Abstract:
Hardmetal compositions each including hard particles having a first material and a binder matrix having a second, different material comprising rhenium or a Ni-based superalloy. Tungsten may also be used a binder matrix material. A two-step sintering process may be used to fabricate such hardmetals at relatively low sintering temperatures in the solid-state phase to produce substantially fully-densified hardmetals. A hardmetal coating or structure may be formed on a surface by using a thermal spray method.
Abstract:
A method is provided for fabricating ceramic microstructures, i.e., microcomponents of micron or submicron dimensions. A polymer composition is prepared containing a polymer, typically a thermally or chemically curable polymer, and nanometer size (1 to 1000 nm in diameter) ceramic particles. A mold, such as a lithographically patterned mold, preferably a LIGA mold, is filled with the polymer composition and the polymer is then cured or otherwise hardened. The elevated segments of the mold are then removed. The surface-attached ceramic microstructures so provided may then be removed from the substrate and, if desired, pyrolyzed and sintered.
Abstract:
A method of fabricating a resilient model of an article of manufacture, such as an earth-boring drill bit body or component thereof, including fabricating the resilient model of the article of manufacture by layered manufacturing techniques. The resilient model may then be employed to cast one or more molds from refractory material. The molds may be used to fabricate the modeled article of manufacture. The invention also includes a resilient, layer-manufactured model of an article of manufacture, such as an earth-boring drill bit.
Abstract:
A drill bit comprises a main body part having a shank for connection to a drill string, an end face, an internal passage for supplying drilling fluid to the end face, a number of blades extending from the end face outwardly and longitudinally of the central axis of rotation of the bit, and a number of cutters mounted on each said blade. Each blade comprises a central metal core at least partly surrounded by solid infiltrated matrix material. A method of manufacturing such a drill bit includes the steps of providing a metal mandrel having said shank and internal passage, and providing on the mandrel, so as to be supported by it, a number of blade cores each having a portion extending outwardly and longitudinally of the central axis of the mandrel, casting infiltrated matrix material around at least a part of each core and around at least a part of the mandrel to form the blades, and then removing portions of the cores so as to detach each core from support by the mandrel to leave within each blade a core which is substantially wholly supported by the surrounding matrix material.
Abstract:
The invention relates to components which are produced or processed by powder metallurgy, and to processes for producing components of this type. The components produced by powder metallurgy are intended both to have porous regions and to provide fluid-tight properties, and it should also be possible to produce them at correspondingly low cost and suitably flexibly. For this purpose, a component of this type has at least one porous region, which is formed from an intermetallic phase or solid solutions. However, it may also have a corresponding surface coating. Moreover, in a component of this type there is at least one areal fluid-tight region which is formed from a meta or metal alloy of the corresponding intermetallic phase or solid solution.
Abstract:
A material is disclosed which produced by a process in which a mold is filled of deformable shaped bodies, after which the mold is filled with a base material. The bodies are removed and the solidified base material forms a material of shell-like structures and an interconnecting pore system between the skeleton structures. The material produced by the process can be used as bone replacement materials, implants, filters and drug delivery systems.
Abstract:
Shaped article replicas which are proportionately accurate replicas of a shaped article and which are equal, greater or smaller in size than said shaped article are made by preparing a swellable polymer replica of said shaped article; immersing said swellable polymer replica in a swelling agent system under conditions which will enlarge said polymer replica to a predetermined extent; forming a casting mold of such enlarged polymer replica; making a powder compact in said casting mold and heating said powder compact to produced a proportionately accurate solid replica of a predetermined size.
Abstract:
A well production assembly includes a production tree which has a lateral production passage extending laterally from a vertical bore of the tree. A tubing hanger, also having a lateral production passage, lands in the tree, with the lateral passages registering with each other. The junction of the lateral passages has flat, tapered sealed areas which mate with one another. An annulus passage extends vertically through the tubing hanger offset from and parallel to the tubing hanger vertical production passage. The annulus passage also has a lateral passage which registers with the lateral passage formed in the tree. The annulus lateral passages have a flat seal area at their junction. The tubing hanger has a downward facing hydraulic connector which registers with an upward facing hydraulic connector located on a shoulder formed in the bore. Once mated, the connectors provide hydraulic or other auxiliary fluid communication to downhole equipment.
Abstract:
A drill bit comprises a main body part having a shank for connection to a drill string, an end face, an internal passage for supplying drilling fluid to the end face, a number of blades extending from the end face outwardly and longitudinally of the central axis of rotation of the bit, and a number of cutters mounted on each said blade. Each blade comprises a central metal core at least partly surrounded by solid infiltrated matrix material. A method of manufacturing such a drill bit includes the steps of forming a main body part from metal, applying to the outer surface of the main body part a coating layer of wax which liquefies at elevated temperature, applying to the coated body part mold-forming material to provide a self-supporting mold surrounding the coated body part, and raising the temperature of the body and surrounding mold sufficiently to liquefy the coating material. The liquefied coating is then drained from the mold, and the cavities left by the coating material are packed with powdered matrix material, which is then infiltrated with a binder alloy at elevated temperature to form a solid infiltrated matrix layer, on the bit body part, corresponding to the layer of wax previously applied.
Abstract:
In forming an article, such as a turbine blade, of metal powder, a container is first formed by electroplating a thin layer of metal over a pattern having a configuration which corresponds to the configuration of the article. The pattern is then removed to leave a container having a cavity with a configuration corresponding to the configuration of the article. The container is filled with metal powder and sealed. The container is then at least partially enclosed with a rigid body of fluid permeable material having inner side surface areas disposed in abutting engagement with the container. Heat and fluid pressure are transmitted through the rigid body to compact the container and metal powder. The fluid pressure causes the side walls of the container to move away from the inner side surfaces of the rigid body of fluid permeable material. As this is occurring, the rigid body of fluid permeable material supports the container and holds it against excessive deflection under the influence of stresses induced in the container.