A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

The present invention relates to a method for producing metal-comprising geometrically complex pieces and/or parts. The method is specially indicated for highly performant components. It is disclosed a method for the production of complex geometry, and even large, highly performant metal-comprising components in a cost effective way. The method is also indicated for the construction of components with internal features and voids. The method is also beneficial for light construction. The method allows the reproduction of bio-mimetic structures and other advanced structures for topological performance optimization.

Sintered cemented carbides are described herein exhibiting enhanced high temperature properties without dramatic losses in bending strength. In some embodiments, a sintered cemented carbide composition comprises tungsten carbide, a metallic binder phase comprising at least one metal of the iron group, and at least one solid solution carbide phase comprising tantalum (Ta) and molybdenum (Mo), wherein a value of (Mo/Ta) in the sintered cemented carbide composition is from 0.3-100, and the sintered cemented carbide composition has a transverse rupture strength of at least 4000 MPa.

A mixture for forming a wear resistant layer on a substrate comprises particles of a first wear resistant particle type, particles of a second wear resistant particle type and a wear resistant layer binder for binding the first and the second wear resistant particles in the wear resistant layer when the layer is formed. As well, wear resistant particle size distributions for the first and second wear resistant particle types have a first mode and a second mode. The first particle type is associated with the first mode and the second particle type is associated with the second mode. Moreover, a number of first wear resistant particles associated with the first mode is larger than a number of second wear resistant particles associated with the second mode. Further, the second mode is larger than the first mode.

A mixture for forming a wear resistant layer on a substrate comprises particles of a first wear resistant particle type, particles of a second wear resistant particle type and a wear resistant layer binder for binding the first and the second wear resistant particles in the wear resistant layer when the layer is formed. As well, wear resistant particle size distributions for the first and second wear resistant particle types have a first mode and a second mode. The first particle type is associated with the first mode and the second particle type is associated with the second mode. Moreover, a number of first wear resistant particles associated with the first mode is larger than a number of second wear resistant particles associated with the second mode. Further, the second mode is larger than the first mode.

Cemented carbide contains a first hard phase and a binder phase. The first hard phase is composed of tungsten carbide particles. The binder phase is composed of cobalt, nickel, iron, and copper as constituent elements. An average content of each of the constituent elements is not lower than 10 atomic % and not higher than 30 atomic %. Cemented carbide contains no second hard phase, or a content of the second hard phase is equal to or lower than 2 mass % of a total amount of cemented carbide. The second hard phase is composed of a compound containing at least one type of a metal element selected from the group consisting of a group-IV element, a group-V element, and a group-VI element in a periodic table except for tungsten and at least one type of an element selected from the group consisting of carbon, nitrogen, and oxygen.

Cemented carbide contains a first hard phase and a binder phase. The first hard phase is composed of tungsten carbide particles. The binder phase is composed of cobalt, nickel, iron, and copper as constituent elements. An average content of each of the constituent elements is not lower than 10 atomic % and not higher than 30 atomic %. Cemented carbide contains no second hard phase, or a content of the second hard phase is equal to or lower than 2 mass % of a total amount of cemented carbide. The second hard phase is composed of a compound containing at least one type of a metal element selected from the group consisting of a group-IV element, a group-V element, and a group-VI element in a periodic table except for tungsten and at least one type of an element selected from the group consisting of carbon, nitrogen, and oxygen.

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

The present disclosure relates to a method of making a cemented carbide mining insert, a cemented carbide mining insert with having a chemical and hardness gradient and to the use thereof. The method includes the steps of providing a green mining insert compact formed from a first powder including a WC-based hard phase, optionally one or more further hard-phase components and a binder, applying a second powder including a grain refiner compound and/or a carbon based grain growth promoter to at least one portion of a surface of the green mining insert compac, and sintering the green mining insert compact to produce a cemented carbide mining insert, wherein the first powder additionally includes Cr, in an amount such that the mass ratio of Cr/binder is of 0.01-0.3.

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.