Infiltrated powdered metal composite article

Claim 2

A metal composite article comprising: (a) less than about 15 percent of the volume of said article of granules of a refractory of about 1 to about 100 micrometers mean diameter, said refractory being (i) metal carbide, boride, oxide, silicide, or nitride, (ii) metal selected from the group consisting of tungsten, molybdenum, tantalum, niobium, vanadium, and titanium, or (iii) combinations thereof; (b) a monolithic skeleton comprising about 35 to about 70 percent of the volume of said article of a solid first metal or alloy which has a homogeneous crystalline appearance at a temperature below its melting point when viewed under an optical microscope and has lower Rockwell hardness than said refractory, said first metal or alloy fully enveloping said refractory granules, the latter being uniformly dispersed in said skeleton; and (c) about 15 to about 50 percent of the volume of said article of a continuous metallic phase occupying the connected porosity in said skeleton, said continuous phase comprising a solid second metal or alloy which wets said skeleton, has a Rockwell hardness less than or equal to the Rockwell hardness of said first metal or alloy, and has a melting point below the melting point of said first metal or alloy; said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 3

An article according to claim 1, wherein said refractory is a metal carbide, boride, oxide, silicide, or nitride.

Claim 4

An article according to claim 1, wherein said refractory is a metal selected from the group consisting of tungsten, molybdenum, tantalum, niobium, vanadium, and titanium.

Claim 5

An article according to claim 1, wherein said refractory is a metal carbide.

Claim 6

An article according to claim 1, wherein said refractory is tungsten carbide.

Claim 7

An article according to claim 1, wherein said refractory is about 8 to about 13 percent of the volume of said article.

Claim 8

An article according to claim 1, wherein said refractory granules have a mean diameter of about 1 to about 25 micrometers.

Claim 9

An article according to claim 1, wherein said refractory granules have a mean diameter of about 1 to about 15 micrometers.

Claim 10

An article according to claim 1, wherein said first metal is iron or ferroalloy.

Claim 11

An article according to claim 1 wherein said first metal or alloy is about 57 to about 62 percent of the volume of said article.

Claim 12

An article according to claim 1, wherein said first metal or alloy is A 6 tool steel.

Claim 13

An article according to claim 1, wherein said second metal or alloy is about 25 to about 30 percent of the volume of said article.

Claim 14

An article according to claim 1, wherein said second metal or alloy is copper or copper alloy.

Claim 15

An article according to claim 1, wherein said first metal is iron or ferroalloy and said second metal or alloy is copper and manganese.

Claim 16

An article according to claim 14, wherein said manganese is about 4 to about 35 percent of the weight of said second metal or alloy.

Claim 17

An article according to claim 1, further comprising at least one layer of an intermediate composition of refractory together with first metal disposed between said refractory granules and said first metal or alloy.

Claim 18

An article according to claim 1, further comprising at least one layer of intermediate alloy of said first metal or alloy and said second metal or an alloying metal present in said second metal or alloy, disposed between said first metal or alloy and said second metal or alloy.

Claim 19

An article according to claim 1, having a Rockwell hardness greater than about 50 and a Charpy unnotched impact strength greater than about 15 joules.

Claim 20

An article according to claim 1, having a density of at least 97 percent of the theoretical density based upon the densities of said refractory, said first metal or alloy, and said second metal or alloy.

Claim 21

An article according to claim 19, having a density of at least 99 percent of said theoretical density.

Claim 22

A precision molded die cavity comprising: (a) 2 to 15 volume percent granules of tungsten carbide of about 1 to about 15 micrometers mean diameter; (b) a monolithic skeleton of about 35 to about 70 volume percent iron or ferroalloy, said iron or ferroalloy fully enveloping said tungsten carbide granules, all of the latter being uniformly dispersed in said skeleton; and (c) a continuous metallic phase of about 15 to about 50 volume percent copper occupying the connected porosity in said skeleton; said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 23

A precision molded die cavity comprising: (a) 2 to 15 volume percent granules of tungsten carbide of about 1 to about 15 micrometers mean diameter; (b) a monolithic skeleton of about 35 to about 70 volume percent iron or ferroalloy, said iron or ferroalloy fully enveloping said tungsten carbide granules, all of the latter being uniformly dispersed in said skeleton; and (c) a continuous metallic phase of about 15 to about 50 volume percent copper occupying the connected porosity in said skeleton; said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 24

A die cavity according to claim 21, wherein said tungsten carbide is about 8 to about 13 percent of the volume of said die.

Claim 25

A die cavity according to claim 21, wherein said iron or ferroalloy is about 57 to about 62 percent of the volume of said die.

Claim 26

A die cavity according to claim 21, wherein said copper is about 25 to about 30 percent of the volume of said die.

Claim 27

A die cavity according to claim 21, wherein said tungsten carbide is about 8 to about 13 percent of the volume of said die, said iron or ferroalloy is A 6 tool steel and is about 57 to about 62 percent of the volume of said die, and said copper is about 25 to about 30 percent of the volume of said die.

Claim 28

A die cavity according to claim 21, having a Rockwell hardness greater than about 50, a Charpy unnotched impact strength greater than about 15 joules, and a density of at least 97 percent of the theoretical density based upon the densities of said tungsten carbide, said iron or ferroalloy, and said copper.

Claim 29

A process for forming a precision molded composite article, comprising the steps of: (a) blending granules of a refractory having about 1 to about 100 micrometers mean diameter with granules of a first metal or alloy having about 1 to about 100 micrometers mean diameter, said refractory being metal carbide, boride, oxide, silicide, or nitride, or a metal selected from the group consisting of tungsten, molybdenum, tantalum, niobium, vanadium, and titanium, or combinations thereof, said first metal or alloy having a homogeneous crystalline appearance at a temperature below its melting point when viewed under an optical microscope and lower Rockwell hardness than said refractory, thereby forming a uniform mixture; (b) mixing said uniform mixture with up to 50 volume percent of a heat fugitive, organic binder, with the resulting mixture containing less than about 15 volume percent of said refractory and about 35 to about 70 volume percent of said first metal or alloy; (c) molding the resulting mixture in a heated flexible mold, cooling said mold and its contents to room temperature, and demolding said contents by applying a vacuum to the outside of said mold thereby forming an essentially void-free green molded preform having the size and shape of said mold; (d) heating said green molded preform to thermally remove said binder and form a rigid, handleable skeletal preform; (e) placing said skeletal preform in contact with a second metal or alloy which will wet said skeleton and which has a Rockwell hardness less than or equal to the Rockwell hardness of said first metal or alloy; (f) infiltrating said skeletal preform with said second metal or alloy by heating said skeletal preform and said second metal or alloy above the melting point of said second metal or alloy, but below the melting point of said first metal or alloy, whereby said second metal or alloy melts and wicks into the connected porosity of said preform by capillary action and said first metal or alloy fully envelopes said refractory granules, with the proviso that said refractory granules do not completely dissolve in said first metal or alloy; and (g) cooling the infiltrated part to room temperature to form a substantially void-free precision molded article.

Claim 30

A process for forming a precision molded composite article, comprising the steps of: (a) blending granules of a refractory having about 1 to about 100 micrometers mean diameter with granules of a first metal or alloy having about 1 to about 100 micrometers mean diameter, said refractory being metal carbide, boride, oxide, silicide, or nitride, or a metal selected from the group consisting of tungsten, molybdenum, tantalum, niobium, vanadium, and titanium, or combinations thereof, said first metal or alloy having a homogeneous crystalline appearance at a temperature below its melting point when viewed under an optical microscope and lower Rockwell hardness than said refractory, thereby forming a uniform mixture; (b) mixing said uniform mixture with up to 50 volume percent of a heat fugitive, organic binder, with the resulting mixture containing less than about 15 volume percent of said refractory and about 35 to about 70 volume percent of said first metal or alloy; (c) molding the resulting mixture in a heated flexible mold, cooling said mold and its contents to room temperature, and demolding said contents by applying a vacuum to the outside of said mold thereby forming an essentially void-free green molded preform having the size and shape of said mold; (d) heating said green molded preform to thermally remove said binder and form a rigid, handleable skeletal preform; (e) placing said skeletal preform in contact with a second metal or alloy which will wet said skeleton and which has a Rockwell hardness less than or equal to the Rockwell hardness of said first metal or alloy; (f) infiltrating said skeletal preform with said second metal or alloy by heating said skeletal preform and said second metal or alloy above the melting point of said second metal or alloy, but below the melting point of said first metal or alloy, whereby said second metal or alloy melts and wicks into the connected porosity of said preform by capillary action and said first metal or alloy fully envelopes said refractory granules, with the proviso that said refractory granules do not completely dissolve in said first metal or alloy; and (g) cooling the infiltrated part to room temperature to form a substantially void-free precision molded article.

Claim 31

A process according to claim 27, wherein said refractory is tungsten carbide.

Claim 32

A process according to claim 28, wherein said first metal or alloy is iron or ferroalloy.

Claim 33

A process according to claim 28, wherein said granules of first metal or alloy have about 1 to about 44 micrometers mean diameter.

Claim 34

A process according to claim 27, wherein said second metal or alloy is copper or copper alloy.

Claim 35

A process according to claim 27, wherein said second metal or alloy comprises copper and manganese.

Claim 36

A process according to claim 27, wherein said refractory is tungsten carbide, said first metal or alloy is iron or ferroalloy, said second metal or alloy is copper and is about 15 to about 50 percent of the volume of said article, and said molded article is a die cavity.

Claim 37

A process according to claim 27, wherein the change in any lineal dimension between the dimensions of said void-free green molded preform and the dimensions of said void-free precision article is less than about 1 percent.

Claim 38

A process according to claim 34, wherein said change in any lineal dimension is less than about 0.5 percent.

Claim 39

A process according to claim 34, wherein said article has a density at least 97 percent of the theoretical density of said article.

Claim 40

A process according to claim 34, wherein said article has a density at least 99 percent of the theoretical density of said article.