INTERLOCKING COMPONENTS FOR FORMING A WEAR RESISTANT LAYER
A wear-protected substrate includes a substrate and a continuous wear protection layer brazed to the substrate. The continuous wear protection layer includes components having interlocking features that are configured to interlock the components side-by-side to form the continuous wear protection layer.
1 . A wear-protected substrate, comprising:
a substrate; and
a continuous wear protection layer brazed to the substrate, wherein the continuous wear protection layer comprises components having interlocking features that are configured to interlock the components side-by-side to form the continuous wear protection layer.
2 . The wear-protected substrate of claim 1 , wherein the interlocking features comprise dovetail, mortises, keyholes, or a combination thereof.
3 . The wear-protected substrate of claim 1 , wherein the components are attached to one another via one or more methods comprising brazing, gluing, shrink fitting, tight fitting, tight interfacing, epoxying, or a combination thereof.
4 . The wear-protected substrate of claim 3 , wherein the components are attached to one another via brazing, and a brazing alloy is disposed along the interlocking features and between the components.
5 . The wear-protected substrate of claim 1 , wherein the components are formed of diamond, polycrystalline diamond (PCD), PCD on a carbide substrate, carbide, cBN silicon carbide (SiC)-diamond, thermally stable diamond composite, or a combination thereof.
6 . The wear-protected substrate of claim 1 , wherein the substrate is formed of metal, metal alloy, steel, superalloy, Inconel alloy, or composite.
7 . The wear-protected substrate of claim 1 , wherein the area of the continuous wear-protection layer is scalable by increasing or decreasing the number of components.
8 . The wear-protected substrate of claim 1 , wherein the continuous wear-protection layer is substantially free of gaps between the components that are brazed to one another and/or brazed to the substrate.
9 . The wear-protected substrate of claim 1 , wherein the continuous wear protection layer is brazed to the substrate using a brazing alloy comprising ticusil, incusil, or a combination thereof.
10 . A method of forming a protected substrate, comprising:
providing a plurality of components having interlocking features, wherein the plurality of components are formed of diamond, PCD, PCD on a carbide substrate, carbide, SiC-diamond, thermally stable diamond composite, or a combination thereof;
providing a substrate;
assembling and attaching the plurality of components to the substrate; and
forming a continuous protection layer on the substrate.
11 . The method of claim 10 , comprising disposing a brazing alloy on the substrate.
12 . The method of claim 10 , comprising assembling the plurality of components on the brazing alloy and the substrate.
13 . The method of claim 10 , comprising attaching the plurality of components side-by-side via one or more methods comprising brazing, gluing, shrink fitting, tight fitting, tight interfacing, epoxying, or a combination thereof.
14 . The method of claim 10 , comprising brazing the assembled components on the substrate.
15 . A wear protection layer brazed to a substrate, wherein the wear protection layer comprises components having interlocking features that are configured to interlock the components side-by-side, and wherein the wear protection layer is continuous and substantially free of gaps between the components.
16 . The wear protection layer of claim 15 , wherein the interlocking features comprise dovetail, mortises, keyholes, or a combination thereof.
17 . The wear protection layer of claim 15 , wherein the components are formed of diamond, PCD, PCD on a carbide substrate, carbide, SiC-diamond, thermally stable diamond composite, or a combination thereof.
18 . The wear protection layer of claim 15 , wherein the components are attached to one another via one or more methods comprising brazing, gluing, shrink fitting, tight fitting, tight interfacing, epoxying, or a combination thereof.
19 . The wear protection layer of claim 15 , wherein the components are attached to one another via brazing, and a brazing alloy is disposed along the interlocking features and/or between the components.
20 . The wear protection layer of claim 15 , comprises a brazing alloy disposed between the components.