Dimensionally-controlled cobalt-containing precision molded metal article

Claim 2

A shaped, homogeneous, monolithic metal article, comprising: A. a skeleton, comprising (i) a plurality of generally spherical domains having an average diameter less than about 200 micrometers, said domains, when viewed using backscattered electron imaging, comprising granules of chromium carbide homogeneously dispersed throughout a first solid solution comprising cobalt and chromium; (ii) a second solid solution comprising cobalt and chromium, said second solid solution (a) containing a greater percentage of cobalt and a lesser percentage of chromium than said first solid solution, (b) being essentially free of carbides, and (c) enveloping the majority of said spherical domains, the so-enveloped domains and second solid solution being interconnected to form said skeleton; and (iii) iron or nickel as an additional component of said first and second solid solutions; and B. infiltrant, comprising a continuous phase of metal or alloy occupying the volume of said article not occupied by said skeleton; said skeleton and said infiltrant thereby comprising two intermeshed matrices and said article being substantially void-free.

Claim 3

An article according to claim 1, further comprising granules of tungsten carbide homogeneously dispersed throughout said first solid solution.

Claim 4

An article according to claim 1, wherein the total content of iron and nickel in said second solid solution is greater than the total content of iron and nickel in said first solid solution.

Claim 5

An article according to claim 3, wherein the percentage content of iron plus nickel in said second solid solution is 1.3 or more times as great as the percentage content of iron plus nickel in said first solid solution.

Claim 6

An article according to claim 1, wherein said second solid solution comprises cobalt, chromium, iron, and carbon.

Claim 7

An article according to claim 5, wherein said first solid solution contains about 6% or more iron, and said second solid solution contains about 7% or more iron.

Claim 8

An article according to claim 5, wherein said first solid solution contains about 10% or more iron, and said second solid solution contains about 13% or more iron.

Claim 9

An article according to claim 1, wherein said spherical domains have an average diameter between about 1 and about 44 micrometers.

Claim 10

An article according to claim 1, wherein the portions of said second solid solution enveloping individual spherical domains have an average thickness, measured radially outward from the center of such spherical domains, of 5 micrometers or less.

Claim 11

A shaped, homogeneous, monolithic metal article, comprising: A. a skeleton, comprising (i) a plurality of generally spherical domains having an average diameter between about 1 and about 44 micrometers, said domains, when viewed using backscattered electron imaging, comprising granules of chromium carbide and granules of tungsten carbide homogeneously dispersed throughout a first solid solution comprising cobalt, chromium, and at least 6% by weight iron; (ii) a second solid solution comprising cobalt, chromium, and at least 7.8% by weight iron, said second solid solution (a) containing a greater percentage of cobalt and a lesser percentage of chromium than said first solid solution, (b) being essentially free of carbides, and (c) enveloping the majority of said spherical domains, with the portions of said second solid solution enveloping individual spherical domains having an average thickness, measured radially outward from the center of such spherical particles, of 5 micrometers or less, and with the so-enveloped domains and second solid solution being interconnected to form said skeleton; and B. infiltrant, comprising a continuous phase of copper/tin alloy occupying the volume of said article not occupied by said skeleton; said skeleton and said infiltrant thereby comprising two intermeshed matrices and said article being substantially void-free.

Claim 12

A shaped, homogeneous, monolithic metal article, comprising: A. a skeleton, comprising (i) a plurality of generally spherical domains having an average diameter between about 1 and about 44 micrometers, said domains, when viewed using backscattered electron imaging, comprising granules of chromium carbide and granules of tungsten carbide homogeneously dispersed throughout a first solid solution comprising cobalt, chromium, and at least 6% by weight iron; (ii) a second solid solution comprising cobalt, chromium, and at least 7.8% by weight iron, said second solid solution (a) containing a greater percentage of cobalt and a lesser percentage of chromium than said first solid solution, (b) being essentially free of carbides, and (c) enveloping the majority of said spherical domains, with the portions of said second solid solution enveloping individual spherical domains having an average thickness, measured radially outward from the center of such spherical particles, of 5 micrometers or less, and with the so-enveloped domains and second solid solution being interconnected to form said skeleton; and B. infiltrant, comprising a continuous phase of copper/tin alloy occupying the volume of said article not occupied by said skeleton; said skeleton and said infiltrant thereby comprising two intermeshed matrices and said article being substantially void-free.

Claim 13

A die cavity according to claim 10.

Claim 14

In a process for making infiltrated molded metal articles by molding in a flexible mold of a master a plastic mixture of spherical cobalt-containing powder and heat fugitive binder comprising thermoplastic material to form a green article of predetermined shape and dimensions, removing said green article from said mold, heating said green article to remove said binder and consolidate said spherical cobalt-containing powder in the form of a porous, monolithic skeleton of particles of cobalt-containing metal, infiltrating said skeleton with a molten metal having a melting point that is at least 25° C. less than the melting point of the lowest melting of said cobalt-containing metal particles, and cooling the infiltrated skeleton, the improvement comprising adding to said spherical cobalt-containing powder up to about 11% by weight, based on the weight of said spherical cobalt-containing powder, of elemental iron or elemental nickel particles having an average particle diameter less than about 10 micrometers.

Claim 15

In a process for making infiltrated molded metal articles by molding in a flexible mold of a master a plastic mixture of spherical cobalt-containing powder and heat fugitive binder comprising thermoplastic material to form a green article of predetermined shape and dimensions, removing said green article from said mold, heating said green article to remove said binder and consolidate said spherical cobalt-containing powder in the form of a porous, monolithic skeleton of particles of cobalt-containing metal, infiltrating said skeleton with a molten metal having a melting point that is at least 25° C. less than the melting point of the lowest melting of said cobalt-containing metal particles, and cooling the infiltrated skeleton, the improvement comprising adding to said spherical cobalt-containing powder up to about 11% by weight, based on the weight of said spherical cobalt-containing powder, of elemental iron or elemental nickel particles having an average particle diameter less than about 10 micrometers.

Claim 16

A process according to claim 12, wherein said elemental iron is carbonyl iron or said elemental nickel is carbonyl nickel.

Claim 17

A process according to claim 12, wherein said particles of cobalt-containing metal have an average particle diameter between about 1 and about 44 micrometers, said elemental particles are carbon-bearing carbonyl iron particles having an average particle diameter between about 3 and about 5 micrometers, and said article is a die cavity.