Low weight cemented carbide punch for manufacturing metal beverage cans, and method of manufacturing metal beverage cans

Abstract

This invention provides a low-weight punch for manufacturing metal beverage cans, the punch having a fused-bonded sintered carbide punch composition comprising a hard carbide phase having: tungsten carbide (WC) in an amount of about 67 wt.% to about 76 wt.% based on the total weight of the fused-bonded sintered carbide punch composition; and a γ phase having at least about 10 wt.% to about 17 wt.% of titanium (Ti) and niobium (Nb) as γ phase components based on the total weight of the fused-bonded sintered carbide punch composition. The fused-bonded sintered carbide punch composition further comprises: a binder phase comprising at least about 12 wt.% to about 13 wt.% of cobalt (Co) and chromium (Cr) in an amount of about 12 wt.% to about 13 wt.% based on the total weight of the fused-bonded sintered carbide punch composition; and the balance being carbon. A method for producing such a low-weight sintered carbide punch is further disclosed.

Description

[Technical Field]

[0001] This disclosure relates to low-weight sintered carbide punches for manufacturing metal beverage cans, and related methods for producing such low-weight sintered carbide punches. [Previous Technology]

[0002] The can industry is constantly evolving, with approximately 400 billion cans produced worldwide each year. A single production line can manufacture up to 800,000,000 cans annually using materials such as aluminum or steel strips in a continuous process.

[0003] The body of a two-piece can is manufactured through drawing, redrawing, and wall ironing processes. The manufacture of the two-piece can body typically involves first stamping a metal disc from a sheet metal. Next, a metal cup is formed from the cut metal disc. A high-quality metal can body begins with a good metal cup. Successful production of a defect-free cup begins with proper tooling design that takes into account the appropriate clearance between the tools (called the matching clearance). The formed metal cup is pushed through a can-forming ironing die with a plurality of annular rings; this is referred to in this technique as drawing or redrawing the metal cup. The clearance between the can-forming punch and the plurality of annular rings gradually decreases, resulting in a reduction in the thickness of the cup wall and an elongation of the metal cup. This operation is generally referred to as the wall ironing process. As an example, further detailing the aforementioned process, the cup, pressed from a sheet metal, is typically formed into the can body in approximately one-fifth of a second during a continuous stamping stroke. This forms the inner diameter of the can by approximately 66 mm, then the height of the can is increased from approximately 33 mm to 57 mm, and then the wall is stretched to approximately 130 mm high before forming a concave dome at the lower base of the can.

[0004] This is a particularly demanding, multi-step operation that results in high wear and tear on the tools used in the can forming process. This operation is also especially sensitive to dimensional changes and lubrication conditions. As the can industry thrives with the large volume of beverage cans produced annually, there is a constant pursuit of optimization in each step of the manufacturing process. This can potentially provide significant savings across the entire can manufacturing process.

[0005] Tools used to impart a desired shape, form, or finish to materials, such as drawing dies, can-forming punches, and the like, ideally possess favorable characteristics of good hardness, fracture toughness, compressive strength, and stiffness. This is particularly necessary when shaping beverage cans made of metal or equivalent materials. Punches and dies used in the mass production of beverage cans for commercial applications should also ideally be resistant to abrasion and tearing, and to breakage caused by repeated and continuous stress and abrasion-inducing process steps. Furthermore, these tools should also exhibit good corrosion resistance to prevent damage from surrounding corrosive liquid media (i.e., coolants / lubricants).

[0006] For stamping tools that perform the required functionality, other requirements are even more important. As stamping tools move rapidly, any reduction in their weight will lead to a significant improvement in cost and lifespan. In fact, if the stamping tool is lighter and has lower density, much less energy is required to run the entire process, and the bending of the ram will be reduced. This effect will provide much better alignment of the punch within the tool kit, and less damage will extend to the die. Therefore, due to the reduced bending effect on the ram, both the punch and the die suffer less damage during the process.

[0007] Therefore, in view of the above, it is obvious that a low-weight sintered carbide punch is required when manufacturing metal beverage cans, and this disclosure thus meets such a requirement. [Summary of the Invention]

[0008] A low-weight punch for manufacturing metal beverage cans is provided, the punch having a fused sintered carbide punch composition comprising a hard carbide phase having: tungsten carbide (WC) in an amount of about 67 wt.% to about 76 wt.% based on the total weight of the fused sintered carbide punch composition; and a γ phase having at least about 10 wt.% to about 17 wt.% of titanium (Ti) and niobium (Nb) as γ phase components based on the total weight of the fused sintered carbide punch composition. The sintered carbide punch composition further comprises: a binder phase comprising at least about 12 wt.% to about 13 wt.% of cobalt (Co) and chromium (Cr) based on the total weight of the fused sintered carbide punch composition; and the balance being carbon.

[0009] Depending on the circumstances, the Vickers hardness of the fused sintered carbide punch composition is in the range of about 1520 HV30 to about 1570 HV30.

[0010] Depending on the circumstances, the fracture toughness of the fused sintered carbide punch composition is in the range of about 10.2 MPa √m to about 10.6 MPa √m.

[0011] Depending on the circumstances, the density of the fused sintered carbide punch composition is in the range of about 11.2 g / cm3 to about 12.5 g / cm3.

[0012] Depending on the circumstances, the WC has a grain size of about 0.3 µm to about 0.8 µm when fused.

[0013] Depending on the circumstances, the γ phase components have a grain size of about 0.85 µm to about 1.65 µm when fused.

[0014] A method for manufacturing a metal beverage can is also provided, comprising using a fusion-bonded punch having a sintered carbide composition in a drawing or wall-shrinking operation to form a metal beverage can. The fusion-bonded sintered carbide punch composition includes a hard carbide phase having: WC in an amount of about 67 wt.% to about 76 wt.% based on the total weight of the fusion-bonded sintered carbide punch composition, and a γ phase comprising at least about 10 wt.% to about 17 wt.% Ti and Nb as γ phase components based on the total weight of the fusion-bonded sintered carbide punch composition. The sintered carbide punch composition further includes: a binder phase comprising at least about 12 wt.% to about 13 wt.% Co and Cr based on the total weight of the fusion-bonded sintered carbide punch composition; and the balance being carbon.

[0015] Other systems, features, and advantages will be apparent or will become apparent to those skilled in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, features, and advantages be included in this specification, within the scope of this disclosure, and protected by the following claims. Nothing in this section should be construed as limiting the scope of those claims. Other forms and advantages are discussed below with reference to examples of this disclosure. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory, and are intended to provide further explanation of the claims made in this disclosure.

Implementation Method

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the field of the subject matter to which this description pertains.

[0021] Where a range of values ​​is provided (e.g., a concentration range, a percentage range, or a ratio range), it should be understood that, unless the context explicitly indicates otherwise, all intermediate values ​​(to one-tenth of the unit of the lower limit) between the upper and lower limits of that range, and any other stated values ​​or intermediate values ​​within that stated range, are included within the subject matter described. The upper and lower limits of such smaller ranges may be independently included within the smaller ranges, and such examples are also included within the subject matter described, subject to any particular exclusive limitation within the stated range. When a stated range includes one or both of the limit values, the range excluding any or both of the included limit values ​​is also included within the subject matter described.

[0022] The following definitions describe the parameters of the subject being described.

[0023] As used herein, the terms “about” and “close” refer to a numerical value plus or minus 5% of the value of a number used with it in the claims and in this disclosure. Thus, “about” can be used to provide flexibility to the endpoints of a numerical range, where a given value may be “above” or “below” a given value. Therefore, for example, the value of 50% could be intended to cover a range that can be defined by, for example, the following: 47.5% to 52.25%, 47.5% to 52.5%, 47.75% to 50%, 50% to 52.5%, 48% to 48.5%, 48% to 48.75%, 48% to 49%, 48% to 49.5%, 48% to 49.75%, 48% to 50%, 48% to 50.25%, 48% to 50.5%, 48% to 50.75%, 48% to 51%, 48% to 51.5%, 48% to 51.75%, 48% to 52%, 48% to 52.25%, 48% to 52.5%. %, 48.25% to 48.5%, 48.25% to 48.75%, 48.25% to 49%, 48.25% to 49.5%, 48.25% to 49.75%, 48.25% to 50%, 48.25% to 50.25%, 48.25% to 50.5%, 48.25% to 50.75%, 48.25% to 51%, 48.25% to 51.25%, 48.25% to 51.5%, 48.25% to 51.75%, 48.25% to 52%, 48.25% to 52.25%, 48.25% to 52.5%, 48.5% to 48.75%, 48. 5% to 49%, 48.5% to 49.5%, 48.5% to 49.75%, 48.5% to 50%, 48.5% to 50.25%, 48.5% to 50.5%, 48.5% to 50.75%, 48.5% to 51%, 48.5% to 51.25%, 48.5% to 51.5%, 48.5% to 51.75%, 48.5% to 52%, 48.5% to 52.25%, 48.5% to 52.5%, 49% to 49.25%, 49% to 49.5%, 49% to 49.75%, 49% to 50%, 49% to 50.25%, 49% to 50.5%. 49% to 50.75%, 49% to 51%, 49% to 51.25%, 49% to 51.5%, 49% to 51.75%, 49% to 52%, 49% to 52.25%, 49% to 52.5%, 49.5% to 49.75%, 49.5% to 50%, 49.5% to 50.25%, 49.5% to 50.5%, 49.5% to 50.75%, 49.5% to 51%, 49.5% to 51.75%, 49.5% to 52%, 49.5% to 52.25%, 49.5% to 52.5%, 49.75% to 50%, 49.75% to 50.25%, 49.75% to 50.5%, 49.75% to 50.75%, 49.75% to 51%, 49.75% to 51.25%, 49.75% to 51.5%, 49.75% to 51.75%, 49.75% to 52%, 49.75% to 52.25%, 49.75% to 52.5%, 50% to 50.25%, 50% to 50.5%, 50% to 50.75%, 50% to 51%, 50% to 51.25%, 50% to 51.5%, 50% to 52%, 50% to 52.25%, 50% to 52.5%, etc. As used in this disclosure, the term "major" means covering at least 95% of a given entity.

[0024] As used herein, the terms “ambient conditions” and “room temperature” mean 25°C and 298.15 K at a pressure of 101.325 kPa (1.01325 bar).

[0025] As used herein, the terms “depegged” and “dewax” are used interchangeably.

[0026] As used herein, the term "fracture toughness" (KIc) refers to the ability of a pre-cracked material to resist further crack propagation after absorbing energy. Fracture toughness (KIc) is calculated as follows: where A is a constant of 0.0028, HV is the hardness (N / mm2), P is the applied load (N), and ΣL is the sum of the imprinted crack lengths (mm).

[0027] As used herein, "γ phase" refers to a phase composed of metal carbides, and in some cases metal nitrides and / or, in some cases, metal carbonitrides, which is beneficial for grain refinement of the γ phase relative to the phase containing hard WC. Nitrogen may be added in the form of Me(C, N), where Me is any or a combination of Ti, Ta, V, Nb, Zr, Hf, W, Mo, Cr. Metal carbides, metal nitrides, and / or metal carbonitrides may include any or a combination of Ti, Ta, V, Nb, Zr, Hf, thereby forming the γ phase. Sintered carbides may include TiC, NbC, TaC, and / or TiCN, thereby forming the γ phase. Specifically, the γ phase of sintered carbides may include cubic mixed carbides, such as, for example, (Ti, Ta, Nb, W)C. Such compositions are advantageous for improving strength, fracture toughness, and wear resistance, and also provide better performance as tools for metal forming, processing, and / or machining. Some grains of the γ phase may be more enriched in a specific chemical element, while other grains of the γ phase may have a greater quantity of combinations of other chemical elements. In addition, the γ phase may also have a core-rim structure, indicating a gradient of chemical elements formed in a given grain of the γ phase.

[0028] Wherever used throughout this disclosure, the term “generally” means “about,” “typically,” or “closely” or “in the vicinity or range of.”

[0029] As used herein, the term "green" refers to material in the form of compressed powder or compressed plate before it has been physically fused together.

[0030] As used herein, the term "HV30 Vickers hardness" (i.e., 30 kgf load applied) is a measure of a sample's resistance to localized plastic deformation, which is obtained by indenting the sample with a Vickers tip at 30 kgf.

[0031] As used herein, the terms “drilling die” or simply “die” (which are used interchangeably) and “punch” refer to specialized tools used in the manufacturing industry to shape materials into desired forms.

[0032] As used herein, ISO 28079-2009 specifies a method for measuring the fracture toughness and hardness of hard metals, cermets, and sintered carbides at room temperature by indentation. ISO 28079-2009 is applicable to the measurement of fracture toughness and hardness by using the indentation from the corner of a Vickers hardness indentation and the diagonal length of the crack, and is intended for use with metallic bonded carbides and carbonitrides (e.g., hard metals, cermets, or sintered carbides). The test procedures presented in ISO 28079-2009 are intended for use at ambient temperatures but may be extended to higher or lower temperatures by agreement. The test procedures presented in ISO 28079-2009 are also intended for use in normal laboratory air environments. They are typically not intended for use in corrosive environments, such as strong acids or seawater. The ISO 28079-2009 standard can be directly compared with the ASTM B771 standard, as disclosed, for example, in the "Comprehensive Hard Materials book," 2014, Elsevier Ltd., page 312. Therefore, it can be assumed that the fracture toughness and hardness measured using the ISO 28079-2009 standard will be the same as those measured using the ASTM B771 standard.

[0033] As used herein, the term "low weight" typically refers to any density spanning the following density ranges: about 11.2 g / cm³ to about 12.5 g / cm³, such as, for example, about 11.2 g / cm³ to about 11.4 g / cm³, about 11.4 g / cm³ to about 11.6 g / cm³, about 11.6 g / cm³ to about 11.8 g / cm³, about 11.2 g / cm³ to about 11.6 g / cm³, about 11.2 g / cm³ to about 11.8 g / cm³, about 11.2 g / cm³ to about 12.0 g / cm³, about 11.2 g / cm³ to about 12.2 g / cm³, about 11.8 g / cm³ to about 12.0 g / cm³, about 11.8 g / cm³ to about 12.0 g / cm³, about 12.0 g / cm³ to about 12.2 g / cm³, about 12.2 g / cm³ to about 12.5 g / cm³, about 11.4 g / cm³ to about 12.5 g / cm³, and so on. g / cm3 to about 12.5 g / cm3, about 11.6 g / cm3 to about 12.5 g / cm3, about 11.8 g / cm3 to about 12.5 g / cm3, about 12.0 g / cm3 to about 12.5 g / cm3, about 12.2 g / cm3 to about 12.5 g / cm3, or about 12.4 g / cm3 to about 12.5 g / cm3.

[0034] As used herein, the term "fusion bonding" refers to a process of heating under controlled pressure to minimize the surface area of ​​a particulate system, which is associated with the formation of bonds between adjacent small particles or particles and the subsequent shrinkage of the aggregated particles or particles. Densification of dense solid masses is performed by heating particles under controlled pressure.

[0035] As used herein, the term “particle” refers to one or more discrete entities.

[0036] As used herein, the term “substantial” refers to the complete or nearly complete degree or extent of an action, characteristic, nature, state, structure, item or result.

[0037] As used herein, “spherical” refers to a grain having a substantially “circular” shape.

[0038] The sidewalls of the main body of a metal beverage can typically have two different thicknesses. In the lower and middle sections, there is an intermediate wall thickness, which is often referred to as a 'thin wall' because it is the thinnest wall in the entire can body. In the upper section, there is a top wall thickness, which is also referred to as a 'thick wall' because it is thicker than the intermediate wall. The main reason for this is that the upper section requires a greater overall thickness to allow for the subsequent necking process. Otherwise, the necking process cannot be successfully completed.

[0039] The transition between the thin wall and the top wall is controlled by a step on the punch. The deeper the step, the greater the difference between the thin wall and the top wall. A typical step value is about 0.0020" (0.05 mm).

[0040] For a successful necking process, it is important that the top wall region, which extends around the circumference of the can, has a uniform thickness. As used herein, the variation between the thinnest and thickest sections of the top wall is commonly referred to as the "can top wall thickness variation".

[0041] As used herein, the term “vacuum” refers to free space, which contains no physical matter. As used herein, the term “vacuum” is a region with gas pressure that is significantly less than atmospheric pressure under ambient conditions, i.e., at a temperature of 25°C and 298.15 K and a pressure of 101.325 kPa (1.01325 bar).

[0042] As used herein, unless otherwise specifically stated, "wt.%" refers to a given weight percentage of the total weight of a batch of powdered material forming a sintered carbide composition for a low-weight punch in the manufacture of metal beverage cans. To obtain a total of 100 wt.%, unless otherwise specified, carbon may be used as alkali in the fused sintered carbide punch composition. Low-weight sintered carbide punches for manufacturing metal beverage cans

[0043] This disclosure relates to a novel low-weight sintered carbide for producing punches in the manufacture of metal beverage cans. Therefore, the use of lighter punching tools logically attracts significant attention from can manufacturers, as it will potentially help them reduce overall manufacturer maintenance and setup. Furthermore, it will improve can wall thickness consistency, which is particularly important when reducing metal thickness, i.e., reducing aluminum thickness to reduce can weight and thus aluminum consumption. Finally, it will reduce energy consumption per can produced. The reduction in sintered carbide density can potentially and ideally be achieved by increasing the ductile soft metal binder phase or by adding cubic carbides such as, for example, niobium carbide (NbC), i.e., forming a γ phase. By specifically employing this strategy, the density has been significantly reduced to below 12.6 g / cm³, which is the density characterized by the reference sintered carbide material used. An optimal density range has been identified, specifically spanning from approximately 11.2 g / cm³ to approximately 12.5 g / cm³, in which HV30 Vickers hardness and fracture toughness are unexpectedly well maintained. This is remarkable, as it achieves a low-density equilibrium in the formation of the sintered carbides of the punch described herein while simultaneously maintaining good hardness and fracture toughness.

[0044] Therefore, especially in the density range of about 11.2 g / cm3 to about 12.5 g / cm3, this disclosure overcomes the previous inherent limitations of this technology, characterized by the following concepts: increasing the amount of soft ductile binder will reduce the HV30 Vickers hardness, and increasing the γ phase content by adding cubic carbides will promote the brittleness and embrittlement of the material, and thus reduce the fracture toughness.

[0045] The hard carbide phase of the sintered carbide composition forming the low-weight punch typically comprises WC in an amount of about 59 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition. In some examples, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises WC in an amount of about 62 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition. In other examples, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises WC in an amount of about 65 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition. In still other examples, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises WC in an amount of about 68 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition. In yet another example, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises WC in an amount of about 71 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition. In even more other examples, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises WC in an amount of about 74 wt.% to about 76 wt.% based on the total amount of the sintered carbide composition.

[0046] The hard carbide phase of the sintered carbide composition forming the low-weight punch may also include WC in amounts of 59 wt.% to about 62 wt.%, about 62 wt.% to about 65 wt.%, about 65 wt.% to about 68 wt.%, about 59 wt.% to about 71 wt.%, about 62 wt.% to about 71 wt.%, about 65 wt.% to about 71 wt.%, about 68 wt.% to about 71 wt.%, about 68 wt.% to about 74 wt.%, about 62 wt.% to about 68 wt.%, about 62 wt.% to about 70 wt.% or about 71 wt.% to about 74 wt.%.

[0047] The hard carbide phase forming the sintered carbide composition of the low-weight punch may include titanium carbide (TiC) in an amount of about 5 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition. In some examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes TiC in an amount of about 6 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition. In other examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes TiC in an amount of about 7 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition. In still other examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes TiC in an amount of about 8 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition. In yet another example, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises TiC in an amount of about 9 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition. In even more other examples, the hard carbide phase of the sintered carbide composition forming the low-weight punch comprises TiC in an amount of about 10 wt.% to about 11 wt.% based on the total amount of the sintered carbide composition.

[0048] The hard carbide phase of the sintered carbide composition forming the low-weight punch may also include TiC in amounts of about 5 wt.% to about 6 wt.%, about 6 wt.% to about 7 wt.%, about 7 wt.% to about 8 wt.%, about 5 wt.% to about 7 wt.%, about 5 wt.% to about 8 wt.%, about 5 wt.% to about 9 wt.%, about 5 wt.% to about 10 wt.%, about 6 wt.% to about 8 wt.%, about 6 wt.% to about 9 wt.%, about 6 wt.% to about 10 wt.%, about 8 wt.% to about 9 wt.%, about 8 wt.% to about 10 wt.%, or about 9 wt.% to about 10 wt.% based on the total amount of the sintered carbide composition.

[0049] The hard carbide phase forming the sintered carbide composition of the low-weight punch may include NbC in an amount of about 7 wt.% to about 16 wt.% based on the total amount of the sintered carbide composition. In some examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes NbC in an amount of about 9 wt.% to about 16 wt.% based on the total amount of the sintered carbide composition. In other examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes NbC in an amount of about 11 wt.% to about 16 wt.% based on the total amount of the sintered carbide composition. In still other examples, the hard carbide phase forming the sintered carbide composition of the low-weight punch includes NbC in an amount of about 13 wt.% to about 16 wt.% based on the total amount of the sintered carbide composition.

[0050] The hard carbide phase of the sintered carbide composition forming the low-weight punch may also include, based on the total amount of the sintered carbide composition, approximately 7 wt.% to 9 wt.%, approximately 9 wt.% to 11 wt.%, approximately 11 wt.% to 13 wt.%, approximately 7 wt.% to 10 wt.%, approximately 7 wt.% to 11 wt.%, approximately 7 wt.% to 12 wt.%, approximately 7 wt.% to 13 wt.%, approximately 7 wt.% to 14 wt.%, approximately 7 wt.% to 15 wt.%, approximately 8 wt.% to 10 wt.%, approximately 8 wt.% to 11 wt.%, approximately 8 wt.% to 12 wt.%, approximately 8 wt.% to 13 wt.%, approximately 8 wt.% to 14 wt.%, approximately 8 wt.% to 15 wt.%, or approximately 8 wt.% to 16 wt.% of the total sintered carbide composition. The amounts of NbC are from about 9 wt.% to about 10 wt.%, about 9 wt.% to about 12 wt.%, about 9 wt.% to about 13 wt.%, about 8 wt.% to about 14 wt.%, or about 9 wt.% to about 15 wt.%.

[0051] The ductile binder phase of the sintered carbide composition forming the low-weight punch typically includes about 11 wt.% to about 14 wt.% of Co based on the total amount of the sintered carbide composition. In some examples, the binder phase of the sintered carbide composition forming the low-weight punch includes about 12 wt.% to about 14 wt.% of Co based on the total amount of the sintered carbide composition. In other examples, the binder phase of the sintered carbide composition forming the low-weight punch includes about 13 wt.% to about 14 wt.% of Co based on the total amount of the sintered carbide composition. In still other examples, the binder phase of the sintered carbide composition forming the low-weight punch includes about 11 wt.% to about 12 wt.% of Co based on the total amount of the sintered carbide composition. In even other examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Co in an amount of about 11 wt.% to about 13 wt.% based on the total amount of the sintered carbide composition. In even further examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Co in an amount of about 12 wt.% to about 13 wt.% based on the total amount of the sintered carbide composition.

[0052] The ductile binder phase of the sintered carbide composition forming the low-weight punch may include Cr2C3 in an amount of about 0.50 wt.% to about 0.60 wt.% based on the total amount of the sintered carbide composition. In some examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Cr2C3 in an amount of about 0.52 wt.% to about 0.60 wt.% based on the total amount of the sintered carbide composition. In other examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Cr2C3 in an amount of about 0.54 wt.% to about 0.60 wt.% based on the total amount of the sintered carbide composition. In other examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Cr2C3 in an amount of about 0.56 wt.% to about 0.60 wt.% based on the total amount of the sintered carbide composition. In even more examples, the binder phase of the sintered carbide composition forming the low-weight punch includes Cr2C3 in an amount of about 0.58 wt.% to about 0.60 wt.% based on the total amount of the sintered carbide composition.In further examples, the binder phase forming the sintered carbide composition of the low-weight punch may comprise, based on the total amount of the sintered carbide composition, about 0.50 wt.% to about 0.51 wt.%, 0.50 wt.% to about 0.52 wt.%, about 0.52 wt.% to about 0.54 wt.%, about 0.54 wt.% to about 0.56 wt.%, about 0.50 wt.% to about 0.53 wt.%, about 0.50 wt.% to about 0.54 wt.%, about 0.50 wt.% to about 0.55 wt.%, about 0.50 wt.% to about 0.56 wt.%, about 0.50 wt.% to about 0.57 wt.%, about 0.50 wt.% to about 0.58 wt.%, about 0.50 wt.% to about 0.59 wt.%, about 0.51 wt.% to about 0.51 wt.% wt.% to about 0.52 wt.%, about 0.51 wt.% to about 0.53 wt.%, about 0.51 wt.% to about 0.54 wt.%, about 0.51 wt.% to about 0.55 wt.%, about 0.51 wt.% to about 0.56 wt.%, about 0.51 wt.% to about 0.57 wt.%, about 0.51 wt.% to about 0.58 wt.%, about 0.51 wt.% to about 0.59 wt.%, about 0.52 wt.% to about 0.53 wt.%, about 0.52 wt.% to about 0.55 wt.%, about 0.52 wt.% to about 0.57 wt.%, about 0.52 wt.% to about 0.58 wt.%, about 0.52 wt.% to about 0.59 wt.%, about 0.52 wt.% to about 0.56 wt.% Cr2C3 in amounts of wt.% or about 0.56 wt.% to about 0.58 wt.%.

[0053] Once fused, the WC grain size typically exhibits an average grain size in the range of about 0.3 µm to about 0.8 µm. In some examples, the WC grain size may be in the range of about 0.4 µm to about 0.8 µm. In other examples, the WC grain size may be in the range of about 0.5 µm to about 0.8 µm. In still other examples, the WC grain size may be in the range of about 0.6 µm to about 0.8 µm. In yet another example, the WC grain size may be in the range of about 0.7 µm to about 0.8 µm.

[0054] The WC grain size can also be in the range of about 0.3 µm to about 0.4 µm, about 0.4 µm to about 0.5 µm, about 0.4 µm to about 0.6 µm, about 0.4 µm to about 0.7 µm, about 0.5 µm to about 0.6 µm, about 0.3 µm to about 0.5 µm, about 0.3 µm to about 0.6 µm, about 0.3 µm to about 0.7 µm, about 0.4 µm to about 0.7 µm, about 0.5 µm to about 0.7 µm, or about 0.6 µm to about 0.7 µm.

[0055] Once fused, the NbC and TiC-based cubic carbides forming the γ phase typically have an average grain size ranging from about 0.85 µm to about 1.65 µm. In some examples, the cubic carbides forming the γ phase may have a grain size ranging from about 1.00 µm to about 1.65 µm. In other examples, the cubic carbides forming the γ phase may have a grain size ranging from about 1.15 µm to about 1.65 µm. In still other examples, the cubic carbides forming the γ phase may have a grain size ranging from about 1.30 µm to about 1.65 µm. In yet still other examples, the cubic carbides forming the γ phase may have a grain size ranging from about 1.45 µm to about 1.65 µm.

[0056] Cubic carbides based on NbC and TiC forming the γ phase can also exhibit sizes from about 0.85 µm to about 1.00 µm, from about 1.00 µm to about 1.15 µm, from about 1.15 µm to about 1.30 µm, from about 0.85 µm to about 1.15 µm, from about 0.87 µm to about 1.15 µm, from about 0.90 µm to about 1.15 µm, from about 0.92 µm to about 1.15 µm, from about 0.94 µm to about 1.15 µm, from about 0.96 µm to about 1.15 µm, from about 0.98 µm to about 1.15 µm, from about 1.02 µm to about 1.15 µm, from about 1.04 µm to about 1.15 µm, from about 1.06 µm to about 1.15 µm, from about 1.08 µm to about 1.15 µm, and from about 1.10 µm. Approximately 1.15 µm to 1.15 µm, approximately 1.12 µm to 1.15 µm, approximately 0.85 µm to 1.30 µm, approximately 0.87 µm to 1.30 µm, approximately 0.90 µm to 1.30 µm, approximately 0.92 µm to 1.30 µm, approximately 0.94 µm to 1.30 µm, approximately 0.96 µm to 1.30 µm, approximately 0.98 µm to 1.30 µm, approximately 1.02 µm to 1.30 µm, approximately 1.04 µm to 1.30 µm, approximately 1.06 µm to 1.30 µm, approximately 1.08 µm to 1.30 µm, approximately 1.10 µm to 1.30 µm, approximately 1.12 µm to 1.30 µm, approximately 1.14 µm to 1.30 µm, approximately 1.16 µm Approximately 1.30 µm to 1.18 µm to 1.30 µm, approximately 1.20 µm to 1.30 µm, approximately 1.22 µm to 1.30 µm, approximately 1.24 µm to 1.30 µm, approximately 1.26 µm to 1.30 µm, approximately 1.28 µm to 1.30 µm, approximately 0.85 µm to 1.30 µm, approximately 0.85 µm to 1.45 µm, approximately 0.87 µm to 1.45 µm, approximately 0.90 µm to 1.45 µm, approximately 0.92 µm to 1.45 µm, approximately 0.94 µm to 1.30 µm, approximately 0.96 µm to 1.30 µm, approximately 0.98 µm to 1.45 µm, approximately 1.02 µm to 1.45 µm, approximately 1.04 µm μm to about 1.45 µm, about 1.06 µm to about 1.45 µm, about 1.08 µm to about 1.45 µm, about 1.10 µm to about 1.45 µm, about 1.12 µm to about 1.45 µm, about 1.14 µm to about 1.45 µm, about 1.16 µm to about 1.45 µm, about 1.18 µm to about 1.45 µm, about 1.20 µm to about 1.45 µm, about 1.22 µm to about 1.45 µm, about 1.24 µm to about 1.45 µm, about 1.26 µm to about 1.45 µm, about 1.28 µm to about 1.45 µm, about 1.30 µm to about 1.45 µm, about 1.32 µm to about 1.45 µm, about 1.34 µm to about 1.45 µm, about 1.36 µm to about 1.45 µm, about 1.38 µm to about 1.45 µm, about 1.40 µm to about 1.45 µm, about 1.42 µm to about 1.45 µm, about 0.85 µm to about 1.30 µm, about 1.00 µm to about 1.30 µm, about 1.00 µm to about 1.45 µm, or about 1.30 µm to about 1.45 µm. Grain size in the µm range.

[0057] The grain size of the WC or γ phase, as defined by the sintered carbide, can be determined by a linear intercept technique using lines drawn across calibrated scanning electron microscope (SEM) images of the sintered carbide. The length of the line can be measured using calibrated rules, wherein the line intercepts WC grains or γ phase grains, and the linear intercept technique is repeated for at least 100 WC or γ phase grains to obtain the average grain size of the WC or γ phase. Alternatively, to determine a specific grain size, those skilled in the art typically employ sieve analysis, dynamic digital image analysis (DIA), static laser light scattering (SLS) (also known as laser diffraction), or visual measurement by electron microscopy, techniques known as image analysis and light masking. Each method covers a range of measurable feature sizes. These ranges partially overlap. However, the results for measuring the same sample can vary entirely depending on the specific method used. Those with ordinary knowledge in the technical field of determining grain size or grain size distribution will easily understand how the methods mentioned are typically performed and practiced.

[0058] The low-weight sintered carbides used in the manufacture of the punches disclosed herein typically exhibit densities ranging from about 11.2 g / cm³ to about 12.5 g / cm³. In some examples, the density ranges from about 11.2 g / cm³ to about 11.4 g / cm³. In other examples, the density ranges from about 11.4 g / cm³ to about 11.6 g / cm³. In still other examples, the density ranges from about 11.6 g / cm³ to about 11.8 g / cm³. In yet another example, the density ranges from about 11.2 g / cm³ to about 11.6 g / cm³. In even more examples, the density ranges from about 11.2 g / cm³ to about 11.8 g / cm³. In further examples, the density may range from about 11.2 g / cm³ to about 12.0 g / cm³, from about 11.2 g / cm³ to about 12.2 g / cm³, or from about 11.2 g / cm³ to about 12.4 g / cm³. In even further examples, the density may range from about 11.8 g / cm³ to about 12.0 g / cm³. In other examples, the density may range from about 12.0 g / cm³ to about 12.2 g / cm³. In still other examples, the density may range from about 11.4 g / cm³ to about 12.0 g / cm³, from about 11.4 g / cm³ to about 12.3 g / cm³, or from about 11.4 g / cm³ to about 12.5 g / cm³. In other examples, the density may range from about 11.6 g / cm³ to about 12.0 g / cm³, from about 11.6 g / cm³ to about 12.3 g / cm³, or from about 11.6 g / cm³ to about 12.5 g / cm³. In still other examples, the density may range from about 11.8 g / cm³ to about 12.3 g / cm³, or from 11.8 g / cm³ to about 12.5 g / cm³. In even still other examples, the density may range from about 12.0 g / cm³ to about 12.5 g / cm³, from about 12.2 g / cm³ to about 12.5 g / cm³, or from about 12.4 g / cm³ to about 12.5 g / cm³.

[0059] The low-weight sintered carbides used to manufacture the punches described herein typically exhibit an HV30 Vickers hardness value in the range of about 1520 HV30 to about 1570 HV30. In some examples, the HV30 Vickers hardness value is in the range of about 1525 HV30 to about 1570 HV30. In other examples, the HV30 Vickers hardness value is in the range of about 1530 HV30 to about 1570 HV30. In still other examples, the HV30 Vickers hardness value is in the range of about 1535 HV30 to about 1570 HV30. In yet another example, the HV30 Vickers hardness value is in the range of about 1540 HV30 to about 1570 HV30. In still further examples, the HV30 Vickers hardness value is in the range of about 1545 HV30 to about 1570 HV30. In other examples, the HV30 Vickers hardness value ranges from about 1550 HV30 to about 1570 HV30. In still other examples, the HV30 Vickers hardness value ranges from about 1555 HV30 to about 1570 HV30. In yet another example, the HV30 Vickers hardness value ranges from about 1560 HV30 to about 1570 HV30. In even more examples, the HV30 Vickers hardness value ranges from about 1565 HV30 to about 1570 HV30.

[0060] The HV30 Vickers hardness value of the low-weight sintered carbides used to manufacture the punches described herein can also be from about 1520 HV30 to about 1525 HV30, from about 1525 HV30 to about 1530 HV30, from about 1530 HV30 to about 1535 HV30, from about 1520 HV30 to about 1530 HV30, from about 1520 HV30 to about 1535 HV30, from about 1520 HV30 to about 1540 HV30, from about 1520 HV30 to about 1545 HV30, from about 1520 HV30 to about 1550 HV30, from about 1520 HV30 to about 1555 HV30, from about 1520 HV30 to about 1560 HV30, from about 1520 HV30 to about 1565 HV30, and from about 1525 HV30 to about 1565 HV30. HV30 to approximately 1535 HV30, approximately 1525 HV30 to approximately 1540 HV30, approximately 1525 HV30 to approximately 1545 HV30, approximately 1525 HV30 to approximately 1550 HV30, approximately 1525 HV30 to approximately 1555 HV30, approximately 1525 HV30 to approximately 1560 HV30, approximately 1525 HV30 to approximately 1565 HV30, approximately 1530 HV30 to approximately 1540 HV30, approximately 1530 HV30 to approximately 1545 HV30, approximately 1530 HV30 to approximately 1550 HV30, approximately 1530 HV30 to approximately 1555 HV30, approximately 1530 HV30 to approximately 1560 HV30, approximately 1530 HV30 to approximately 1565 HV30 HV30, approximately 1535 HV30 to approximately 1540 HV30, approximately 1535 HV30 to approximately 1545 HV30, approximately 1535 HV30 to approximately 1550 HV30, approximately 1535 HV30 to approximately 1555 HV30, approximately 1535 HV30 to approximately 1560 HV30, approximately 1535 HV30 to approximately 1565 HV30, approximately 1540 HV30 to approximately 1545 HV30, approximately 1540 HV30 to approximately 1550 HV30, approximately 1540 HV30 to approximately 1555 HV30, approximately 1540 HV30 to approximately 1560 HV30, approximately 1540 HV30 to approximately 1565 HV30, approximately 1545 HV30 to approximately 1550 HV30, approximately 1520 HV30 to approximately 1550 HV30, approximately 1525 HV30 to approximately 1550 HV30, approximately 1530 HV30 to approximately 1550 HV30, approximately 1535 HV30 to approximately 1550 HV30, approximately 1540 HV30 to approximately 1550 HV30, approximately 1550 HV30 to approximately 1555 HV30, approximately 1555 HV30 to approximately 1560 HV30, approximately 1560The range is from HV30 to about 1565 HV30, from about 1550 HV30 to about 1560 HV30, and from about 1550 HV30 to about 1565 HV30.

[0061] The low-weight sintered carbides used in the manufacture of the punches described herein exhibit fracture toughness values ​​ranging from about 10.2 MPa √m to about 10.6 MPa √m. In some examples, the fracture toughness values ​​range from about 10.3 MPa √m to about 10.6 MPa √m. In other examples, the fracture toughness values ​​range from about 10.4 MPa √m to about 10.6 MPa √m. In still other examples, the fracture toughness values ​​range from about 10.5 MPa √m to about 10.6 MPa √m.

[0062] The fracture toughness value of the low-weight sintered carbide used to manufacture the punch described herein can also range from about 10.2 MPa √m to about 10.3 MPa √m, about 10.3 MPa √m to about 10.4 MPa √m, about 10.4 MPa √m to about 10.5 MPa √m, about 10.2 MPa √m to about 10.4 MPa √m, about 10.2 MPa √m to about 10.5 MPa √m, or about 10.3 MPa √m to about 10.5 MPa √m. Method for preparing a low-weight sintered carbide punch for manufacturing metal beverage cans.

[0063] The specific target WC or γ phase grain size for the sintered carbide composition used to manufacture the low-weight punches described herein can be produced by subjecting WC, TiC, NbC and Cr3C2 hard phase powders (i.e., forming at least two different carbide hard phases, for example, consisting of at least a WC-containing hard phase and a γ hard phase formed by adding cubic NbC and TiC during fusion) and Co-based metal binder phase powders to environmental conditions (i.e., at 25°C, 298.15 K and 101.325 kPa pressure in a ball mill, vertical ball mill or planetary mill) for several hours (e.g. 4, 8, 16, 32, 64 hours) to form a powder blend. In some examples, instead of using ball mills, vertical ball mills, or planetary mills as physical mixing equipment, any other mixing method known to those skilled in the art to which powder processing, such as ultrasonic mixing, belongs, may be appropriately chosen as the mixing method. Thus, in this case, ultrasonic mixing uses acoustic energy to efficiently process, for example, powders, pastes, liquids, and combinations thereof, with penetration speed, quality, and repeatability. Powders of virtually any size, material characteristics, or shape can be rapidly and thoroughly mixed using, for example, acoustic mixers. Acoustic processing is typically several orders of magnitude faster than conventional techniques. Here, the acoustic mixer may, for example, employ a 60 Hz motion, which then causes each particle to collide randomly with neighboring particles, thereby changing its path, colliding again, and then colliding again with other particles exhibiting the same chaotic behavior.

[0064] The main purpose of wet milling is to promote a uniform and homogeneous distribution of the Co-based metal binder phase powder within the carbide hard phase powder, and to achieve favorable wettability of the WC, TiC, NbC, and Cr3C2 hard phase and Co metal binder phase powder components. Exposing the powder mixture to wet milling is essentially essential for enhancing the bulk integrity of the WC, TiC, NbC, and Cr3C2 hard phase and Co-based metal binder phase powders. This further process deagglomerates the WC, TiC, NbC, and Cr3C2 hard phase and Co-based metal binder phase powders. An acceptable uniform and homogeneous distribution of the Co-based metal binder phase powder and good wettability of the WC, TiC, NbC, and Cr3C2 hard phase and Co metal binder phase powder components are key to obtaining sintered carbides with excellent bulk quality for low-weight punches used in the production of aluminum and steel beverage cans. On the other hand, if the distribution of the Co metal binder phase powder and the wettability of the binder and carbide hard phase powder components are of poor quality, then pores and cracks may potentially occur unfavorably in the final fused body of the low-weight punch, which will adversely affect the overall can production process.

[0065] As will be apparent to those skilled in the art, to manufacture punches for beverage can manufacturing, wet milling (i.e., blending) is performed by first adding a grinding liquid to a powder mixture to form a grinding powder slurry composition. The grinding liquid may suitably be water; alcohols, such as, but not limited to, ethanol, methanol, isopropanol, butanol, cyclohexanol; another organic solvent, such as acetone or toluene; an alcohol mixture; an alcohol and another solvent mixture; or similar components. The properties of the grinding powder slurry composition depend particularly on the amount of grinding liquid added. Because drying the grinding powder slurry composition requires a large amount of energy, the amount of grinding liquid used should be minimized to maintain low cost. However, sufficient grinding liquid needs to be added to achieve a grinding powder slurry composition that is easy to pump and to avoid clogging of the blending system. Furthermore, other compounds commonly known to those skilled in the art may be added to the slurry composition, such as dispersants, pH adjusters, lubricants, and antiflocculation agents. Non-limiting examples of one or more organic binders, such as, for example, polyethylene glycol (PEG), paraffin wax, polyvinyl alcohol (PVA), long-chain fatty acids, waxes, or any combination thereof, or similar components, may be used prior to wet milling, typically in amounts from, for example, about 2 wt.% to about 3.5 wt.%, such as, for example, about 2.25 wt.% to about 3.5 wt.%, about 2.5 wt.% to about 3.5 wt.%, about 2.75 wt.% to about 3.5 wt.%, about 3 wt.% to about 3.5 wt.%, about 3.25 wt.% to about 3.5 wt.%, about 2 wt.% to about 2.25 wt.%, about 2.25 wt.% to about 2.5 wt.%, about 2.25 wt.% to about 2.75 wt.%, about 2.25 wt.% to about 3 wt.%, about 2.25 wt.% to about 3.25 wt.%. An amount of wt.%, about 2 wt.% to about 2.5 wt.%, about 2 wt.% to about 2.75 wt.%, about 2 wt.% to about 3 wt.%, or about 2 wt.% to about 3.25 wt.% is added to the milled powder slurry composition. This is essentially done to act as a compression formulation, and to add toughness and allow for easy handling of the prepared green body in the following pressing / forming steps, which are further described below.

[0066] The wet-milled powder slurry composition may then be spray-dried, freeze-dried, air-dried, oven-dried, or vacuum-dried, and granulated to form small, free-flowing ready-to-press (RTP) powder blend aggregates, typically exhibiting spherical or substantially spherical shapes. Theoretically, any drying method inconsistent with and incompatible with the objectives of the subject matter of this invention may be implemented. As used herein, the term "free-flowing" refers to the loosely packed sintered carbide powder exhibiting pore space between the free-flowing carbide particles of the sintered carbide powder without any physical constraints or barriers that would inhibit the free-flowing ability of the sintered carbide powder particles.

[0067] Specifically, in the case of spray drying as shown in Figure 1, a wet-milled powder slurry composition consisting of WC, TiC, NbC, and Cr3C2 hard phase powder 5 mixed with an organic liquid, a Co-based metal binder phase powder 3, and one or more organic binders can be atomized by forming a spray through a suitable nozzle 1 or rotary atomizer 1 in a drying tower. The formed small discrete droplets 4, after forming liquid bridges 4A, are instantaneously dried by horizontally flowing a hot gas stream (e.g., nitrogen (N2), argon (Ar), or air stream) into the drying tower to form small spherical or substantially spherical powder aggregates 5A with free-flowing properties. As used herein, "atomization" refers to a process in which a bulk liquid feed is transformed into discrete droplets 4 by forming a spray through a nozzle 1 or rotary atomizer 1, thereby ultimately increasing the surface area of ​​the formed discrete droplets 4 and thus significantly increasing the achievable evaporation rate of a given solvent (i.e., the milling liquid). The atomization stage is designed to create optimal conditions for the evaporation of a given solvent from the milled powder slurry composition. Nozzle 1 and rotary atomizer 1 are used in the drying tower to form a spray. The drying tower may be equipped with only one such nozzle 1 and rotary atomizer 1, or alternatively with multiple such nozzles 1 and rotary atomizers 1, to form small particles (i.e., RTP powder) of spherical or substantially spherical powder admixture aggregate 5A with free-flowing properties.

[0068] The powder to be pressed (RTP) is then pressed / formed, or otherwise consolidated into a green body in preparation for the fusion process described below. The green body is formed from a sintered carbide powder blend using pressing / forming techniques known in the field of powder metallurgy, such as (but not limited to) cold tooling pressing techniques, including: multi-axial pressing (MAP), extrusion or metal injection molding (MIM), cold isostatic pressing (CIP, i.e., applying isostatic pressure in three directions or axes), pellet pressing, additive manufacturing (AM), additive layer manufacturing (ALM), tape casting, and other pressing / forming methods generally known in the field of powder metallurgy. Theoretically, any pressing / forming consolidation method that is inconsistent with and incompatible with the objectives of the subject matter of this invention may be used. Since the processed material is essentially in the form of a compressed powder, pressing / forming produces a green body density and / or strength that allows for easy handling and machining of the green body. In one example disclosed herein, forming is achieved by a pressing operation. Here, pressing can be performed using a uniaxial pressing consolidation operation with a commonly used force of 5 to 300 tons. Additionally, machining may be required in the green state to achieve the desired green shape.

[0069] The green blank may be subjected to a pre-melting temperature rise process to completely remove one or more organic binders from the melting furnace, which is also referred to in appropriate techniques as the removal or dewaxing of one or more organic binders. This may be carried out in the same melting furnace when the melting process, which is further described below, is finally performed. Suitable temperatures for the complete removal of one or more organic adhesives can be used, such temperatures starting at 150°C and ending at 450°C, starting at 150°C and ending at 500°C, starting at 150°C and ending at 550°C, starting at 200°C and ending at 600°C, starting at 250°C and ending at 450°C, starting at 250°C and ending at 500°C, starting at 250°C and ending at 550°C, starting at 250°C and ending at 600°C, starting at 300°C and ending at 450°C, starting at 300°C and ending at 500°C, starting at 300°C and ending at 550°C, or starting at 300°C and ending at 600°C. A dwell time can be introduced at the highest temperature within the operating temperature range, typically from about 1 minute to about 60 minutes. Alternatively, a residence time can be introduced at the highest temperature within the applied temperature range and at a specific pressure range, typically 20 to 60 minutes, 25 to 60 minutes, 30 to 60 minutes, 35 to 60 minutes, 40 to 60 minutes, 45 to 60 minutes, 50 to 60 minutes, or 55 to 60 minutes. This can typically be performed in a reactive H2 atmosphere, wherein the hydrogen (H2) flow rate is applied at approximately 1000 L / h to approximately 10000 L / h, approximately 3000 L / h to approximately 10000 L / h, approximately 6000 L / h to approximately 10000 L / h, or approximately 9000 L / h to approximately 10000 L / h. The temperature can typically be increased at, for example, a rate of approximately 0.70 °C / min. In some examples, after the removal of one or more organic binders, the temperature may be increased sequentially in series at a rate of about 2°C / min, becoming about 10°C / min when a certain temperature within the operating temperature range has been reached, or again changing to about 7°C / min at a rate of about 2°C / min, or changing to about 5°C / min at a rate of about 2°C / min when a specific temperature within the operating temperature range has been reached. The aforementioned temperature range for dewaxing (i.e., complete debinding of the organic binder) is typically reached after heating the green in a melting furnace for about 60 to about 90 minutes, or alternatively, about 60 minutes to about 7 hours. Therefore, generally, a specific type of heating mode is determined and executed, and sustained for a specific amount of time in a manner that provides and thereby imparts the desired complete dewaxing phase transition (i.e., 100% removal of the green).Generally, a pre-melting cycle for completely dewaxing one or more organic adhesives can be carried out in a reactive (H2) atmosphere, under vacuum conditions, or in a non-reactive inert atmosphere (e.g., nitrogen (N2) or argon (Ar)).

[0070] Next, the pre-fused, fully debonded green compact undergoes a fusion consolidation process in a fusion furnace to ultimately form a low-weight punch fused sintered carbide. As used herein, the term "consolidation process" is intended to include any process that simultaneously compresses (i.e., presses) and consolidates (i.e., densifies, thereby fusing the material by high-temperature heating operations) sintered carbide powder in a combined manner, or densifies solely by high-temperature heating operations applied only during vacuum fusion, which does not involve any compression / pressure occurring during the vacuum fusion operation.

[0071] The fusion bonding process can typically be performed using pressures of 50 to 75 bar, 50 to 80 bar, 50 to 85 bar, 50 to 90 bar, 60 to 75 bar, 60 to 80 bar, 60 to 85 bar, 60 to 90 bar, 70 to 75 bar, 70 to 80 bar, 70 to 85 bar, or 70 to 90 bar. However, depending on the composition, this pressure range can decrease to 35 to 60 bar at temperatures ranging from 1200°C to 1500°C, from 1200°C to 1600°C, from 1200°C to 1700°C, from 1200°C to 1800°C, from 1400°C to 1500°C, from 1400°C to 1600°C, from 1400°C to 1700°C, from 1400°C to 1800°C, from 1500°C to 1600°C, from 1500°C to 1700°C, or from 1500°C to 1800°C. A residence time can be introduced at the highest temperature within the operating temperature range, typically ranging from about 1 minute to about 60 minutes. Alternatively, a residence time may be introduced at the highest temperature within the applied temperature range and at a specific pressure range, typically 20 to 60 minutes, 25 to 60 minutes, 30 to 60 minutes, 35 to 60 minutes, 40 to 60 minutes, 45 to 60 minutes, 50 to 60 minutes, or 55 to 60 minutes.

[0072] In the fusion operation, a specific fusion temperature range is selected in such a way that a sufficient melt is produced during fusion to generate a Co-based metal binder phase. Without being bound by any particular theory, when the binder matrix is ​​formed after fusion is complete, Co may contain multiple elements dissolved therein, such as, for example, Cr, W, C, Ti, and / or Nb. During this process, the formed Co-based metal binder phase eventually enters the liquid phase due to melting, while the carbide grains, having much higher melting points, remain in the solid phase. The molten Co-based metal binder matrix is ​​anchored by the coating process with the formed Co-based metal binder, thereby sintering the carbide grains. Therefore, this formation represents a sintered carbide composite with a Co-based metal binder matrix, which possesses different material properties for preparing low-weight punches. The temperature can typically be increased continuously at a rate of, for example, about 0.70°C / min. In some examples, the temperature can be sequentially increased in series at a rate of approximately 2°C / min, switching to approximately 10°C / min when a specific temperature within the operating temperature range is reached, or, for example, again changing to approximately 7°C / min at a rate of approximately 2°C / min, or switching to approximately 5°C / min at a rate of approximately 2°C / min when a specific temperature within the operating temperature range is reached. After the dwell time at the highest temperature within the operating temperature range has been performed, the cooling process can typically be performed by a first temperature drop characterized by a decrease rate of approximately 50°C / min, generally lasting approximately 3, 4 to 5 minutes, or up to 6 minutes. Subsequently, all heating energy can be terminated and dissipated by a rapid temperature drop, ideally using coolant to reach a final ambient temperature of approximately 25°C.

[0073] The pre-melted green body can alternatively be vacuum-melted in a non-reactive, inert atmosphere supplied with, for example, argon (Ar) or nitrogen (N2), at a very low pressure typically in the range of 10⁻² mbar to 10⁻⁴ mbar. During vacuum melting, the pre-melted green body is placed in a vacuum furnace and melted at temperatures ranging from 1200°C to 1500°C, from 1200°C to 1600°C, from 1200°C to 1700°C, from 1200°C to 1800°C, from 1400°C to 1500°C, from 1400°C to 1600°C, or from 1400°C to 1700°C. A residence time can be introduced at the highest temperature within the operating temperature range, typically from about 1 minute to about 60 minutes. Alternatively, a residence time may be introduced at the highest temperature within the applied temperature range and at a specific pressure range, typically 20 to 60 minutes, 25 to 60 minutes, 30 to 60 minutes, 35 to 60 minutes, 40 to 60 minutes, 45 to 60 minutes, 50 to 60 minutes, or 55 to 60 minutes.

[0074] For example, hot isostatic pressing (HIP) can be performed on pre-fused sintered carbides, or alternatively, as an additional consolidation step performed sequentially on already vacuum-fused sintered carbides. HIP is a relatively slow process, and the pressing is isostatic, that is, pressure is applied isostatically in three directions or axes. Heating is performed simultaneously by components integrated into the press. Thus, HIP subjectes the sintered carbide powder to both high temperature and isostatic gas pressure simultaneously in, for example, a high-pressure sealed container. The pressurized gas used can be, for example, argon (Ar). Inert gases such as argon (Ar) are most typically used so that the material undergoing HIP does not undergo a chemical reaction. The chamber is heated, increasing the pressure inside the container. Pressure is applied to the sintered carbide powder from all three directions or axes. Inert argon (Ar) gas is typically applied from about 7,350 psi (about 50.7 MPa) to about 45,000 psi (about 310 MPa), with about 14,500 psi (about 100 MPa) generally being the most typical applied pressure, or alternatively from about 800 bar (80 MPa) to about 1200 bar (120 MPa). In such cases, the sintered carbide powder is wet-milled, dried, and pressed to form a green body as previously described, and is typically followed by vacuum fusion in a non-reactive inert argon (Ar) or N2 atmosphere. The vacuum-fused sintered carbide may then undergo an additional continuous vacuum fusion post-HIP process, typically 30 to 60 minutes, thus creating a high-pressure HIP process. This additional HIP process serves the important purpose of eliminating any potential porosity that may still exist in the vacuum-fused sintered carbide.The applied temperature can be, for example, starting at 1300°C and ending at 1500°C, starting at 1300°C and ending at 1600°C, starting at 1300°C and ending at 1700°C, starting at 1300°C and ending at 1800°C, starting at 1300°C and ending at 1900°C, starting at 1300°C and ending at 2000°C, starting at 1400°C and ending at 1500°C, starting at 1400°C and ending at 1600°C, starting at 1400°C and ending at 1700°C. The temperature ranges from 1400℃ to 1800℃, from 1400℃ to 1900℃, from 1400℃ to 2000℃, from 1500℃ to 1600℃, from 1500℃ to 1700℃, from 1500℃ to 1800℃, from 1500℃ to 1900℃, or from 1500℃ to 2000℃, and the applied pressure is typically around 7,350 °C. The pressure ranges from approximately 50.7 MPa to approximately 45,000 psi (approximately 310 MPa), with approximately 14,500 psi (approximately 100 MPa) generally being the most typical applied pressure, or alternatively from approximately 800 bar (80 MPa) to approximately 900 bar (90 MPa), approximately 800 bar (80 MPa) to approximately 1000 bar (100 MPa), approximately 800 bar (80 MPa) to approximately 1100 bar (110 MPa), approximately 800 bar (80 MPa) to approximately 1200 bar (120 MPa), approximately 900 bar (90 MPa) to approximately 1000 bar (100 MPa), approximately 900 bar (90 MPa) to approximately 1100 bar (110 MPa), approximately 900 bar (90 MPa) to approximately 1200 bar (120 MPa), approximately 1000 bar (100 MPa) to approximately 1200 bar (120 MPa), approximately 1000 bar (100 MPa) to approximately 1200 bar (120 MPa), approximately 1000 bar (100 MPa) to approximately 1200 bar (120 MPa), approximately 1000 bar (100 MPa) to approximately 1200 MPa, approximately 1000 MPa ... (MPa) to about 1100 bar (110 MPa), about 1000 bar (100 MPa) to about 1200 bar (120 MPa) or about 1100 bar (110 MPa) to about 1200 bar (120 MPa).

[0075] However, it should be emphasized that the general concept of fusion bonding falls largely within the standard process scope defined by removal, solid-state fusion bonding, or liquid-phase fusion bonding, and the fused material is ultimately cooled to ambient conditions after the fusion bonding operation is fully completed. Therefore, those skilled in the art will recognize that the aforementioned steps in the fusion bonding process described above can be performed all at once in the same fusion furnace. Alternatively, those skilled in the art will recognize that they can also be performed one after another in different fusion furnaces. Examples

[0076] The following embodiments are provided to provide a complete disclosure and description of how to manufacture and use the described subject matter to those skilled in the art, and are not intended to limit the scope of what the inventors consider to be the disclosure, nor are they intended to represent all or only the experiments performed. Efforts have been made to ensure accuracy with respect to the figures used, but some experimental errors and biases should be taken into account. Unless otherwise indicated, parts are parts by weight, molecular weights are weight average molecular weights, temperatures are in degrees Celsius, and pressures are at or near atmospheric pressure. Example 1: Preparation of low-weight sintered carbide punch samples

[0077] Low-weight sintered carbide punch samples A to H were prepared according to known manufacturing methods, having specific powder compositions in weight (wt.)% as per Table 1. The sintered carbide powder used had a final average WC grain size of about 0.3 µm to about 0.8 µm and a final γ-phase grain size spanning from about 0.85 µm to about 1.65 µm. The low-weight sintered carbide punch samples were prepared from powders comprising a hard component of WC, TiC, NbC, Cr3C2, and a Co-based metal binder phase, thereby ultimately forming a fused soft ductile binder matrix composed of Co having multiple elements dissolved therein (such as, for example, Cr, W, C, Ti, and / or Nb). In a ball mill, the powder mixture, along with approximately 2 wt.% polyethylene glycol (PEG) based on the total weight of the powder mixture, is wet-milled in an ethanol-based milling solvent medium with a lubricant and an anti-flocculating agent for approximately 8 hours until a homogeneous mixture is obtained. This mixture is then granulated by spray drying to form a recombinant physical powder (RTP), which is then sieved through a sieve with an appropriate mesh size (e.g., a 2500 mesh) to separate the flow-through while retaining the formed RTP powder. The RTP powder is isostatically pressed to form a green body before removal at 450°C, and subsequently fused in a zirconia crucible to remove the sintered carbides and increase density. Fusion is performed for approximately 1 hour at 1410°C under vacuum conditions, in a non-reactive, inert atmosphere supplied with, for example, argon (Ar) or nitrogen (N2), at extremely low pressures typically ranging from 10⁻² mbar to 10⁻⁴ mbar. This was subsequently achieved by continuously applying 50 bar of argon (Ar) gas at a fusion temperature of 1410°C for an additional 30 minutes during the HIP process to finally obtain a fully densified structure (i.e., a density of up to approximately 12.5 g / cm³), followed by final cooling of the densified structure to ambient conditions at approximately 25°C. In certain specific embodiments of the subject matter, the weight of the sole chemical component of the powder in the composition of the low-weight sintered carbide punch samples A to H is as listed in Table 1 below (i.e., plus or minus 5% of each value shown in Table 1). Furthermore, Table 2 shows the amount of chemical components in the finally fused sintered carbide punch samples A to H (i.e., plus or minus 5% of each value shown in Table 2).

[0078] Figure 2A shows the hardness (HV30) of the present invention as a function of the density of different low-weight sintered carbide punch samples prepared as described above, and a reference material having the composition 78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co and 0.5 wt.% Cr3C2. Figure 2B shows the fracture toughness of the present invention as a function of the density of different low-weight sintered carbide punch samples prepared as described above, and again shows the same reference material. Basically, the prepared lightweight sintered carbide punch samples exhibit an optimized density range substantially spanning from about 11.2 g / cm3 to about 12.5 g / cm3, and further have an HV30 Vickers hardness spanning from about 1520 to about 1570 and a fracture toughness spanning from about 10.2 MPa √m to about 10.6 MPa √m. Importantly, as shown in Figures 2A and 2B, the fracture toughness obtained by the stable lightweight sintered carbide sample is maintained, and the HV30 Vickers hardness is firmly maintained, especially in the density range covering 11.2 g / cm³ to approximately 11.2 g / cm³. The optimized density range obtained for the low-weight sintered carbide punch sample, covering 11.2 g / cm³ to approximately 12.5 g / cm³, is substantially reduced to below the density of the reference material, which is 12.6 g / cm³.

[0079] Increasing the content of soft ductile binder increases fracture toughness while decreasing HV30 hardness. Nevertheless, Figure 2A shows that the hardness remains within a tight range, i.e., HV30 of approximately 1520 to approximately 1570. This is attributed to compensation by increasing the amount of γ phase, i.e., caused by the addition of increased cubic carbides (such as, for example, NbC), which are generally known to be more brittle phases. According to Figure 2B, for sample E, at densities below, for example, 11.2 g / cm3, which is a lower density cutoff point, fracture toughness begins to decrease significantly, indicating that the increased γ phase formation caused by the addition of increased cubic carbides essentially leads to material brittleness and embrittlement. However, particularly across the tight density range of 11.2 g / cm3 to 12.5 g / cm3 (i.e., samples A to E), both hardness and fracture toughness are steadily maintained. Importantly, with sample E representing the optimized lower density cutoff, samples A to E thus represent a lower density range spanning 11.2 g / cm³ to 12.5 g / cm³. This is compared to a reference material with a density of 12.6 g / cm³, which exhibits substantially similar hardness and equivalent fracture toughness to the tested reference sample.

[0080] [Table 1] Sample size (Wt.%) WC (Wt.%) TiC (Wt.%) NbC (Wt. %) Co (Wt.%) Cr3C2(Wt.%) Total (wt.%) Density (g / cm³) 3 ) A 76.5 4.7 6.8 11.5 0.5 100.0 12.5 B 74.3 5.5 8.0 11.7 0.5 100.0 12.2 C 72.0 6.3 9.2 12.0 0.5 100.0 11.9 D 69.6 7.1 10.4 12.3 0.6 100.0 11.6 E 67.1 8.0 11.7 12.6 0.6 100.0 11.2 F 64.4 8.9 13.1 13.0 0.6 100.0 10.9 G 61.6 9.9 14.5 13.4 0.6 100.0 10.7 H 58.6 11.0 16.1 13.7 0.6 100.0 10.4 Ref. 78.4 4.0 5.9 11.2 0.5 100.0 12.6

[0081] [Table 2] sample WC (Wt.%) Ti (Wt.%) Nb (Wt.%) Co (Wt.%) Cr(Wt.%) Carbon (Wt.%) Total (wt.%) Density (g / cm³) 3 ) A 76.50 3.76 6.05 11.50 0.44 margin 100.00 12.5 B 74.30 4.40 7.12 11.70 0.44 margin 100.00 12.2 C 72.00 5.04 8.19 12.00 0.44 margin 100.00 11.9 D 69.60 5.68 9.26 12.30 0.52 margin 100.00 11.6 E 67.10 6.40 10.41 12.60 0.52 margin 100.00 11.2 F 64.40 7.12 11.66 13.00 0.52 margin 100.00 10.9 G 61.60 7.92 12.91 13.40 0.52 margin 100.00 10.7 H 58.60 8.80 14.33 13.70 0.52 margin 100.00 10.4 Ref. 78.40 3.20 5.25 11.20 0.44 margin 100.00 12.6 Example 2: Improving tank production efficiency by reducing the variation in tank top wall thickness.

[0082] According to the subject matter of the invention, the wear performance and life of a sample E punch representing an optimized lower density cutoff endpoint were evaluated in two different ways. This was accomplished by testing a punch with the same weight as the reference material (78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co and 0.50 wt.% Cr3C2) (i.e., the sample E "same weight as Ref." type punch shown in Table 3 below) and by testing a punch with the same geometry but lighter than the reference material (i.e., the sample E "same geometry lighter than Ref." type punch shown in Table 3). The produced can has an inner diameter of 66 mm and is a 33cl can.

[0083] In the sample E punch, the wear resistance performance was not adversely affected by the presence of the increased brittle γ phase. As shown in Table 3, the sample E "lighter than Ref. with the same geometry" and sample E "same weight as Ref." punches, as well as the reference material punch, all exhibited an average wear of 0.4 micrometers per million cans produced. Furthermore, as shown in Table 3, the average mesh count of cans produced using the sample E "same weight as Ref." punch was greater than that of the reference material punch, i.e., 41.89 million cans versus 36 million cans. The sample E "lighter than Ref. with the same geometry" punch produced 39.73 million cans, which is also greater than the 36 million cans produced using the reference material punch.

[0084] Importantly, a significant improvement was observed in the can top wall thickness variation produced using the Sample E "same geometry, lighter than Ref." punch compared to the reference material punch. The Sample E "same geometry, lighter than Ref." punch unexpectedly resulted in a can top wall thickness variation of 4.87 µm. On the other hand, the reference material punch and the Sample E "same weight as Ref." punch showed can top wall thickness variations of 6.00 µm and 6.10 µm, respectively. Here, the critical reduction of approximately 19% in the can top wall thickness variation of the Sample E "same geometry, lighter than Ref." punch compared to the reference material punch is significant for the entire can production process. The lower can top wall thickness variation of the Sample E "same geometry, lighter than Ref." punch essentially improves overall can production efficiency by reducing the percentage of defective cans during the necking process.

[0085] [Table 3] Reference punch (Ref.) Sample E (same weight as Ref.) Sample E (lighter than Ref. with the same geometry) Punch weight (Kg.) 3.30 3.30 2.88 Producing one million cans 36.00 41.89 39.73 Average wear (µm) / million cans 0.4 0.4 0.4 Variation in tank top wall thickness (µm) 6.00 6.10 4.87 Standard deviation of tank top wall thickness variation (µm) 2.30 2.30 2.15 Example 3: Low-weight sintered carbide punches consume low energy in can manufacturing.

[0086] The total energy consumption of a sample E-type punch (lighter than Ref. for the same geometry) representing the optimized lower density cut-off endpoint was evaluated in two different can manufacturing plants and compared with that of a reference material punch in can manufacturing (78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co, and 0.50 wt.% Cr3C2). The collected data represent the energy consumption per million cans produced, which is shown in Table 4 below. The produced cans have an inner diameter of 66 mm and are 33 cl cans.

[0087] The sample E "lighter than Ref. with the same geometry" punch consumes 3901.2 kWh and 2626.6 kWh per million cans in Plant 1 and Plant 2, respectively. In contrast, the reference material punch consumes higher energy levels, characterized by 3904.8 kWh and 2642.5 kWh per million cans in Plant 1 and Plant 2, respectively. This results in energy savings of approximately 0.1% and 0.7% in Plant 1 and Plant 2, respectively. Therefore, in summary, the sample E "lighter than Ref. with the same geometry" punch, having a density of 11.2 g / cm³ representing the optimized lower density cutoff point of all tested low-density punch levels, advantageously consumes less energy than the reference material punch exhibiting a density of 12.6 g / cm³, which is advantageous for can manufacturers.

[0088] [Table 4] factory level Punch mass (Kg.) save(%) Production per million cans of KWh Machine speed (cpm) Length of time for recording power Machine operation during can production Factory 1 Reference punch (Ref.) 3.3 0% 3904.8 280 20 min After heating up for 20 minutes, continue running for another 20 minutes. Sample E (lighter than Ref. with the same geometry) 2.9 -0.1% 3901.2 Factory 2 Reference punch (Ref.) 4.0 0% 2642.5 0 to 260 to 320 6 days Start and stop according to production requirements. Sample E (lighter than Ref. with the same geometry) 3.6 -0.7% 2626.6

[0089] Although this disclosure has been described in conjunction with examples, those skilled in the art will understand that additions, omissions, modifications and substitutions not specifically described may be made without departing from the spirit and scope of this disclosure as defined in the appended claims.

[0090] Regarding the use of any plural and / or singular terms in this document, those skilled in the art may interpret plural as singular and / or singular as plural where appropriate for the context and / or application. For clarity, various singular / plural arrangements are not explicitly described herein.

[0091] The topics described herein sometimes refer to different components contained within or connected to other different components. It should be understood that such depicted architectures are merely illustrative, and many other architectures can actually be implemented to achieve the same functionality. Conceptually, any configuration of components that achieve the same functionality is actually "associated" to achieve the desired functionality. Therefore, any two components combined herein to achieve a particular functionality can be considered "associated" with each other to achieve the desired functionality, regardless of the architecture or intermediate components. Similarly, any two such associated components can also be considered "operably connected" or "operably coupled" to each other to achieve the desired functionality, and any two components that can be suchly associated can also be considered "operably coupled" to each other to achieve the desired functionality. Specific examples of being operablely coupled include, but are not limited to, components that can physically cooperate and / or physically interact, and / or wirelessly interactive and / or wirelessly interactive components, and / or logically interactive and / or logically interactive components.

[0092] In some cases, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable / operable to,” “adaptable / adaptable,” “capable of,” “fitting / compliant,” etc. Those skilled in the art will recognize that, unless the context otherwise requires, such terms (e.g., “configured to”) may generally cover active state components and / or inactive state components and / or standby state components.

[0093] Although specific aspects of the subject matter of the invention described herein have been shown and described, it will be apparent to those skilled in the art that, based on the teachings herein, changes and modifications can be made without departing from the subject matter and its broader aspects described herein, and therefore, the appended claims cover all such changes and modifications within the true spirit and scope of the subject matter described herein. Those skilled in the art will understand that, generally, the terms used herein and especially in the appended claims (e.g., the subject of the appended claims) are generally intended to be "open-ended" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "at least having," the term "include" should be interpreted as "including but not limited to," etc.). Those skilled in the art will further understand that if a particular number of introduced technical solutions are desired, such intention will be explicitly stated in the technical solutions, and without such statement, this intention will not exist. For example, to aid understanding, the appended claims may include the use of the introductory phrases “at least one” and “one or more” to introduce a description of a technical solution. However, the use of such phrases should not be construed as implying that the introduction of a description of a technical solution by the indefinite article “a (a or an)” limits any particular technical solution containing such a description to only one such description, even when the same technical solution includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a (a or an)” (e.g., “a (a and / or an)” should generally be interpreted as meaning “at least one” or “one or more”); the same applies to the use of definite articles to introduce a description of a technical solution.

[0094] In addition, even if a specific number of the introduced technical solutions are explicitly described, those skilled in the art will recognize that such a description is typically to mean at least the number described (e.g., a bare description of "two descriptions" without other modifiers usually means at least two descriptions or two or more descriptions).

[0095] Furthermore, in cases where conventions such as "at least one of A, B, and C" are used, generally, such constructions are intended to be understood in the manner that a person with ordinary knowledge in the relevant technical field would understand the meaning of the convention (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or systems having A, B, and C together). In cases where conventions such as "at least one of A, B, or C" are used, generally, such constructions are intended to be understood in the manner that a person with ordinary knowledge in the relevant technical field would understand the meaning of the convention (e.g., "a system having at least one of A, B, or C" includes, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or systems having A, B, and C together).

[0096] Those skilled in the art will further understand that, unless the context otherwise requires, the use of separate words and / or phrases that typically present two or more alternative terms, whether in the description, the scope of the claim, or the drawings, should be understood to encompass the possibility of including one of such terms, any one of such terms, or both of such terms. For example, the phrase "A or B" should typically be understood to include the possibility of "A" or "B" or "A and B".

[0097] Those skilled in the art, in relation to the appended claims, will understand that the operations listed herein can generally be performed in any order. Furthermore, although various operational flows are presented in one or more sequences, it should be understood that the various operations may be performed in a different order than described, or may be performed simultaneously. Unless the context otherwise requires, examples of such alternative ordering may include overlapping, interleaving, interruption, reordering, incrementing, preparatory, supplementary, synchronous, reverse, or other variations of ordering. Furthermore, unless the context otherwise requires, terms such as "in response to," "related to," or other past tense adjectives are generally not intended to exclude such variations.

[0098] Those skilled in the art should understand that the aforementioned specific exemplary processes and / or apparatus and / or techniques represent more general processes and / or apparatus and / or techniques taught elsewhere herein, such as in the scope of the claims filed in this application and / or elsewhere in this application.

[0099] Although various forms and examples have been disclosed herein, other forms and examples will be obvious to those skilled in the art. The various forms and examples disclosed herein are for illustrative purposes and are not intended to be restrictive, and their true scope and spirit are indicated by the following claims.

[0100] The illustrative examples described in the embodiments, drawings and claims are not intended to be limiting. Other examples and other changes may be used without departing from the spirit or scope of the subject matter presented herein.

[0101] Where a range of values ​​is provided, it should be understood that, unless the context explicitly indicates otherwise, all intermediate values ​​(to one-tenth of the lower limit unit) between the upper and lower limits of that range, and any other stated values ​​or intermediate values ​​within that stated range, are included in this disclosure. The upper and lower limits of such smaller ranges, which may be independently included in a smaller range, are also included in this disclosure, subject to any particular exclusive limitation within the stated range. When a stated range includes one or both of the limit values, the range excluding one or both of the included limit values ​​is also included in this disclosure.

[0102] Those skilled in the art will recognize that the components (e.g., operation), devices, objects, and accompanying discussions described herein are used as examples for the sake of conceptual clarity and are open to various configuration modifications. Therefore, as used herein, the specific examples and accompanying discussions are intended to represent their more general categories. In general, the use of any particular example is intended to represent its category, and the omission of specific components (e.g., operation), devices, and objects should not be considered limiting.

[0103] Furthermore, for example, any one or more sequences and / or the temporal order of sequences of the systems and methods described herein are illustrative and should not be construed as limiting in nature. Therefore, it should be understood that process steps may be shown and described in sequence or temporal order, but are not necessarily limited to being performed in any particular sequence or order. For example, steps in such processes or methods can typically be performed in various different sequences and orders, while still falling within the scope of this disclosure.

[0104] Finally, the application disclosures and / or patents discussed herein only provide disclosures prior to the filing date of the described disclosure. Nothing in this document should be construed as an admission that the described disclosures are not entitled to precede this disclosure by means of previously disclosed disclosures. [Simplified Explanation of the Diagram]

[0016] The accompanying drawings are included and incorporated in this specification and form part of this specification to provide a further understanding of the subject matter and are used together with the description to explain the principles of this disclosure.

[0017] [Figure 1] is a flowchart illustrating individual steps of spray drying by atomization in the preparation of low-weight sintered carbide punch samples according to the subject matter of the present invention.

[0018] [Figure 2A] shows the hardness (HV30) of the subject matter of the present invention as a function of the density of different low-weight sintered carbide punch compositions, and a reference material having compositions of 78.41 wt.% WC, 4.00 wt.% TiC, 5.87 wt.% NbC, 11.22 wt.% Co and 0.50 wt.% Cr3C2.

[0019] [Figure 2B] shows the fracture toughness (KIc) of the present invention as a function of the density of different low-weight sintered carbide punch compositions, and a reference material having compositions of 78.41 wt.% WC, 4.00 wt.% TiC, 5.87 wt.% NbC, 11.22 wt.% Co and 0.50 wt.% Cr3C2.

Claims

1. A low-weight sintered carbide punch for manufacturing metal beverage cans, the low-weight sintered carbide punch having a fused sintered carbide punch composition comprising: a carbide hard phase comprising tungsten carbide (WC) present in an amount of 67 wt.% to 76 wt.% based on the total weight of the fused sintered carbide punch composition; and a γ phase comprising at least 10 wt.% to 17 wt.% of titanium (Ti) and niobium (Nb) as γ phase components based on the total weight of the fused sintered carbide punch composition; a binder phase comprising at least 12 wt.% to 13 wt.% of cobalt (Co) and chromium (Cr) present in an amount of 12 wt.% to 13 wt.% based on the total weight of the fused sintered carbide punch composition; and the balance being carbon, wherein the WC of the low-weight sintered carbide punch has a content of 0.3%. The grain size is from µm to 0.8 µm, and the γ phase composition of the low-weight sintered carbide punch has a grain size of 0.85 µm to 1.65 µm.

2. The low-weight sintered carbide punch as claimed in claim 1, wherein the Vickers hardness of the low-weight sintered carbide punch is between 1520 HV30 and 1570 HV30.

3. The low-weight sintered carbide punch as claimed in claim 1, wherein the fracture toughness of the low-weight sintered carbide punch is from 10.2 MPa √m to 10.6 MPa √m.

4. The low-weight sintered carbide punch as claimed in claim 1, wherein the density of the low-weight sintered carbide punch is from 11.2 g / cm3 to 12.5 g / cm3.

5. The low-weight sintered carbide punch of claim 1, wherein the WC of the low-weight sintered carbide punch has a grain size of 0.4 µm to 0.8 µm.

6. The low-weight sintered carbide punch of claim 5, wherein the WC of the low-weight sintered carbide punch has a grain size of 0.5 µm to 0.8 µm.

7. The low-weight sintered carbide punch of claim 6, wherein the WC of the low-weight sintered carbide punch has a grain size of 0.6 µm to 0.8 µm.

8. The low-weight sintered carbide punch of claim 7, wherein the WC of the low-weight sintered carbide punch has a grain size of 0.7 µm to 0.8 µm.

9. The low-weight sintered carbide punch of claim 1, wherein the γ phase composition of the low-weight sintered carbide punch has a grain size of 1.00 µm to 1.65 µm.

10. The low-weight sintered carbide punch of claim 9, wherein the γ phase composition of the low-weight sintered carbide punch has a grain size of 1.15 µm to 1.65 µm.

11. The low-weight sintered carbide punch of claim 10, wherein the γ phase composition of the low-weight sintered carbide punch has a grain size of 1.30 µm to 1.65 µm.

12. The low-weight sintered carbide punch of claim 11, wherein the γ phase composition of the low-weight sintered carbide punch has a grain size of 1.45 µm to 1.65 µm.

13. A method of manufacturing metal beverage cans, comprising: forming the metal beverage cans using a low-weight sintered carbide punch in drawing and wall ironing operations, the low-weight sintered carbide punch having a fused sintered carbide punch composition comprising a carbide hard phase comprising tungsten carbide (WC) present in an amount of 67 wt.% to 76 wt.% based on the total weight of the fused sintered carbide punch composition, and a γ phase comprising at least 10 wt.% to 17 wt.% of titanium (Ti) and niobium (Nb) as γ phase components based on the total weight of the fused sintered carbide punch composition; and a binder phase comprising at least 12 wt.% to 13 wt.% based on the total weight of the fused sintered carbide punch composition. The low-weight sintered carbide punch contains cobalt (Co) and chromium (Cr) in an amount of wt.%; and the balance is carbon, wherein the WC of the low-weight sintered carbide punch has a grain size of 0.3 µm to 0.8 µm, and the γ phase of the low-weight sintered carbide punch has a grain size of 0.85 µm to 1.65 µm.

14. The method of claim 13, wherein the HV30 Vickers hardness of the low-weight sintered carbide punch is 1520 HV30 to 1570 HV30.

15. The method of claim 13, wherein the fracture toughness of the low-weight sintered carbide punch is from 10.2 MPa √m to 10.6 MPa √m.

16. The method of claim 13, wherein the density of the low-weight sintered carbide punch is from 11.2 g / cm3 to 12.5 g / cm3.

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