Methods of forming a metallic or ceramic article having a novel composition of functionally graded material and articles containing the same

摘要

There is disclosed a method of making a metallic or ceramic component, such as a cutting or forming tool, from at least two distinct powder precursors. In one embodiment, the method comprising forming a first mixture comprised of a plurality of coated particles, such as Tough-Coated Hard Powder (TCHP) composite particles created by encapsulating extremely hard core particles with very tough binder and structural materials, and at least one support powder, such as a carbide, typically WC—Co. The mixture is formed into a green body and sintered to form a functionally graded or multicomponent article. Non-limiting examples of the articles made from the disclosed methods are also disclosed and include drills, mills, cutting tools, forming tools, wires dies and mechanical components.

主权项

1. A method of making a metallic or ceramic component, said method comprising:
a) providing at least one first powder, said first powder comprising a plurality of composite particles, made of a core particle material, an intermediate layer on said core particle material, and an outer layer, wherein said core particle material has a hardness higher than both the intermediate layer and the outer layer, and said intermediate layer has a fracture toughness greater than both the core particle material and the outer layer; b) providing at least one second powder comprising a carbide material; c) forming a green body comprised of said first and second powder mixtures such that the first powder mixture forms a first portion of said green body with the second powder mixture forming a second portion of said green body; d) molding, pressing or shaping said green body to form a compact; and e) sintering said compact to form an article having portions of different juxtaposed properties, said first portion of said green body forming hard wear-resistant portion of said article and said second portion of said green body forming a tough, strong load bearing portion of said article.