Lubricant packed wire drawing dies

Claim 2

A wire drawing die comprising a mass having a centrally-located double tapered hole extending therethrough with micro-rough walls having pores, said mass comprising predominately a material selected from the group consisting of compacted polycrystalline diamond, compacted polycrystalline cubic boron nitride and mixtures thereof, wherein said mass has been compacted at a pressure of at least about 40 kilobars, and wherein substantially only the pores which are exposed at the surface of said micro-rough walls in said hole are densely packed with a lubricant for wire drawing.

Claim 3

A wire drawing die as defined in claim 1 wherein the micro-rough walls have been formed during polishing.

Claim 4

A wire drawing die as defined in claim 1 wherein said lubricant is a material selected from the group consisting of graphite, molybdenum disulfide, hexagonal boron nitride, fats, waxes, soaps, polytetrafluorethylene, and mixtures thereof.

Claim 5

A wire drawing die as defined in claim 3 wherein said lubricant is graphite.

Claim 6

A wire drawing die as defined in claim 1 wherein said mass is predominately compacted polycrystalline diamond.

Claim 7

A wire drawing die as defined in claim 5 wherein said mass is predominately compacted polycrystalline boron-doped diamond.

Claim 8

A wire drawing die as defined in claim 5 wherein said mass is predominately compacted polycrystalline boron-alloyed diamond.

Claim 9

A wire drawing die as defined in claim 1 wherein said mass is predominately compacted polycrystalline cubic boron nitride.

Claim 10

A wire drawing die as defined in claim 8 wherein said mass is predominately compacted polycrystalline beryllium-alloyed cubic boron nitride.

Claim 11

A wire drawing die as defined in claim 1 wherein said walls have micro-voids therein, said micro-voids located along crystal grain boundaries of said polycrystalline material.

Claim 12

A composite wire drawing die comprising in combination: i. an inner mass having a centrally-located double tapered hole extending therethrough with micro-rough walls having pores, said inner mass comprising predominately a material selected from the group consisting of compacted polycrystalline diamond, compacted polycrystalline cubic boron nitride and mixtures thereof, wherein said mass has been compacted at a pressure of at least 40 kilobars, and wherein substantially only the pores which are exposed at the surface of said micro-rough walls in said hole are densely packed with a lubricant for wire drawing; ii. at least one mass of metal bonded carbide directly bonded to and girding said inner mass for symmetrical support thereof, said mass of metal bonded carbide being predominately of carbide material selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide and mixtures thereof with the metal bonding material therein being present in a quantity of from about 3 percent to about 25 percent by weight and being selected from the group consisting of cobalt, nickel, iron and mixtures thereof; and iii. an interface between (i) and (ii) which is free of voids, irregular and interlocking on the scale of 1-100 micrometers.

Claim 13

A composite wire drawing die comprising in combination: i. an inner mass having a centrally-located double tapered hole extending therethrough with micro-rough walls having pores, said inner mass comprising predominately a material selected from the group consisting of compacted polycrystalline diamond, compacted polycrystalline cubic boron nitride and mixtures thereof, wherein said mass has been compacted at a pressure of at least 40 kilobars, and wherein substantially only the pores which are exposed at the surface of said micro-rough walls in said hole are densely packed with a lubricant for wire drawing; ii. at least one mass of metal bonded carbide directly bonded to and girding said inner mass for symmetrical support thereof, said mass of metal bonded carbide being predominately of carbide material selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide and mixtures thereof with the metal bonding material therein being present in a quantity of from about 3 percent to about 25 percent by weight and being selected from the group consisting of cobalt, nickel, iron and mixtures thereof; and iii. an interface between (i) and (ii) which is free of voids, irregular and interlocking on the scale of 1-100 micrometers.

Claim 14

A composite wire drawing die as defined in claim 11 wherein said lubricant is a material selected from the group consisting of graphite, molybdenum, disulfide, hexagonal boron nitride, fats, waxes, soaps, polytetrafluoroethylene and mixtures thereof.

Claim 15

A composite wire drawing die as defined in claim 12 wherein said lubricant is graphite.

Claim 16

A composite wire drawing die as defined in claim 11 wherein said inner mass is predominately compacted polycrystalline diamond.

Claim 17

A composite wire drawing die as defined in claim 11 wherein said inner mass is predominately compacted polycrystalline cubic boron nitride.

Claim 18

A composite wire drawing die as defined in claim 11 wherein the inner mass is in a generally cylindrical form and the carbide mass is in the form of a jacket there around.

Claim 19

A composite wire drawing die as defined in claim 16 wherein the composite is in the shape of a truncated core.

Claim 20

A composite wire drawing die as recited in claim 11 wherein the inner micro-rough mass is both flanked and girded by the mass of metal bonded carbide.