W-Re Coated PCBN Tool Microstructure Uniformity
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Solution Overview
Problem
Existing methods for forming cutting tools and friction stir welding tools using hard materials result in non-uniform sintered microstructures, limiting the volume percent of ultra hard materials to less than 80% due to the need for a high volume percent of binder phase, which affects wear resistance and tool performance.
Innovation Solution
Coating ultra hard material particles with tungsten and rhenium followed by high temperature and high pressure sintering to form a polycrystalline material with a tungsten-rhenium matrix, allowing for a higher volume percent of ultra hard material grains while maintaining a lower volume percent of binder phase, resulting in improved hardness and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high volume percent of binder phase is used to form hard materials, then the material can be sintered with conventional methods, but the volume percent of ultra hard materials is limited to less than 80% and wear resistance deteriorates
Solution Approach 1:
The ultra hard material particles are pre-coated with tungsten and rhenium before sintering. This preliminary coating action ensures uniform distribution of the binder phase throughout the ultra hard material matrix, allowing the ultra hard material volume percent to exceed 80% while maintaining structural uniformity and wear resistance.
2Quantity of substance
If the volume percent of binder phase is reduced to increase ultra hard material content, then wear resistance improves, but the microstructure becomes non-uniform and sintering becomes difficult
Solution Approach 1:
Instead of uniformly distributing binder phase throughout the material, the invention applies binder phase locally by coating it onto the surface of each ultra hard material particle. This local application ensures that even with less than 20% binder phase by volume, the ultra hard material content can exceed 80% while maintaining uniform microstructure through the coating layer distribution.
3Quantity of substance
If conventional sintering methods are used with high ultra hard material content, then the binder phase can be reduced, but the microstructure becomes non-uniform affecting tool performance
Solution Approach 1:
The ultra hard material particles are pre-coated with tungsten and rhenium before sintering. This preliminary coating action ensures uniform distribution of the binder phase throughout the ultra hard material matrix, allowing the ultra hard material volume percent to exceed 80% while maintaining structural uniformity and wear resistance.
Solution Approach 2:
The invention creates a composite material structure where ultra hard material particles are embedded in a tungsten-rhenium binder matrix. The composite structure combines the wear resistance of ultra hard materials (>80% volume) with the binding capability of the W-Re alloy, achieving both high performance and reliability.
4Manufacturing precision
If more binder phase is used to ensure uniform microstructure, then sintering is easier, but the volume percent of ultra hard materials is limited and wear resistance decreases
Solution Approach 1:
Instead of uniformly distributing binder phase throughout the material, the invention applies binder phase locally by coating it onto the surface of each ultra hard material particle. This local application ensures that even with less than 20% binder phase by volume, the ultra hard material content can exceed 80% while maintaining uniform microstructure through the coating layer distribution.
Solution Approach 2:
The invention creates a composite material structure where ultra hard material particles are embedded in a tungsten-rhenium binder matrix. The composite structure combines the wear resistance of ultra hard materials (>80% volume) with the binding capability of the W-Re alloy, achieving both high performance and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves a more uniform microstructure with higher volume percent of ultra hard material grains, enhancing wear resistance and tool performance by forming a dense, chemically bonded polycrystalline material with improved high-temperature properties.
Implementation Method 1
The coating may be performed by a method selected from the group consisting of chemical vapor deposition, electroless plating, physical vapor deposition and combinations thereof
Implementation Method 2
The coating may be performed by a method selected from the group consisting of chemical vapor deposition, electroless plating, physical vapor deposition and combinations thereof
Implementation Method 3
The coating may be performed by a method selected from the group consisting of chemical vapor deposition, electroless plating, physical vapor deposition and combinations thereof
Implementation Method 4
sintering the coated ultra hard material particles at ultra high temperature and high pressure (HPHT)
Implementation Method 5
sintering the coated ultra hard material particles includes forming a chemical bond between the ultra hard material particles and at least one of the tungsten or rhenium
Data Source
AI summary
The present invention relates to tungsten-rhenium coated compounds, materials formed from tungsten-rhenium coated compounds, and to methods of forming the same. In embodiments, tungsten and rhenium are coated on ultra hard material particles to form coated ultra hard material particles, and the coated ultra hard material particles are sintered at high temperature and high pressure.