, e.g., coba.t
15 maten~. The ~.iq~e p~v~.~.~ of ~ ~ t~ -.cu~-~, e.g., t~u~ , h~.e~, ~.
wear rr~i~t~r, result from t~.c c~ .a~ of a r.gid carbide ~ct~ c ~.~ a tou~hc. metal
substruct~ The gen~c ~u.r~ of cernentet t~..~t~-~ c~b:~ a k_t ~u~ ,CO~ ;,;t~
of a c~ .-r.. ic ph~se in eQ~ wi~h ~ maal pha~, is similar in all c~.. t~
The~ .h~ n ' -'--1 prop~u~s of I~J~~a~ lu~ ~s~ c and ~ear
20 ~r;~1~ is well kIlo~n for such co~ t1on~1 CC ~ t ~C;~I glade C~ ~-t ~~ carbide
materials, and is ill~lr~t~ p~ ~' folm in FIG. 2. Hardnes~ is ;ndi~tPd by Rûck~vcll A
~R~) m-rnl~r, fiwtwe ~Q~ n~QQ i~ 1 by Kk ~ si-~), and wear .- Q ~ P iS
' bs~ ~ear number (l,00v n~tcm3). As ;ll ~ ~ ~t AL~ FlG. 2, p,o~.l;~s of tu-~ and
h~dl.ess a~: inversely ~.v~.tiun~l to one anothe~ while l,.u~.ti~.~ of h~-L_~ and wear
2s resict~n~e are p.~m~ to one another. F~G. 3 ~s another F~ t~,t;~n of the relPtior~chir
v~ La~tul~ t~ n--~c and wcar ~ for conve~ on~l co - ~ yade cF..-~r~l
~-n~ten c~ide.
For co"v~ P.~t~ ~ ~ carbide . ~t~ ru~.lics of h~
~ and wear 1. ~n~rcanbevarledwithin a defined wind.~ of between 85 to ~4 HR~
(hJIr~l~), ~t.. ~ 8 to 19 Icsi-in~ (&actu~e ~UI~ 1), and beh~een 1 to 15 (l,000 revlcm' -
we~r r~3i~ ). For exarnp}e, it is blown to i.,c-c~ the fiac D ~û~J~ 5i of suchconventional c l~ y~,~t~.~ carl~ide ~ ~ to the higher end of the Kk e~ lo~ by
~eamountofcob~tp~n~inthe~ t~ r~ c~bite. The ~ ~n~ssof ~e
. car'oide comes rnainly ~om ~he plastic ~f f~ ;o~ of the cobalt phase during
3~ the ~actlure p~ocess. Yet, the r~lting tS .L.~ ofthe ce~ - ~ t_.~ carbide de~;.~ as
~he amount of ductilc cobal~ c~as~s~ In most ro.~-~nn-1y used Cf .. ~t~ carbide
gratcs, cobalt is no more than abou~ 20 pe~cent by weight of the total c~ .~ ;;tc.




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Conv~ ,t;~ 1 grades of c~ t~ tungs~en carbide used for she~r cutter '-~ ~ in drag bits
and cutting ~h.l.lu.. inse~s in ~ock drilling bits contain in t~e ~nge of ~om about 6 to 16
S pacent by wdg~t cobalt, and have gra~n s~zes in the ra~ge o f fi om a~out one to tcn .~ .. t.r~.
Such c~Jn. ~ ~1 ;onA~ les of c~ At.~g n carbide u5ed for cut~ng ~ .1~l~. ins~ts in rock
drillirlg bits have a Ra ~..~ in the range of fiom about 85 to 91, a f~ . in lhe
range of ~om about 9 to 18 Icsi-in~2. and havc a wcar nurnber in thc range of ~om about 1.5 to
11 (1,000 re~/cm3).
Refe~g back to E~IG. 1, it is e~ndent ~at the cobalt phase 14 is not c~ in ~hc
cc,l.._.lt;un~l cementet ~ carbide .. ~ua~ t~e~paltiCll~ y ~ c~ 4r'l nn~ with a low
cobalt CCn~ h~ ,n ~he COnV~ n~t IJ.iC.~,~L~ ,-~, haS a ~ ,elY ~ fi"-....... rl;~;b~ Of
t~ gs~:cncarbido ~n a cobalt m~ix. Thlls, c~k l,~v~ ~c~t;~n ~ h thc ~ ~11 o*en
~vcl tL.. I~ thc lcs~ ductile ~ L; t- ~- carbide ~ either transE~anularly IL.v~ t~-.
c~b;c~/wbalt ;.. t~- r-~c 15, or L~1L I ~ V~ en c ~ e'1~ t~ bide
i~ f~ff 16. As aresult7c~ ,tP;~1~~-"_t~,~-carbide of~n e,.~ grossbrittlcL~ d~g
mon~ ~ "9 ,A;-,~ A~ii~-l;otl~, which may lead to c~li.c fail~e.
FIG 4, i1' ~ - the~ .o~u..,~e of a doublc L- .. -,t~ .~ carbite c~ ;t~ 18 ~ d
açcol~ling, ~o principles of this i~ -.. lhe class of c~ - t~y~ r~ling tothis
invention have a double c~ -.t~1 l,fic~sh~l lu.c. A fi~ d ~f~,t~ c C~.~Ji~S
a con~enti~n~ t~-~ c~ide l~Cl~CtUX(C.g.,~ t~ ?~ .wc-co)~
describet above, while a second c~ ..- rtf~ v~ u l~ c~ ;~s hard ph e particles 20
fo~ned fiom the first ct..- .rl~d mi-1u~1~. (e.g., ~VC-Co ~icles) ~ O~C~ by a
cu.~ ductile binder phaSG 22 (c.g.~ formcd from a ductilc metal or metal alloy). Ihus ~e
25 teml "double c~ .nt~d~ or "du~l .e ~ e~" is used to refer to the fact that the r~""~
matenal of this invention is in ~e form of a C~...P..~t~ A~lU-G that itself co ~ ~s a
cemented mi-;-u.l,u~t~ as one of i¢s c~ tc Double cr~ t~ c~ .t~ ~ of thi5
tiol. re fo~med using m~t~ lc and IJIU-~eO~_S that achieve the desired ~"~h~ d p,u~ .s
of f~act~re to~n~ss ~thou~ s-c rifi~ g wear ~t Si~ e.
Broadly, double .~ carbite c.". ~,i~- ~ of this in~ iO~ are made by mir~gJir~
c ~ d phase p~ticles ~th a ductile phase binder under cc ~ r.~ the cemented
hard phase palticles to be c~ .,t~ ~ by thc ductile phase ~inder. ~rom a laminate ~, ~ e,
-qCG~V~ strUC~l~ C~ a s~ack of shects tha~ r---t~ matenals along
one g.o...etl;c di~ ,- ion ~ fi~er ~l~u~n~c ~rith a bind~ is corl~idcred to be a 2-D !~ir~lf
35 lhe double ~ t~ d carbide C~ G~ of this in~ention can, the.crole, be vicwed ~o be a 3-D
~in~t~.




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The . ~ .,t~ of double . m~ carbide ~JI ~p~G~;r~'~ of ~his ir.~,ntiv.. provide~c a
that h~s a much hig~ fi~ re tn~ P~c than con~rer ti~r~1 c~ t~, . carbide
due to ~ h,.~ c~clc bluntlng and d-,fl~li~_ effect~ of lhe c~ ~ binder phase ~2 that
~iu~ u~d5 each hard phase particle 20. The c~ J~ b~nder pbase il~.~s ~e ove~all
rrcL tu~ tou~ . of the c~ ., .~ite~ by b1~ or t1- a - ~; n~J the ~ont of a ~v~ t; ~ ~ c~ck
if one occu~s, u,rithou~ ~~~firir~g eit~er the ove~ll l ~r~ or wPar resist~ce of ~e cc ~
l~e ovaall h~ c of the c.!A~ ,it~ is not ~Cnfir~ a~ ~e original ductile metal phase of the
10 hard ~clcs k.g., t~e cobalt p~ase of t~e c ~ Ar.~t ~ h ~ ~ carbite h~rt p ~ s) is mcrel~
~erl jc~r;huted ~,t~ ~... the h~d particle phsse and the new or scco~d binder p~ase~ Ihc overall
wcar re i~11r~ of the double ~ ~ t-! ~1 cY~l~rr tl is much higher than that of a ~,.~._t.;~r '
c .. -.t~A l..~ t~ A c~r~ide ~ hc ;-1 that c.~ ~ c the sarne amount ofthe total ductile binter
phase -~
DoublecementetcaIbide ~ r ~ ~ of 1~canbe fo~nedu~Cin~ ypcs
of '~ as the h~d phase l~ s 20. ~Im'9~ gle for f~ the hard pha5e ~ - ~cl. s
20 an: c~- ...- 15 ~hat ~lude hard ~ fo~mcd ~om c_b~ or borides formed fi~ f
metals such a~ ~, Ti, Mo, N~, V, Hf, Ta, Cr, and a m~ t; ~E agenl. ~ ha~
grain ~ t.,i~l~ include WC, TiC, TaC, r~2~ or Cr2C3, Ihe m~ C~ t;r~L agcnt may ~e
20 sel~d fil~m the groYp of ducdle m~t~ q ;~ onc or a c~n ~ of Co, ~i, Fe, which
may be alloyet ~th each other or wi~ C, B, Cr, Si ~d Mn P~cfe~ vt~ usefill fot
fo~g ~e har~l phas ~ es 20 include c ~-.. -,t~ ~ t ~ T~ n carbide w~th co~alt as the binder
phase (~C-Co) and other ,-cj" 1~ such as ~C-Ni, WC-~e, WC~Co, l~i, Fe) ~ their alloy~.
lbe ha~ phase 1~ s 20 usefi~l for f~ ~ do~bk carbide co ~~l~osit~ - of ~hi5 invelltion
include con~ tior~l c~,~ b, such a~ c~ ted 1~ carb;d- having the follo~ing
comros;t;on ~ange: ca~bide cu..,~... ~~t in the ran~e of from about 7S to 97 percent by weight,
and metallic ~ . .r.~l,~ agent Ot binder ~n ~e tange of ~om about 3 to 25 pe~cent by weight
l'hc hard phaso ~l~cl~ 20 can also be fo~ned fiom ~henc~l cast ~- ~'d~. S~>~.i.~l cast
carbide may l~ c-~t~ J using the ~in~in~ disk r~pid s ol;~ifi~ n process described in U.S.
Pa~ent l~o. 4,7~3,996 a~d U S. Patent No. 5,089,182. SF~h, ;~ ~l cast ca*lidc is a e ~t. ~tiG of WC
and ~2C. If des~red, the hard phase ~&~ ,S ~0 CaIl be formed ~om ~ es of c~"~.t~ ~1
tungsten ca~bide and sphP-r~l cast carbide, ot coll~h;n~t;v~c of other ha~d phase p~licles
descri~ed above.
In 2UI e~ npl~ P~ t, ~he h~rd phase par~iclc~ are formed ftom con~ .ti~
35 c~ sten car'oide, as i ~ in ~ h~ . each particle compri~cs a c~~bc:l~
of t ~ carbide grains bonded by cobalt (WC-Co). The c~ t~ ~ h ~E~ . carbide pa~icles
can be made ~ c~n.~ tionul miYi-~g, press~ng, and ~;nt~ to fonn a c~ t~ g~vn




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carbide body. Such a baiy can then be ¢n~shed and sc~Ln~d to obtain a desired pa~ticle size fior
use u~ ~is in~cntion. Alt~natively, the particle~ can be made dir~ctly by fi~ 8 ~k~ s
of L~ . csrbide and cob~lt of ~ u~ size which are rhen ~te~,d to near net si~. I'his
enables one to d~ the shEIpe ~s ~ell as tbe size of ~he par~cles.
Hard phase particles 20 made fiom c~ t-d h~ t -- carbite are p.of~.n~ in t~le form
of s~ ts~l~tially ~ cles Sllch ~-k~ particles can be ma~e ~om p~llehz~
mixtures of cobalt ar~d Iv ~t~ .- c~ide pa~cles or by r~ l n~ crushed c~ r,r- ~i T~
10 c~bide. ~ f~ y~ C~ c~bidcpc~ctsa~bondedwi~
cobalt. Probsbly 90~XO or more of the pellets an~ r9l or ve~ ~y ,~ A small
f~ 'don a~ smootll but su~ ' ' oval (oblate or prolste) or e~g shaped. This i~ r~ h ~ .te~ U~rith
L~l~_l carbide which bas ~n angular profile.
The ~- " .~r. A j ~ a~bidc pcl1ets ha~re 8 partiClC SL~ ~hat is ~ f~ less ~hm
about S00 ~J~ .. - h ~ whilc larger sked ~ Licl~s may exhibit ~etter wear ~ ~ - e~
~ey are blo~n to display a higher t_i~de~ for i~d ~ p~,.,l. ~-1 l,.Yt~les to ll.,cro~ or pull~t
dunng ab,~;.~ wear sitl~ti
~ ~ ~,.f~ d r~.1;... n~ t~ ~ G~bid¢ pe~e~ have a pa~icle sze
the Iange of fi~m about 20 to 300 ~.,r~ t .~ A hard phase pellet size within this range is
~.~;f~c~ ~ C~ it pro~idcs a good ~omhirqtinn of ~Y ~ tA~C~ to ~oth wear and c~
rç,~ t _ - ca~bide pellets ~bat are too fi~e, e g., that have a paIticle size of less than
about 20 mi~ t~ ~, a~ ~I!;O no~ dcs~red ~ J~ while such paIticles Inay display a low
tr~r~ tO cIack, as the particle size of the c~ t~ d nlngctr~ csrbide "1'~ s ~e size of
the intividual carl~ide g~ains, ~e ~,-ic~ u~ i of ~e ~ ~Sjt~ ~p~ ,achcs ~at of
co.~ I c - r r~ d tungstcn carbide.
The ~lative s~ze and volume fi~ction ofthe hard pha~e p~ticl~s ;~0 ~d the ductile binder
phase 2~! yl~ro~ in~ the l~rd ph~se palticlcY ~- t~ the combined ~ rh~ l and
tribolog~cal bebavior of ~e fin~l c~ o~ s. Double c~ t~d carbide c ~...p~;s;t~ i of this
u.~ Lon may ~o ~l7 ;~ in the lange of ~om abo~t 40 to 95 percent by volurne of the hard phase
30 ~ cles 20 based on the total volume ofthe cc....~ lhe volume fj~tjon of tha~ hard pbase
pa~icles is one of ~he most inlpc,~t facto~ he .~.~cl~ a.l ~ ~.Lc~ of the final
~ul It is desiled that touble c~ car~ite cc.~ ;tes be pnc~,~ed using g~atcr
abo~ 40 percent by volumc hard phase particles bcc~ e using le~s than this 9~n~ can p~duce
~ final C~ ;t~ having an ove~all modull~s, and l,.u~.li~.s of ~hc,.~ d vvear ~ e ~hat
35 are ew low for t ~ n~ ~pplirqti~ nc such as shear cutter ~ ~k.~ ~t~ ~ for drag bit~ or inselts for
~ller cone roek bits It is desired that double ~ t~ A ca~bide co ~ c of this invention be
p~c~ using less than 95 percent by volume hard phasc pa~icles L_c ~ us~ng more than this




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3 0760JG~IJS6 1

amount can ~ a final co~ hav~ng a low ~ t~ C s~milar to th~t of
Cunv~ Qh~l c. .~ t.~ "r~ Fbide.
The e~ ~tno l~t ofthe hard phase particles 20 that are used wil~ Yary ~lepcn~in~ on the
desired ~ p~oy.~ ;. for a palticYlar ~ t ~;nt~ Por CA_ _~Jlf~ when the double
cemented carbitc r ~ . . ~ is uscd in an calth boring drill bit~ it is ~.efi".~i ~a~ t~e hard phase
particles be in the range of *om about 60 to 80 percent by volume of ~e total volume of ~e
~-C~ .;t,
The ductile bi~dcr p~c 22 of double cemented carbide ~ g of this invention is
x~ d ~om dle Izroup of materi~ls co. .~ ~;Y;~g one ormore ductile metal, ductile melal alloy,
re~actory metals, adJili._.., and ~JI~u~c:g thereof. In a first ~ double c~ ~ ~t~1
carbide cc l..po~;t~ the tuetile b~nder phasc 22 ~at ~ ~ The hard p~sse E ti~le~.20is
selec~d Lvm tho g~up of duc~le meb~ls, ductilc met~l ~lloy~ and ~e1;~t~ metals. T~e ductile
1~ metals can include cobalt, niekel, iro~, cast iron, and the ductile mctal alloys can inclute s~eels
of various carbon and alloying levels, s~ninl~<;s stecls, cobalt alloys, nickel alloys, Fe-Ni-Co
alloy~ having a lo~r ~ ~ ".. ,-1 of thermal exp~n~ion such as Sealvar mA I, ~fi~ d by Am~çc
I~c., of r~ ..7~1~ania, ~ t~ ~ alloys such as W-Ni-Fe7 a~d the lilce. Dc~ kl~ Iow ~ennal
~ ~1 .A-~Cll-n ~lloys includc ~ose having a c~ of Thermal exp~nsion of les~ than al~out 8
20 ,um/m-K. Such low ~ mal e~ ... alloys zlre desired ~ they a~o bo~h t~ y
c ~ the hard phase ~ s, ~eby i,..~u~;..g the~al fatigue cn~ck ~c~ and
because they ~e mole duc~le ~e most ~ r.,"~ rate steels The ductile binter phase 2Z can
~e one, or a ~n~h ~ -- o~, the follow~ng: W, Co, Ni, Fc, Mo, r, T~. Y, Nb. llle ductile binder
phasc 22 can be alloyed with C. B, Cr and 1~
Co is a y~ef .~d duc~1e binder phase malerial ~hen the hard phase p~liclc~ are fonned
fio~5l c~rn.~rlt~ carbide (WC-Co) ~ it bas ~etter ~ .~..ic cc-~,dtibility,
wetting, and i..~ g with WC ~, as co~ to nickel or ir~n. C'---
t~n~ct~n ca~ide cc.l ~ki~p coball as a binder offers the best comb~dlio~ of hz.t~.ss and
t~ ~hel~ C r r~d to that folmet by usîng ot~er binder ~ L~ her bindcr rnS~t~ c
30 such as r~ckel are usefill in certain ~ ianC where othe~ ~ ~h~ ...,~.ties an: d~ e.g.,
nickel is uset as a bhder ~n ~ ..t~ where ~ nl ,f . i~ ,r corr~sion ~ c is ~ed~
~ n the fir~t emb~ t where the tuctile binder phj~ 22 comprises a ductile meral,
ductilc met31 alloy. o~ ~o,~ ti~.~. thereof, it is tesired that the double ,_ .. r,~ carbide
~O1~rO~C~JI~J;~CIeSS than about 60 perc~nt by volunnc, and more p.~f~ in the nange of
35 lhm about ~0 to 40 percent by vol~me, of t:be ductile b~nder phase ba~ed on the total volumc of
the cu...l~ir~ l~e fi~nc~on of the ductile binder phase is to enh~ the fiact~e to.,~ of
~he final c~.m~sir~ by p~ d- f~ ;r~g during crask pl~.p~ r The overall el~stic

-8-




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mnt~ , c~ y~ re al~ ~h and wear .c~ c of ~he final CG~_it~, will de.,.ea
~ ,.tly~c$~t~ul 60 pq~ent by volume ofthe duct~e binder is ~d, ~9~i~e ~e
final c~ f~r ~rplirS-tinnc v~here c~ cl~ hea~y load and ab.~ wesr is
know~ to occur.
M~~jPI' usefill as the ductile binder phase 22 in~lude duaib steel. The te~m "ductile
steel~ is used heroin to refer to e mild stcels that display greau~ an about 5 percent elongation
a~r heat 1, ~ t,have a carbon content of less than a~out 0.8 pcrcent by weight, and ha~e
10 total ~lloy contem o~less than about ~ percent by weigi~t of the tot~l stcel c~ Such
steels, ~IYa~ of their ~nake up and heat 1.. ~.. -1 ha~e a desi~d deg~ee of du~tilit~ to
pl~stic~lly defo~m a ~.lT;~;o~ amount during crack ~op.a~ and, the~by i~..~ tbe
fi7~ture t.~q;h,~ of the double c ~ d carbide co.~os'~ n is ~ - ,.~0~ that ~uch ductile
steels do no~ includc sl~ls l~viIlg (l) an el- .~g,~1;o~ eater th~n abot~t 5 p~cnt after heat
~ ; or alloyed steels that both ha~e8 c~rbon content of grcatcr than about 0.8 percent by
weight, and have a total alloy content of gres~er thall about 5 percent ~y weight, that may ~¢
ef~ d to a~ tool or hig~-speed steels. lhe term "alloyed steer' as us~d he~in refa~ to tbosc
steels tha~ include alloy~ of such me~a}s as ~V, Co, Ni, Fe, Mo, Ti, Ta, V, Nb, Cr~ and ~he
l~e
The initial palticle size and size dismbution of the powrler &ts ~e mixing and
ho...o~.n~ of the final ~ r .Ja1r~ of the ~ hr ~ç ~e f~nish of the as-
conc~olt~1~ted part is also i.fT~,t. ~ b~ the ~n~tial particlc size and sizc ~ bvfior nf both dle
ductilc binder phase an~ hard phase ~ After consolid~ion it is desired that ~e h~rd
phase ~Lcl~ ~in ~eir ~ntegriy with some P.l~ . . ~.1~1 ~1; IT..';~.. -, which may occur dunn~ high
25 t~ .c consoli~ nn proccss. l~e duc~ile binder phase parlicle~, ho. _.~r, bc~.l._s a
contin~Jous or ,~ v ~ onc matIix phase dunng such concnlirl-~jrn its orig~nal powder
L~ t l;~riçs no long~exi~, and it has a ~ cl~ simllar to buLlc metals wit~ equi-axet ~,
althouB~ h~~ t heat t~Jt ~ t ~ould ~lter its ~in s~ructure. For ~xa n ~1~, if duc{ile steel
is used as ~be ductile b~nder p~ u~ lCtllIe Call be ~.,a.te~ c. pearlite, ba~nite or othe~s
30 depe"~i-tg on the ~ I;n heat ~c.~ ..t or thermal histoly of the IhaTerial. At the il~h.r~cc
the binder allo~ and ~ard phase p~ l.s there could be ~lifTu~ , ~n~ g ~ g
on the ~ ;f~c m~ s~l systems.
In a sccond ~b~ -t double c~ t~d ca~bide cG. p~Ji~ ~c duc~le binder pha.se
~ includcs OhO or ~o~ of Ihe .- ~ty ~ descnbed ~ove for the filst rrnbc~ -t plus one or
35 more particula~e additives. Sui~ablc additives include WC, VC7 N~C, TiB2, TiC, MoC, Cr3C;"
PUIYUYS~ ne ~ nQI~ (PCD), cB~, other carbides, borides. nilsites, c~ itl.t_"
c~ob~ les, and n~ixh~les thereof. Ad.li~ .s, in this secont e~ o~1;m~ are an in~e~al part




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30760/G~IIS61

oft~e ductile binder phase, In lnany ab~ e wear ~rpli~a~io~ r~ wear of ehe binder
phaseist}lepri~wear~ ,S~............... h~ E antm~gthewcarr ~ ofthe
S binder phase also e~h-~r. J ~e we~r .~ of ~e hn~l composite. The particle s~ze of the
additi~res needs to be smaller than t~at of ~e hard ph~ palticles, and also llOedStO be small
enoug~ to be lmifntmly dismbuted throu~h the bunder pha~e. As a general p.~;~le of
~ t,t;i~n or.1;~ n~c~ h~ g u~fi~ ~iclesincludc~osc~ngingfiom~ ~n
to a few ~crons in s~. P~icle sizes of c~ P~ .3ar much smaller ~an
10 the mean ~ee pa~h bc~ cc~ pelle~. ~ o~her words, the paIticle sizes are smallc~ t}~ ~he width
of the duc~le b~der phase b.~ he pe~ of c~ .n~h~
Dcp~ on ~ w~r ~,"~ ns, ~ L~ for f~.. ;.~ ~xond
çml~o~ t co~r~itec of t~is il~ t;G~ ay have a pa~ticle size in as large as about 20
micru~ te~s. I~ a ~,~f..J~ sccond - :..ho~l;.~.~..t, the additi~ es have a .,~.~.i"v.~ cle si~,
15 or a paTticle sizc in ~e Iange of ~om a~out one to ten ~ ...- h ~ In some; t ~
hanol..ct~ ~ow~ ch a~ the N~oc~ powder (WC~Co) . lf ~ ed by ~od~ne, Illc.,
of New Bru~ ric~, New Je~sey, may be used The ~1. ~ " of ~ddl~ e on the
particul~ ~rpli~A~ n Ihe use of such fine pa~ticle size 3dtil;._s is desired to ~ ,~
- ductile binter pllase, reduce l,rer~ ual vrear of the tuc'dle binde~ pha~c, and i,.,~,.o.~ tl e
overallwear.~ /t~ n 4~com~n~,l.ofthedo~blec~ t- dc~oidec~ . it~
~ cond ~..4b~' n~rlt double ~ ,t~ carbide cc~ si~, whe~ ~e tuctile binder
pl~se 22 con.E,.,~s an adtitive in~ iQr~o a ductile me~l or ductile metal alloy, it is tesired
that the dollble c ..f ot~A c~ide cu...po~ite ~o...r~i _ less than about 60 pe~cenr by volume of
thc b~nder (i,e. ,~ etil~ metal or ductile me~al alloy) based on the total volume of the CO".~ r,
and l~q than abvu~ 30 prcent ~ olume of ~e ~d~ based on the total volume of the binder,
~1tl~o~ a plcr~.,~ amount of ~e ~ddi~ is - ~,ptY.xi~ately l S percent ~y ~ol~ne The use of
such stren~ dtitives may have an advelse impaa on the duc~li~ of the binder. A~c a
general ~ule, as you increase the ,~;,."1h of ~he binter you d~ the duc~i~ity of the binder
Using less than about 30 pe~cent by ~rolume of The ad~iti~-, based on the total Yolume of the
bindcr, has been shown to p~ovide a d.,~ de~ree of vvear ~ wjthout ci~ifir~ ly
5~rrjfiri~g ductili~ or t~ ~nt ss. while if the ~olume fi~ction of ~e ad~ ,.s is gn~ater than
abou~ 30 pe~nt, ~e fia~t~l-e to~lu.css or ~e final e~ t- may be below what is neeted for
pa~iC~I~rFIir~tin~c
Double c~- ~ car~ide co~ of this invention c~ &~:l by u number of
different, ~ c c g., by rapid G~n~ I;nrt~ t ~r ~ROC) p~cess, hot ~.~,ng,
infilt~ti~ solid s~ale or liquid phase cinte~ing ho~ iSO~ticln~ 6, (H ~)~rr~ t;c j~5~-jr
forE~ng, and eu, . ~h;~ cthe~eof. ~e_c pr~e~s are desi~ !; - thcy are needed to form

-10-




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the desin:d &0~ 0~ 5~u~ c~ of this ~n~ention having a ~ .if~ o . of ha~d
phase particl~ withi~ ~e ductile phase~ thercby l,n~ .vr~ ,.v~.Lcs of ~acTure
S to.JJ.. ~ wi~vU~ P wear ~ a~ ~ bald phase p~iclcs du~ ~ used
to make c~ m..~tl,n carbide .~ it~ ~ of lhis i ~ t;C~ can be formed into pellets by
Cu~ n~l ~ ~h~A~
Speci~ y, whe~e the ha~d phase pa~ticles 20 arc formed f~om sintcrcd or c~ t~d
tu~ . c~bide ha~ing, for ~ , about 1 to 1~ ~c.oh~_ter WC particles bonded to~;c
10 by SLX percent cobalt~ suc~ pellet~, are made by co,.~ n~l closed die ~ ;lg of a c~ ~, ,t~ ~
t -- v5~ ~ car~ite powder ~t~. d~,~ ~g and ~~cuum sinten~g. I~e le ~ canbe ~ hc~ to form p~liclcs in the rangc of ~om about 20 to 300 .~ 0!''- t~ ~ Altema~i~rely,
WC ~nd Co ~ .t~,.., can be mixet uiti~ a ~ c binder in ~ atlTitor or ball mill and
pellets in the range of ~!0 to 300 ~c.~ s ~si~ ter ~ t .~ ncd ~m the ..~1
Oversize and !~ pelle~ a~c .~_1~1 to achieve the desired parliclc size range. The pellets
are d~,w~..d and ~b,.~d and then br~ n up as n~-.d to ~.~,.;de 20 to 300 m~ t~
pellet~. These pellets catl ~hen ~e ~onned into a double CC....~A;I~; by any of the four above-
-n-l-~ plo~ e~ ~e Pelle~ are blnn~l~d with the ~ tuc~le binder phase 2~
and ~is ser~ ~e is pr~sed into a desired shape, such as the shape of a ro11er cone rock
20 bil ins~ and thc likc. The p~essed sl~es are then
Li~nid Phase Si.~t~
Ihe sccond ~;nt~ir~e of the pressed shapes may be done by liquid phax si~rt .i~c where
the dc~uble C~ A car'oide CQ~ ;t-iS heatet abo~e the n~ point of ~he ductile metal or
binder phase, or by ~ Iiquid phase eint~lnp whe~e ~he double c~,~. t~t~.1 carbide
25 ~o~ ~~ll¢ is heated above the solidus ~ d~ ofthe ductile binder phasc or above an alloy
col..~s;tjon fonned by com~ of the ductile metal phase and binder in the pellets, but
belo~v the fi~ c ~ ---r - 'n e. An &d~ of liquid phasc cint~!tmE~ over other cv~ csi
fom~ng yl~ ~ s is its relali~ely lo~ cost, ant the fact that it is well suited for mass ~ J~ .n
A disad~antage of liquld phase ~;rt~;~gisthat its use limiLs ~e s~kc~ of alloy sy~tems to
those whe~e the bindcr alloy can folrn a liquid ~t a t- "~ below the liquid-fG.. i.. g
~f."~ 1"' of the hard phase pcllcts. Fo~ e~m~l~, WC-Co hard phase pelle~s have a1jnnt~ Gofi~ Y;~ y 1,280 C,thustheliquitphases~nteringt~ p~.8
for ~e double ce~ a~d t~ .. c~rbide c..,..~ of ~is ~ve.lt;ol~ 1~ to be below 1,280~t~.
Melting d~ ~-t cl~ such as Si, B or C have to be uset in comhin~;nnwlth ~e steels,
35 nickel, or cobal~ metal ;n orde~ to fonn a liquid during sintenng. Ho~vever, the l,.v~.li~.s of
liquid ph~e Sint~ CO~ ~Sil~t~ri~l~Will~ di~n~ fi om ~u~ of ~loys without mel~ing
poin~ deples~u ~




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HOtF~ U~
Ale ~ ~C~ he;~J~J ~ nnay be hol pre~d t~ a des~ed shape in a closed tie
a~ a t~ J~ below ~he solitus ~ .h~ of ~he ductile bindcr pbase for bnnding by
.v ~ Hot ~. ~ ~L be ~ " ..I~"~ t~ ~ w~th or wi~o~t a liquid phase to ~chieve filll
density. Dunng the hot pressing p~cess, green powder ~..p.~t or loose paclced powder i9
place~l ~n a ~vc.p~.~ die a~d is hcated by the die to a desiret ~ t-.., T~e green po~rder
~"'1- 1 or loose packed powter is pr~ at ehe desiset t ~ fl~ under a p~essure of about
10 one to ten Icsi for a~ t~ d lengt~ of titne, e~g., 30 ~o 60 ~ t~ ~ Ihe hot pLe~i~
process ~ a ~Qable ~.~lu~l;o.~ loO,~ for double c~ ~ vr~tn~ catbidlc co~ ~~;~s of this
i...e~i.~n w~ ~ ~ d to 1i~d phase ~ t~" ~ ~ecause i-c use pc~ts a greater ~ lc~ n of
binderalloyr t ' ' T~ ctorsofthehotp~processfor~ includethehigh
cost ~e~;slte~ vith L~ p?-i~ mold ~.r~ nr., a~ ~ ~t ~ flç1r~ y with ~espect ~o

Hot Tso ~"t;c p~F~
The Hot isos~s~c press (Em~) proces is anoUher option for ,.. ~"l5,eh~ doubleh~ carbide c~ ..r~ :t~COft~ig Lnvention. I~e powder miy~ ofthe hard phase particles
ant the ductile metal phase powder a~e fi~t e~ .v~ in a soft ~etal case (5teel in m~n~
~, F' - tior c) under a vacuum. During HIP~, tlle powder blend ~r ~p ~ Ul the me~al case
i~ corc~ Rted by ~n inert ~ ~g gas ~uch as a~on Ih.~ h the meral case at a
pred~ .;n~ t~ c for iII the range of ~m about 30 ~ ', to ~ hou~ he HIP
IJ1~: is usually in the ~ange of fiom about 10 to 3n ~ Ihe enrire heating and cooling cycle
for the H~P proeess is ~.~ ~ . ~ '.y 15 to 20 houIs in a ~.~u~ ~io ~ Lh~;L~ t -tOuasi~ s
There are othcr quasi-HlP process that can also ~ et for ~ t ri~ double
Cf~.--~ J ca~bide~ ssit-softhisinvention. A~ ofsuchquasi~DlNGprocès~is
the r~ ~ ~ process as A C~ ill U.S. Patent ~Jo. 4,1;73,549, which is incc.~ t~i herein by
l~h.~llcc. Thc Cr~); on p~occss is ~ pseudo hot ;c.~ t;~ ~ug u~ le~ whe~ the shape Is
~re;,inte.~d and ~ eO fi~er cc l~a tjon by hot ~ c pl~;~;n~ )I~G3 orquasi-
HIDI~IG ph~ce~ whcre syh~ ,hile g~n~e~ are used as a ~ a~, t- ~ ;r.l~ media.
Ra~id Ol..nic~ ti~n.~l Co~ tiQn
Aylef~ e~is~ef~Todt~as~idnrnni~;~cti~n~ , tinn (ROC). F.Y~
ROC ~ruc~s arc descnbed in U.S. Paten~s 4,945,073; 4,744,943; 4,656,002; 4,428,906;
4,341,557 and 4,142,888, wh;ch are hereby in.c.. ~ .d b~ l~f~.~.. ce. Broa~ly, the process
involves fi~ g a ~ of pellets and a powder of a ductile ~netal binder, alonE~ with
b ~ wax binter. Ihe ~iAlU-C iS pressed in a closed dic ~08 desin~d shape, such ~; a rock




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bit insert. The rff~llt~ g~en~ is va¢uum d.,~ ~.,d a~ ;nt~.~ci at a relatively low
to achieve a dengity ~..,ciably below filll theoretical de~sicy. l~e ~ t .h~s is only
s~lfficier-t to pcnnit ~ ~lin~ ofthc inse~t for ~ ~ c cqin~,
This green ir~rt is ~ .~1 in 8 first ~,or~t~ and is then placed in seco~d C~ t~ P r
made of a hi8h t- "1~ -c ~igh p~c3;~ self-sealing LF~ ~pt~riAI The second co~lT ~
is filled with 8 speci81 gla~s powder ant the gre¢n parts ~l;cp~$~ ~vithin the first co.~t~ . are
e~ l in tho glass powder. Thc glass po~der has a lower m~lt;n~ po~IIt t~ that of the
green pa~t, o~ of th.~ die. l~e seeond ~ - . is placet i~ a fi~naco to raise it to the
tesi~edr~ t ~ at isdso abovethe~ gpointoftheglas~. For~ u~
for a WC-Co hard phase pellet~obalt ductile metal phasc system, the conc~
is in ~e range of ~om l,OOO~C to 1,500~C. Ttle heated secont e.n~ wit~ thc molrFn ~s
and~enpar~si-,-",. I~inside~placediI~ahydmulicp~ssha~gaclosedcylil~;e~l diesnd
mm tbat presse-s into the dle. Molten glas5 and ~he grecn pa~ts a~ ~ubj~_ted to hi~ ~. in
the ~ealed celamic ,..---1A; .- - . Tlle pslts ~re ic.,~ 1y p~es~ by tl~c liqu~d glass to ~G~
as high as 120 Icsi ~e tempeIature r~p~t iliy of ~e entire p~cess can bc as hi~h as 1,X00~C.
Ihe hig~ ple~., is applied for a shorT penod of ~ime, e.g, less than about fi~e - ~ ! and
one to two min~ C and isostatically c ~ ~ the ~n pa~s to cssert~ y 100
20 percent density.
ll~e ROC p~Dces~ has the follou/in~ ad~antages wllen cot~lp~cd against tl~ ,.oc~s~
(1) ~e ~ is a liquid ~e~ Than a ~s, thereby allowin~ one to start wieh a shaped
~reen pa~ lather ~ ing lo start ~i~ a powder blend that must be both e~ ps~llo~-d and
ev_- ' ~fore HmDnNG; (2) it pennies near net-shapc m~ufach~ng ~ehout ~ ~t
is .;~I.e~ flexible in K~ , unlike ~n~lG that .~ . post ~ , and is not
suitable for small indi~ridual cu-~ t manufhclu--l.g, (3) it o~~Ar!4 a~ au~ as hig~ as
120 ksi, ra~her ehan ae lo~ HlDlNG p~ S of less than about 30 ksi; (4) it ~ ,t~, at high
.~ atu,~, of up to about 1,800~C, rathcr than at HIDlNG t~ ~r ~ c~ of less than abou~
1.500~C; (5) it has a ~hort ~ n~ ~ime of about one to two ~ s at pressure ~nd the
h~t;n~ aod cooling oF~iorc ar ,"~ om the acmal ROC proces~c, rather than havin~ a
longH~)I~Gp~cesctimeof30to 120 m .d a~k,.~ ,and ~J~ . thatr~ e~long
penod fo~ p.e~ and 1....~.~ ~ ~np up, pro~viding a typical cycle time of 10 eo 20 hour,
~6) it do~ not pl re a limit on thç co~n~it~ ange for lfu~ n~li~5-t;c.n ~ ~ ~1~ the L~ Je,..~
high ~,ress~c callses a large arnount of plas ic ~Pft~tior~, unlike HrDlNG that limits thc
3 5 ca bite C~ -, . if solid stat~ cnnen~ n is re~wred, ~ s the c~ncnlid~tion . . .~ F ~ n
dcpends on crccp and solid s~ate diffi.lsioni and (7) it l,.~lu.~ a full~ consolidated product
having less micro defecu such as micro yo.u;,il~, unlike HIDING whe~e the p.~lu l;or of a




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30760/G~IJS6 1

pofosilr-free ~h~el~4~ is d~ d~v ~t on ~e type of c.~."Y~ '1;,... e g., the higher tlle carbide
- rt the hi~ber the p~bal~ r for rnic~ pO~uail~r.
Double~ arbide. .,~ ~ of~is............ ~ .Pbetter~ ~t~odand
~i r ~ 1 With l~f~ cc to the following ~

Exam~le 1 - Double c~ /t~ t~ carbide. c~ ~ed bv ~nfi~ on Process
Mim~s 200 mesh 5~ WC-6Co ~i-lt~ -~l pellets v~ in a ~ e mold to
the desi~d ~hape of an i~sert for use w~th a rot~r cone rock bi~ Tne pelleta ha~rc an average
pa~ticle si~e ~sl the r~nge of from about 40 to 50 .- ~~ .."rt.~ The pellcts ~e p.~ t~.~l in
the mold in a ~ ~-tn at about 1,300~C for i, r~ 30 mr ~ "~,tL.~ insen~
wete tben infi1- I withNi~ t;.~ LM, a nickel ~ -3d infiltration alloy 1- ~7-~ -v~ by Wall
Colmonoy, l:nc. ~he infilhation le p ~ ~ e ~as cont~lled at , ~ 050~C for a
15 ~od of app¢~ .y 30 .: ~ s For thc ~rles used for infilh~ n, -~y~v~ ly 30
percent by weig~t oft~ Ni~...l~,~ LM material was used ~o chargc the mold IIo~/~.", due
to exce~ ;nfilt~-lt piIe ~ on ~e top and bottom of the r ' S, about 40 percent by volume (26
percent by weight) of nickel alloy wa~ in the final as-infil- ~t ~ ~ samples.

20 r ~ 2 - D ~ouble c-- . .- .t~ n~n carbide c.,~ t~ p.~ u ..1 b~r ~ot P~ss P~ces~
Sph ~1 WC~Co si~e ~.d pellets having an ~ , p_rticle size of
appr~Yimq-~ly 40 ~O 50 ~ f~ t~.~ were bl~ d ~nth a low~bon ductile ~eel (i.e., the
duc~leb~nderphase ;1),such~sC~adeAlOOOC,--~-,--r ~ by H~ C~y~rn~iOn
A~.v..;...~tely 36 pe~ent by volwne (i.e., less than 2~ percem by weight) ofthe ductilc steel
w~s used Ihe ~.h. . :. A1 pelletc were minus 200 mesh. i.e. they p~sed ~ Ju~L a ~ d 200
mesh screen. I~e bl~P~ powdet was paelced into a ~,it~ mold that was coated w~th I~BN,
~ndthenhot pressedat~pr~-Yil "a~~ 200~C foronehourata~ cof;~y.~ ~ ~t:'ysix
ksi.

F.Y~m~1e 3. - Double c~ r~1 n~ t, .. carbide CUIn~_ tr.. ~rc;v_~d bY ROC: Prlxess
S~Pn~l W C-6cosiAte~ pelle~ havmg an average pa~icle size of ~ri~ st~ly 40
~O 501~iCnJ~ t~,;.;~ werc Wct milled to~ether wi~h AIOOOC lo~r~arbon tuctilc steel powder in
heptane fluid, and ~p~A' ~ 1 t~o percent by weigllt l~ wax ~as added thereto.
Ap~J~u~;...~t~ly 36 percent by volume (i e., less than 25 percent by wei~ht) of ~he ductile s~eel
was uset. ARer milli-l~ the powter was dried ant it wa3 pressed in~o green inselts on a uni-
axial press ~o a spccifir ~li...- ,..-:on The green insert was then presinte~:d in a vacuum a
approxim~ly 950~C for 30 r~in~ 5 The p.~, 3~tc-~ inxls was tllen subject to a rapid

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~.mni~ ctinn~l c~r~ctiQr~ p~ocess at ~p~ t.l~ 1,100~C uri~ 120 ksi pl.~3_~. Other
ductile metal alloy binde~i were also lJsed to 1~ t~ ~ using the ROC process. Ihe
,~ f ~rere then ev~luated for l.,ic,~,l,~lu.~ and ~ - - !.,-,~;~1 l~n-~ I; .~

E~n~' 9 4 to 9 - ~urth~ Double c~ ..t~ t~ ~ carl~ide ~...~ s~ el bY E~OC
Prlx~
Fulther double c~ d ~ c~ite cc ~ ' ~ were y~y~ in a manna~ similar
tO ~at ~1F ~ ~) aboYe for ExaIslple 3, exeep~ ~at ~e type of ductile binder phsse mater~al sDt
its ~ .,.I;or~ was ~aried in the following ll,&hn_.. ~ ,1~ 4 - app.o~ ~t~l~ 36 perceM by
volume (i.c., less thar4 ~5 pe~cent by wcig~t) Gmte 4650 s~el; ~ !.e 5 - ~pp.~ . . t.~ 30
p~ .t by volume (i.e., le~s tha~ 2~ perccnt by weight) G~alle 4650 steel; F ,)!s 6 -
a~lo~ t~ 38 percent by volume Seah~ ~e-Ni-Co alloy, Example 7 - ~p,~;." -t,ly 3015 pen~ent by .rolume Sealvar, r~ 8 - &yy~u.~ t~l~ 38 per~ent b~r ~olume cobalt; ~nd
FY~rle 9 - ~yy.u~..~ely 30 percent by volume cobalt. In each of ~ese o t~l'3, the
~,ph~, iç~l pellets were minw 200 mesh

EXa~DIe 10- Double~ . .t~ 1nçarbite ~ n.~ swi~ epl~;va~1bY ROC
20 Pro~
A double ~ t~ clrbide co~ ite was ~ t in a ~,~.,. simil_r to '~hat
described above for F~ mpl~ 3? except tl~at the tuctilc binder phase mRtrriRl was cobalt and
i~cluded an additive of WC particles. Sper;fi~lly, the c ~-r cc..~r~ approximalely 38
percent by ~olume tuctile binder phas .-- .T~ l and atdidve, based on ~e total weight of the
25 co,.~ , s3nd a~ ....s~t~ Iy 10 percent by volume WC ~ddi~ve, baset on the total wci~t of
the ductile binder phase mQteriQl and the adLliv~. The ad~ , W53~ ~n the fonn of fine ~n
WC, having an ave~age pa~icle ss2e in the tange of ~om about 10 ~o 15 ...;~ The
sphencal pellets of c- ~ .- .~'ed t~ 1 c3rbide had ~n average p~ticle si~ in the ~nge of f~om
abou~ l S0 to 200 nuc.o. t~
Ibe double c- ~.~ d l~ t~ ~~ carbide CO!~rc;t~s l,~pd~cd ~-~: di.-~ to ~ r~lP c 6 to
lO ~rere testect for such ' ier~ ,~nies ~ I~.e~, f~a~ tou~nPsc~ ~ld wear
e H~n~c w s ~ ,~u~ uslng a Ro~ w 'I A standard ~IRa)~ f;~ t~e tou~hn~sC was
. ,.~,l by using a KlC (~csi~in 2) ~k"~l lest acc~ to ASTM B7~ I -87, and wear r~ n~e
3 5 w~ rep~l r-,d as a wear nurnber ( l ,000 rev/cm3) as cor~ to ASlM B-6 1 1-~5. llle test results
are set forth in the Tabte below.


--lS--




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3 0760/GTL/S6 1

Table of Me sure Mech~icsl F'r. ,a l lies
Sampl~ lD HardneuFract~lro Touglu-e~s, Kk Wear 1;'~ t~ e~
O-,rer~(k~,i-ill-Z) (1,000 1e./~ ')
F~ 6 77 27 2
F le'7 81 23 2
~,~r~8 82 29 2
r , I 9 _ 83 22
r ~ 10 N/A 40 3.8
.
A~ eed in ehe ~able, the double c~ I tungsten Qtbide ~u ~p~,;t, of
Examplcs 6 to 10 each tispla~ chlre b u~ ,~ (Kle) ~er than 20 ksi~in 2, and had a
~earnumber ~reaeerdlan 1.5 (1,000 rl:V~cm3~11t, mon~ ly of ~ F u~ t~ l~r 2 (1,000
rcv/cm3). Each of ehc r ~ - 6 to l O double c~ tungsrer~ carl~ide ~ f ehis
y ' a fiacb Ie t~!.~A- c~ of . .r ~ r 2~ or g~ter, a~d some ~ high ~c 27,
29 and 40.
FIG. S ~-~ly r~ e ~ or~cl~ip ~n ~ L~l~ t~ s alld wcar
}Pcict5-n-~ for both col~v~ t;~ c~ ¢~vA t~ cu~ite ms-t~n~l~, and for the doublç
~,,",~ . ,t. ~ . ca~ide cc~ , of ~eg 6 to 9. As ill~ .t. d ill ~IG. 5, the fiscn~e
~oug}-n~c for ~o.~ ~ n~l cemented t~ carbite m~t~-lC., ha~i~g a u~ar nu--.~. of
~p~u~ateb two or more i~ no g~eater ~an about 18 ksi-in-2, and ~nore ~ A~ly is ~ithin
the lange of fi~m about I 1 to 18. According to dle tcst dal~, double c ~ h~n~t carbide
25 composites of this i..~_~o~ have improved ~lo~.l c5 of r.~ to~ ss~of at least 22
percent and 0s high as 60 percent) when CC ~I~p~ to conv~ ntion~J e~ d ~ r~ carbide
ms~--on~lc w~thouts~ .;rl-~~wear ~L ~ e
~he i~ d firactuIe lo~ss providet by double ~ d t~ ct~ cart~ide
cc,...~ ;tes of this invention is a le~ult of the special a.c~ t~ ~, of the micro~cmTe~
3 0 ~ o~ u ~e h~r~d phase ~ r ~ that act to control the wear rate of the cc r ~;t~ a~ tct
by the duc~le binder phase t~at p~ides a crack blunt~ng, i.e., a ~acture ener~ so.bi~g~ effcc~
to thereby improve the ~acrure to~J~hnrcs of the CO~
Double cer- ~t.~ carbide cc.l..~ of this i~ tio~, ean be used in a number ofdif~erenl applirs~tinn~, such as ~ools for D~inin~ and cons~uction aF~ ti~ whel~e ~ A~
35 p~u~lies of high La-:n~ ougJln~, we~ ~ , ~d h~ are highly dcsircd Doublc~ . ". ~ ~t. ~ cart~ite c~ of ~is inven~ion can be used to form wear and cuning c~ t~
~n such tools ~s roller cone bits, ~lssion or h~ r bits, drag bits, and a number of different

-16-




07/31/97 THU 22:28 [TX/RX NO 6304]

- CA 02212197 1997-08-01

JUL 31'97 ZZ:37 FR CHRISTIE PRRKER ~H~LE 18 577 ~800 TO 916046el40el P.19~35


1 30760/GllJS61

cuKing and ~ ;n~ too~. Fo~ ex~ple. ref~Lo~ to FIG. 6, touble C~ t.,~ carbide
con ~rl~ ~it~ g of ~ ivn ca~ be uset to fonn a mil~ing or tnll bit insert 24. Refe ring to FIG.
1, such an ins~ 24 can be used w1~h a roller cone drill bit 26 C-~ ';gi~ a bod~r ~8 ha~ng three
legs 30, and a cut~er cone 3Z .-.~ d on a lower end of each leg. ~ach roller cone bi~ insert 24
can be r~ ~ d ar ~ 8 to one of the ..~ .h.~. descnbet above. The inserts 24 are l.rv ~ided
in the ~u.r~,c~ of the cutter cone 32 for b~ on a rock f~ being drillet.
R.e~ - .; g to FIG. 8, inserts 24 forInod f~vm touble c- ~--o ~t~ carbide ca--~ ~ ~ ~ of this
i~ ntivu can also b~u~ed wi~ a p~ ,.- or ~ . bit 34, co ~r; - g a hollow stcel body
36 having a 1~icd pin 38 on an end of the body for ~bl~ the bit onto a drill s~ing ~not
shown) for drillirlg oil wells and the lil~e. A pluraliy of ~he ir~serts 24 re t..~.~.;ded in the ~urface
of a head 40 of tlle body 36 for bearing on the 5~ t~ n f ~- ... ~';An belIlg drilled.
R~ f~.~;r~ to FIG. 9, doubb c~ t~1 carbidc cn,~ ;t~ 5 of t~ iv.l can also be
15 used to fonn PCI:) ~hear cutters 42 tha~ a~e used, for example, ~rith a d~g bit for dnlling
subt~ f~ ~ More ~ y, double L~ t~ car~ide c~ ~, of this
invention can bc used to fo~n a shear cuttcr ~~ ~f 44 that is used to ca~Ty a layer of
polyc~alline .Ijh~ ~n~ (PCD) 46 that i~5 s~-~d thereto. 12~f~i~g to FIG. lO, ~ d~ag bit 48
CC-~ Q a plurali~ of such PCD shesr cut~r~s 42 that are each ~ e1 ~d to blades 50 ~t extent
20 fi~om a head 52 of the d~ag bit for cutting aga~nst ~e su~ ,-- ."5~h- ~-- oeing drilled.
Although, limitet Pmki 1i~ r~i of touble cr-....~t '1 carbide co.~ it~ c Of
mal~ng the same, and n~l j~ 3~ for ~e same. haYc been described and ill-~ t~ herein, many
t;.~l,C ~1l be ~ ,.lt to those skilled in the ~t Ac~o~dingly, it is to ~e
t~ -od that w~thin the scope of the r~ d claims, double c~ t~ ~ carbide . u~ e
25 according to ~ ,le s of this i~ tion may be e"-ho~ d other t~an as ~ lly ~.it~d
hcreirL




07/31/97 TIIU 22:28 [TX/RX No 6304l

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2000-10-17
(22) Filed 1997-08-01
Examination Requested 1997-08-01
(41) Open to Public Inspection 1998-02-01
(45) Issued 2000-10-17
Deemed Expired 2008-08-01

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Request for Examination $400.00 1997-08-01
Application Fee $300.00 1997-08-01
Registration of a document - section 124 $100.00 1998-03-11
Maintenance Fee - Application - New Act 2 1999-08-02 $100.00 1999-05-25
Final Fee $300.00 2000-07-14
Maintenance Fee - Application - New Act 3 2000-08-01 $100.00 2000-07-21
Maintenance Fee - Patent - New Act 4 2001-08-01 $100.00 2001-07-19
Maintenance Fee - Patent - New Act 5 2002-08-01 $150.00 2002-07-18
Maintenance Fee - Patent - New Act 6 2003-08-01 $150.00 2003-07-21
Maintenance Fee - Patent - New Act 7 2004-08-02 $200.00 2004-07-21
Maintenance Fee - Patent - New Act 8 2005-08-01 $200.00 2005-07-20
Maintenance Fee - Patent - New Act 9 2006-08-01 $200.00 2006-07-17
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
SMITH INTERNATIONAL, INC.
Past Owners on Record
FANG, ZHIGANG
SUE, J. ALBERT
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 2000-09-20 2 82
Abstract 2000-10-16 1 36
Description 1997-08-01 17 1,051
Description 1997-08-01 1 36
Drawings 1997-11-05 7 133
Claims 1997-08-01 8 338
Drawings 1997-08-01 7 158
Representative Drawing 1998-02-25 1 5
Representative Drawing 2000-09-20 1 8
Cover Page 1998-02-25 1 71
Assignment 1997-08-01 4 108
Correspondence 1997-10-21 1 32
Correspondence 2000-07-14 1 37
Assignment 1998-03-11 3 140
Prosecution-Amendment 1997-11-05 8 159