A heterogeneous composite consisting of near-nano ceramic clusters dispersed within a ductile matrix. The composite is formed through the high temperature compaction of a starting powder consisting of a core of ceramic nanoparticles held together with metallic binder. This core is clad with a ductile metal such that when the final powder is consolidated, the ductile metal forms a tough, near-zero contiguity matrix. The material is consolidated using any means that will maintain its heterogeneous structure.

Methods and compositions are provided for improving metal dusting corrosion, abrasion resistance and/or erosion resistance for various materials, preferably for applications relating to high-temperature reactors, including dense fluidized bed reactor components. In particular, cermets comprising (a) at least one ceramic phase selected from the group consisting of metal carbides, metal nitrides, metal borides, metal oxides, metal carbonitrides, and mixtures of thereof and (b) at least one metal alloy binder phase are provided. Ceramic phase materials include chromium carbide (Cr.sub.23C.sub.6). Metal alloy binder phase materials include β-NiAl intermetallic alloys and Ni.sub.3Sn.sub.2 intermetallic alloys, as well as alloys that contain α-Cr and/or γ′-Ni.sub.3Al hard phases. Preferably, bimetallic materials are provided when the cermet compositions are applied using a laser, e.g., a laser cladding method such as high power direct diode (HPDD) laser, or by plasma-based methods such as plasma transfer arc (PTA) welding and powder plasma welding (PPW).

A polycrystalline super hard construction is disclosed having a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, the polycrystalline super hard material comprising a plurality of grains of super hard material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface, the interface comprising a portion having an uneven topology and a substantially planar portion, the third region comprising a composite material including a first phase comprising a plurality of non-intergrown diamond grains, and a matrix material.

A method for producing hard metal powder suitable for manufacturing hard metal products including metal carbides and a binder is provided. An easy to carry out method that provides high quality hard metal powder includes: a) dissolving in water, water soluble raw materials and a binder source to form an aqueous solution, b) drying the aqueous solution to form a precursor powder having the raw materials homogenously distributed throughout the precursor powder, c) decomposing the precursor powder by heating the powder in an inert atmosphere to remove gas evolved in the decomposition of the raw materials, d) grinding the precursor powder and mixing it with a liquid media to produce a suspension, e) spray drying the suspension to agglomerate the precursor powder, and f) heat treating the agglomerated precursor powder to form a hard metal powder containing agglomerates of carbides evenly distributed and bonded to a metallic matrix.

Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.

In an under component having a proximal end and a distal end, the under component comprising a cylindrical portion extending from the proximal end to the distal end; wherein the proximal end includes a rim that extends laterally from the cylindrical portion and that is flush with the proximal end; the rim extending from the cylindrical portion, wherein the rim includes a proximal edge and a distal edge. An over component having a proximal end and a distal end and a rim having a proximal edge and a distal edge, wherein the distal end of the under component extending to a position flush with a proximal edge of the rim of the over component, wherein the distal end of the over component extending to a position flush with a distal edge of the rim of the under component. A central component, wherein the central component is coupled to the over component, and the over component is coupled to the under component

In an under component having a proximal end and a distal end, the under component comprising a cylindrical portion extending from the proximal end to the distal end; wherein the proximal end includes a rim that extends laterally from the cylindrical portion and that is flush with the proximal end; the rim extending from the cylindrical portion, wherein the rim includes a proximal edge and a distal edge. An over component having a proximal end and a distal end and a rim having a proximal edge and a distal edge, wherein the distal end of the under component extending to a position flush with a proximal edge of the rim of the over component, wherein the distal end of the over component extending to a position flush with a distal edge of the rim of the under component. A central component, wherein the central component is coupled to the over component, and the over component is coupled to the under component

A cutting tool includes a substrate of cemented carbide including hard constituents in a metallic binder. The hard constituents includes WC and the WC content in the cemented carbide is 80-96 wt%. The cemented carbide has a Ni content of 2.5-13 wt%, a weight ratio of Fe / Ni < 1.5 and a weight ratio of Co / Ni < 0.825. The cutting tool includes a rake face, a flank face and a cutting edge there between, wherein the hardness H is measured with Vickers indentation and the crack resistance W is the ratio of the load to the total crack lengths of the cracks in the corners of said Vickers indentation. The product of the hardness at the rake face H(rake) and the crack resistance at the rake face W(rake) for the cutting tool is H(rake)*W(rake) > 2000 HV100*N/.Math.m.

Provided is a NbC based cemented carbide and method of manufacture the same. The NbC based cemented carbide may be devoid of WC. The NbC based cemented carbide may be devoid of Co in the binder phase. The NbC based cemented carbide exhibits enhanced strength and thermal conductivity while maintaining desired toughness and hardness.

Provided is a NbC based cemented carbide and method of manufacture the same. The NbC based cemented carbide may be devoid of WC. The NbC based cemented carbide may be devoid of Co in the binder phase. The NbC based cemented carbide exhibits enhanced strength and thermal conductivity while maintaining desired toughness and hardness.