Abrasive compact with improved machinability
View Patent ↗An abrasive compact may include an ultra-hard phase that may include ultra-hard particles having a Knoop hardness of 5000 KHN or greater, a sinter catalyst, and a reaction phase that may include a catalyst-ceramic compound having a Knoop hardness lower than that of the ultra-hard phase.
1. A method of producing an abrasive compact comprising:
blending ultra-hard particles having a Knoop hardness of 5000 KHN or greater, a sinter catalyst, and reactant particles selected from the group consisting of hexagonal boron nitride, graphite, molybdenum sulfide, tungsten sulfide, a phosphide, or combinations thereof and having a Knoop hardness lower than that of the ultra-hard particles to form a mixture; and
sintering the mixture so that the reactant particles react with the sinter catalyst to form a reaction phase to yield a sintered compact, wherein the reaction phase has a Knoop hardness lower than that of cubic boron nitride.
2. The method of claim 1 , wherein the sintering comprises applying to the mixture a temperature from about 1000° C. to about 2200° C., and a pressure of about 40 kbar to about 200 kbar, for a sintering time of about 5 minutes to about 300 minutes.
3. The method of claim 1 , further comprising pre-coating the reactant particles with the sinter catalyst prior to the blending.
4. The method of claim 1 , further comprising shaping the sintered compact.
5. The method of claim 1 , wherein the sinter catalyst comprises one or more of Fe, Co, W, Mn, Ni, or a compound thereof.
6. The method of claim 1 , wherein, the reaction phase comprises about 0.5 to 20 weight-percent of the abrasive compact.
7. A method of producing an abrasive compact comprising:
sintering ultra-hard particles, a sinter catalyst, and reactant particles so that the reactant particles react with the sinter catalyst to form a reaction phase where the reactant particles are selected from the group consisting of hexagonal boron nitride, graphite, molybdenum sulfide, tungsten sulfide, a phosphide, or combinations thereof and the reaction phase has a Knoop hardness lower than that of cubic boron nitride; and
bonding the reaction phase to the ultra-hard particles to yield a sintered compact.
8. The method of claim 7 further comprising blending ultra-hard particles, a sinter catalyst, and reactant particles into a mixture.
9. The method of claim 7 wherein the reaction phase comprises boron containing product.
10. The method of claim 9 , wherein the boron containing product further comprises tungsten and cobalt.
11. The method of claim 9 , wherein the boron containing product is Co 6 W 6 B 6 .
12. The method of claim 9 , wherein the boron containing product is W 2 Co 21 B 6 .
13. The method of claim 7 , wherein the reactant is pre-coated with the sinter catalyst.
14. A method of making an abrasive compact, comprising:
blending ultra-hard particles having a Knoop hardness of 5000 KHN or greater, a sinter catalyst, and reactant particles selected from the group consisting of hexagonal boron nitride, graphite, a metallic sulfide, an intermetallic sulfide, a metal phosphide, an intermetallic phosphide, or combinations thereof to form a mixture; and
sintering the mixture so that the reactant particles form a reaction phase to yield a sintered compact so that the reaction phase has a Knoop hardness lower than that of cubic boron nitride.
15. The method of claim 14 , wherein the reactant particles react with the sinter catalyst to form a reaction phase.
16. The method of claim 14 , wherein the sinter catalyst comprises one or more of Fe, Co, W, Mn, Ni, or a compound thereof.
17. The method of claim 14 , further comprising pre-coating the reactant particles with the sinter catalyst prior to the blending.