A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa√m.

A drill bit having reinforced binder zones and method of forming same are disclosed. The method includes the steps of mixing reinforcing particles with a binder-reinforcing material, placing the mixture of reinforcing particles and binder-reinforcing material in a mold used in forming a body of the drill bit, placing a universal binder in the mold, and heating the mold. The binder-reinforcing material is infiltrated with the universal binder which thereby forms reinforced binder zones.

A cermet, as a base, containing a plurality of hard particles and a bonded phase between the plurality of hard particles. Each of the plurality of hard particles, when viewed in cross section, includes a first region containing Ti, N, and C, and contains a titanium carbonitride phase as a main constituent. Each of the plurality of hard particles, when viewed in cross-section, includes a second region containing one or more metal elements selected from the group consisting of V, Nb, Ta, Cr, Mo, W, Co, and Ni in a larger amount than the first region. The content of the one or more metal elements in the second region is 9.5 mass % or more in a total amount. A cutting tool has a length extending from a first end to a second end, and includes a holder and the insert described above.

A method of manufacturing a device includes thermally spraying tungsten carbine in feedstock that does not include Cobalt but that includes Nickel, Copper, or a Nickel-Copper alloy, the method improves the base coating toughness, anticorrosion, and antifouling properties for high load application in sea water and brackish water environments. Additionally, a Cobalt-free material lowers material costs and reduces the global demand of Cobalt. Providing a topcoat of a Silicon-doped DLC significantly reduces the topcoat brittleness of common DLC failures such as “egg shell” in high stress applications. Thus, high hardness, low friction applications may be tailored in high stress applications.

A composite structure with an aluminum-based alloy layer containing boron carbide and a manufacturing method thereof are provided. The composite structure includes a substrate with an open hole in that surface and the aluminum-based alloy layer containing boron carbide. The aluminum-based alloy layer is disposed in the open hole and contains aluminum, boron, carbon, and oxygen, wherein the content of aluminum is between 4 at. % and 55 at. %, the content of boron is between 9 at. % and 32 at. %, the content of carbon is between 13 at. % and 32 at. %, the content of oxygen is between 2 at. % and 38 at. %, and the ratio of the content of boron to carbon is between 0.3 and 2.7.

A composite structure with an aluminum-based alloy layer containing boron carbide and a manufacturing method thereof are provided. The composite structure includes a substrate with an open hole in that surface and the aluminum-based alloy layer containing boron carbide. The aluminum-based alloy layer is disposed in the open hole and contains aluminum, boron, carbon, and oxygen, wherein the content of aluminum is between 4 at. % and 55 at. %, the content of boron is between 9 at. % and 32 at. %, the content of carbon is between 13 at. % and 32 at. %, the content of oxygen is between 2 at. % and 38 at. %, and the ratio of the content of boron to carbon is between 0.3 and 2.7.

The present disclosure relates to a hierarchical wear part including a reinforced portion comprising zirconia or an alumina-zirconia alloy. The reinforced portion also includes centimetric inserts with a predefined geometry. The inserts include micrometric particles of metal carbides, nitrides, borides, or intermetallic compounds bonded by a first metal matrix. The inserts are inserted into a reinforcement structure infiltrated by a second metal matrix, the reinforcement structure having a periodic alternation of millimetric areas of high and low concentration of micrometric particles of zirconia or alumina-zirconia alloy. The second metal matrix is different from the first metal matrix.

Embodiments are directed to the field of ceramics and relate to electron-emitting ceramics such as those which can be used as cathode material for electron emissions in space flight systems, for example. Embodiments specify an electron-emitting ceramic which has an improved temperature conductivity with a simultaneously continuous electron emission. The electron-emitting ceramic contains at least>70 vol. % C12A7 electride and a proportion of Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Ru, Os, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, In, Sn, Sb, Te, Tl, Pb, or Bi as metal and/or with Ti, wherein the proportion of the metals lies between>0 and<30 vol. %, and the ceramic has a density of at least 85% of the theoretical density of the ceramic and the ceramic contains 0 to maximally 10 vol. % production-specific impurities.

A process for manufacturing ceramic-metal composite material, comprises dissolving ceramic powder into water to obtain an aqueous solution of ceramic; mixing metal powder having a multimodal particle size where largest particle size is one fourth of the minimum dimension of a device, with the aqueous solution of ceramic to obtain a powder containing ceramic precipitated on the surface of metal particles; mixing the powder containing ceramic precipitated on the surface of the metal particles, with ceramic powder having a particle size below 50 μm, to obtain a powder mixture; adding saturated aqueous solution of ceramic to the powder mixture to obtain an aqueous composition containing ceramic and metal; compressing the aqueous composition to form a disc of ceramic-metal composite material containing ceramic and metal; and removing water from the ceramic-metal composite material; wherein ceramic content of the disc is 10 vol-% to 35 vol-%. Alternatively, ceramic-ceramic composite material may be manufactured.

A process for manufacturing ceramic-metal composite material, comprises dissolving ceramic powder into water to obtain an aqueous solution of ceramic; mixing metal powder having a multimodal particle size where largest particle size is one fourth of the minimum dimension of a device, with the aqueous solution of ceramic to obtain a powder containing ceramic precipitated on the surface of metal particles; mixing the powder containing ceramic precipitated on the surface of the metal particles, with ceramic powder having a particle size below 50 μm, to obtain a powder mixture; adding saturated aqueous solution of ceramic to the powder mixture to obtain an aqueous composition containing ceramic and metal; compressing the aqueous composition to form a disc of ceramic-metal composite material containing ceramic and metal; and removing water from the ceramic-metal composite material; wherein ceramic content of the disc is 10 vol-% to 35 vol-%. Alternatively, ceramic-ceramic composite material may be manufactured.