Abstract A high strength structure made of hard metal particles, such as metal carbide particles, brazed to each other in a porous lattice of a first brazing metal or alloy, the voids and spaces in the brazing metal or alloy being filled by a solidified second brazing metal or alloy of a melting point lower than the melting point of the first brazing metal or alloy. The second brazing metal or alloy may also contain a dispersion of hard metal particles, such as metal carbide particles, generally of a smaller size than that of the original hard metal particles. The structure is made by mixing a predetermined proportion of hard metal particles with the first brazing metal or alloy in the form of a powder, and by sintering in a furnace so as to obtain a substantially porous structure, followed by a second pass in the furnace of the porous structure covered with the second brazing metal or alloy in a powder form so as to impregnate the porous structure with the melted second brazing metal or alloy.
The structure of claim 1 wherein said first particle size range is 6/20 mesh size.
Claim 2
Dependent Claim
15 words
The structure of claim 1 wherein said second particle size range is 10/20 mesh size.
Claim 3
Dependent Claim
15 words
The structure of claim 3 wherein said second particle size range is 10/50 mesh size.
Claim 4
Dependent Claim
14 words
The structure of claim 1 wherein said hard metal particles are metal carbide particles.
Claim 5
Dependent Claim
20 words
The structure of claim 1 wherein said structure is approximately 3/16 to 1/4 inch in (5 to 6.5 mm) thickness.
Claim 6
Dependent Claim
176 words
A heat resistant high strength structure comprising essentially at least a pair of originally porous bodies formed of a plurality of hard metal particles of a first particle size range brazed to each other by a lattice of a softer first brazing material, the weight ratio of said hard metal particles to said first brazing material being about 2 parts to 1 to 5 parts to 1, and a second brazing material of a melting point lower than that of said first brazing material impregnating said lattice and filling the spaces in said lattice of first brazing material so as to form a matrix, said second brazing material including hard metal particles of a second particle size range smaller than said first particle size range dispersed therein and the ratio of the weight of said hard metal particles to the weight of said matrix being comprised between about 0.75 to 1 and about 1 to 1, said bodies being disposed on top of each other and being brazed to each other by means of said matrix.
Claim 7
Dependent Claim
15 words
The structure of claim 7 wherein said first particle size range is 6/20 mesh size.
Claim 8
Dependent Claim
15 words
The structure of claim 7 wherein said second particle size range is 10/20 mesh size.
Claim 9
Dependent Claim
15 words
The structure of claim 7 wherein said second particle size range is 10/50 mesh size.
Claim 10
Dependent Claim
14 words
The structure of claim 7 wherein said hard metal particles are metal carbide particles.
Claim 11
Dependent Claim
14 words
The structure of claim 7 wherein said hard metal particles are metal carbide particles.
Claim 12
Dependent Claim
22 words
The structure of claim 7 wherein each of said bodies is approximately 3/16 to 1/4 in. (5 to 6.5 mm) in thickness.