A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 m, at least one second local maxima at a particle size of about 200 m to about 10 mm, and at least one local minima between a particle size of about 30 m to about 200 m that has a value that is less than the first local maxima.

A spinodal copper-nickel-tin-manganese alloy is disclosed that contains from 0.001 to about 2 weight percent phosphorus. When combined with small hard particles, the alloy has sufficient fluidity to infiltrate and fill at least 90% of the interstices of the hard particles, resulting in a composite article having superior strength and toughness. This composite article can be used in drilling bits and other cutting tools, either as a support body for cutting elements or as the cutting element itself.

A spinodal copper-nickel-tin-manganese alloy is disclosed that contains from 0.001 to about 2 weight percent phosphorus. When combined with small hard particles, the alloy has sufficient fluidity to infiltrate and fill at least 90% of the interstices of the hard particles, resulting in a composite article having superior strength and toughness. This composite article can be used in drilling bits and other cutting tools, either as a support body for cutting elements or as the cutting element itself.

A hardfaced product includes a substrate and a hard composite material bonded to the substrate. The composite material includes boron carbide as a wear-resistant material and a matrix alloy including manganese and at least one of copper, silver, gold, platinum or palladium. The hardfaced product can be made by applying a molten matrix alloy to a substrate wherein the matrix alloy is combined with a wear-resistant material. The matrix alloy includes manganese and at least one of copper, silver, gold, platinum or palladium. The wear-resistant material includes boron carbide.

A method for friction stir forming a metal matrix composite (MMC) structure (76). The method includes the step of providing a substrate (12) comprising a metallic material and securing a preformed MMC layer (14, 16) comprising an MMC material in a position overlying at least a portion of the substrate (12). The method further includes the step of friction stirring the preformed MMC layer (14, 16) with a friction stirring tool (50) which includes a rotating probe (56), including locating the probe (56) at a stirring depth at which the probe (56) extends through the preformed MMC layer (14, 16) into a portion of the substrate (12) and passing the tool (50) through the preformed MMC layer (14) at the stirring depth to friction stir the preformed MMC layer (14, 16) and integrate the preformed MMC layer (14, 16) with the substrate (12).

The present invention provides a preparation method of a light metal/boron carbide composite material, comprising: (A) providing a boron carbide precursor and a light metal powder to perform a pretreatment mixing process to form a precursor; (B) performing a vacuum hot pressing molding or a vacuum cold isostatic pressing molding on the precursor to make the precursor form a light metal/boron carbide compound green body that is uniform; (C) performing a thermal treatment on the light metal/boron carbide compound green body to make the light metal/boron carbide compound green body form a light metal/boron carbide compound sintered body; and (D) performing a cold rolling treatment or a hot rolling treatment on the light metal/boron carbide compound sintered body to obtain a light metal/boron carbide composite material.