High-Performance Friction Stir Welding Tools

BACKGROUND

This application relates to hardmetal compositions, their fabrication techniques, and associated applications.

Hardmetals include various composite materials and are specially designed to be hard and refractory, and exhibit strong resistance to wear. Examples of widely-used hardmetals include sintered or cemented carbides or carbonitrides, or a combination of such materials. Some hardmetals, called cermets, have compositions that may include processed ceramic particles (e.g., TiC) bonded with binder metal particles. Certain compositions of hardmetals have been documented in the technical literature. For example, a comprehensive compilation of hardmetal compositions is published in Brookes' World Dictionary and Handbook of Hardmetals, sixth edition, International Carbide Data, United Kingdom (1996).

Hardmetals may be used in a variety of applications. Exemplary applications include cutting tools for cutting metals, stones, and other hard materials, wire-drawing dies, knives, mining tools for cutting coals and various ores and rocks, and drilling tools for oil and other drilling applications. In addition, such hardmetals also may be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.

Many hardmetals may be formed by first dispersing hard, refractory particles of carbides or carbonitrides in a binder matrix and then pressing and sintering the mixture. The sintering process allows the binder matrix to bind the particles and to condense the mixture to form the resulting hardmetals. The hard particles primarily contribute to the hard and refractory properties of the resulting hardmetals.

SUMMARY

This application describes designs of friction stir welding (FSW) heads and associated FSW systems that use such heads. In various implementations, a FSW head can include a pin and a shoulder to which the pin is engaged. The head is engaged to a shank which is in turn fixed to a rotor. The rotor rotates the shank which spins the head during welding. In operation, the spinning head is pressed to the interface of two metal pieces to be welded together and is moved along the interface. The pin and the shoulder are in direct contact with the two pieces to weld them together. In some imple,mentations, the pin and the shoulder are made of a hardmetal material described in this application. In other implementations, the surfaces of the pin and shoulder may be made of a material described in this application while the inner parts of the pin and shoulder may be made of a different material. Various materials described here exhibit high hardness and toughness under a high temoperature experienced by the pin and shoulder during the friction stir welding and thus can be used for constructing the head.

For example, a friction stir welding tool head described in this application includes a shoulder and a pin engaged to the shoulder. At least one part of each of the shoulder and the pin includes a material described in this application. This material can include, at least, (1) a first material which includes at least one of or a combination of at least one carbide, at least one nitride, at least one boride, and at least one silicide, and (2) a second material that binds the first material and includes rhenium, a mixture of rhenium and cobalt, a nickel-based superalloy, a mixture of a nickel-based superalloy and rhenium, or a mixture of a nickel-based superalloy, rhenium and cobalt. The second material may also include Mo, W, Ta, or Cr. In implementating the above examples, the first material may include at least at least one carbide selected from at least one of TaC, HfC, NbC, ZrC, TiC, WC, VC, Al₄C₃, ThC₂, Mo₂C, SiC and B₄C, or at least one nitride selected from at least one of HfN, TaN, BN, ZrN, and TiN, or at least one boride selected from at least one of HfB₂, ZrB₂, TaB₂, TiB₂, NbB₂, and WB.

The hardmetal materials described below include materials comprising hard particles having a first material, and a binder matrix having a second, different material. The hard particles are spatially dispersed in the binder matrix in a substantially uniform manner. The first material for the hard particles may include, for example, materials based on tungsten carbide, materials based on titanium carbide, materials based on a mixture of tungsten carbide and titanium carbide, other carbides, nitrides, borides, silicides, and combinations of these materials. The second material for the binder matrix may include, among others, rhenium, a mixture of rhenium and cobalt, a nickel-based superalloy, a mixture of a nickel-based superalloy and rhenium, a mixture of a nickel-based superalloy, rhenium and cobalt, and these materials mixed with other materials. Tungsten may also be used as a binder matrix material in hardmetal materials. The nickel-based superalloy may be in the γ-γ′ metallurgic phase.

In various implementations, for example, the volume of the second material may be from about 3% to about 40% of a total volume of the material. For some applications, the binder matrix may comprise rhenium in an amount at or greater than 25% of a total weight of the binder matrix of the final material. For other applications, the second material may include a Ni-based superalloy. The Ni-based superalloy may include Ni and other elements such as Re for certain applications.

Fabrication of the hardmetal materials of this application may be carried out by, according to one implementation, sintering the material mixture under a vacuum condition and performing a solid-phase sintering under a pressure applied through a gas medium. Such hardmetals may also be coated on surfaces using thermal spray methods to form either hardmetal coatings and hardmetal structures.

Advantages arising from various implementations of the described hardmetal materials may include one or more of the following: superior hardness in general, enhanced hardness at high temperatures, and improved resistance to corrosion and oxidation.

Various specific implementations described in this application are summarized as follows. The first group of 265 specific implementations is as follows.

1. A material comprising:

hard particles having a first material; and

a binder matrix having a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium in an amount greater than 25% of a total weight of the material, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

2. The material as in the above item no. 1 or below item no. 14, wherein said first material includes a carbide comprising tungsten.

3. The material as in the above item no. 2, wherein said carbide comprises mono tungsten carbide (WC).

4. The material as in the above item no. 2, wherein said first material further includes another carbide having a metal element different from tungsten.

5. The material as in the above item no. 4, wherein said metal element is titanium (Ti).

6. The material as in the above item no. 4, wherein said metal element is tantalum (Ta).

7. The material as in the above item no. 4, wherein said metal element is niobium (Nb).

8. The material as in the above item no. 4, wherein said metal element is vanadium (V).

9. The material as in the above item no. 4, wherein said metal element is chromium (Cr).

10. The material as in the above item no. 4, wherein said metal element is hafnium (Hf).

11. The material as in the above item no. 4, wherein said metal element is molybdenum (Mo).

12. The material as in the above item no. 2, wherein said first material further includes a nitride.

13. The material as in the above item no. 2 or 12, wherein said nitride includes TiN, ZrN, VN, NbN, TaN or HfN.

14. A material, comprising:

hard particles comprising a first material which comprises a nitride; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

15. The material as in the above item no. 14, wherein said nitride includes TiN, ZrN, VN, NbN, TaN or HfN.

16. The material as in the above item no. 1, wherein said binder matrix further includes cobalt (Co).

17. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and nickel (Ni), wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

18. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and molybdenum (Mo), wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

19. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and iron (Fe), wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

20. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and chromium (Cr), wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

21. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material, a volume of said second material being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and a Ni-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

22. The material as in the above item no. 21, wherein said binder material further includes cobalt.

23. A material comprising:

hard particles having a first material having a mixture selected from at least one from a group consisting of (1) a mixture of WC, TiC, and TaC, (2) a mixture of WC, TiC, and NbC, (3) a mixture of WC, TiC, and at least one of TaC and NbC, and (4) a mixture of WC, TiC, and at least one of HfC and NbC; and

a binder matrix having a second, different material, a volume of said binder matrix being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

24. A material comprising:

hard particles having a first material comprising a material selected from at least one from a group consisting of (1) WC, TiC, and TaC, (2) WC, TiC, and NbC, (3) WC, TiC, and at least one of TaC and NbC, and (4) WC, TiC, and at least one of HfC and NbC; and

a binder matrix comprising a second, different material, a volume of said binder matrix being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and

a Ni-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

25. A material comprising:

hard particles having a first material having a mixture of Mo₂C and TiC; and

26. A material, comprising:

hard particles comprising a first material which comprises TiN, Mo₂C and TiC; and

a binder matrix comprising a second, different material, a volume of said binder matrix being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

27. A material, comprising:

hard particles comprising a first material comprising Mo₂C and TiC; and

a binder matrix comprising a second, different material, a volume of said binder matrix being from about 3% to about 40% of a total volume of the material, said binder matrix comprising rhenium and a Ni-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

28. A method comprising:

forming a grade power by mixing a powder of hard particles with a binder matrix material comprising rhenium;

processing the grade powder to use the binder matrix material to bind the hard particles to produce a solid hardmetal material, wherein the processing includes (1) sintering the grade powder in a solid phase under a vacuum condition, and (2) sintering the grade power in a solid phase under a pressure in an inert gas medium.

29. The method as in the above item no. 28, wherein the binder matrix material further includes a Ni-based superalloy.

30. The method as in the above item no. 29, wherein the binder matrix material further includes cobalt.

31. The method as in the above item no. 28, wherein the binder matrix material further includes cobalt.

32. The method as in the above item no. 28, wherein each sintering is performed a temperature below an eutectic temperature of the hard particles and the binder matrix material.

33. A material comprising:

hard particles having a first material; and

a binder matrix having a second, different material comprising a nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

34. The material as in the above item no. 33 or 47, wherein said first material includes a carbide comprising tungsten.

35. The material as in the above item no. 34, wherein said carbide comprises mono tungsten carbide (WC).

36. The material as in the above item no. 34, wherein said first material further includes another carbide having a metal element different from tungsten.

37. The material as in the above item no. 36, wherein said metal element is titanium (Ti).

38. The material as in the above item no. 36, wherein said metal element is tantalum (Ta).

39. The material as in the above item no. 36, wherein said metal element is niobium (Nb).

40. The material as in the above item no. 36, wherein said metal element is vanadium (V).

41. The material as in the above item no. 36, wherein said metal element is chromium (Cr).

42. The material as in the above item no. 36, wherein said metal element is hafnium (Hf).

43. The material as in the above item no. 36, wherein said metal element is molybdenum (Mo).

44. The material as in the above item no. 34, wherein said first material further includes a nitride.

45. The material as in the above item no. 34 or 44, wherein said nitride includes at least one of ZrN, HfN, VN, NbN, TaN and TiN.

46. The material as in the above item no. 34 or 44, wherein said first material includes a carbide.

47. A material, comprising:

hard particles comprising a first material which comprises a nitride; and

a binder matrix comprising a second, different material comprising a nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

48. The material as in the above item no. 47, wherein said nitride includes at least one of ZrN, VN, NbN, TaN TiN and HfN.

49. The material as in the above item no. 33 or 47, wherein said nickel-based superalloy comprises primarily nickel and also comprises other elements.

50. The material as in the above item no. 49, wherein said other elements include Co, Cr, Al, Ti, Mo, Nb, W, and Zr.

51. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy and a second, different nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

52. The material as in the above item no. 51, wherein said binder matrix further comprises rhenium.

53. The material as in the above item no. 52, wherein said binder matrix further comprises cobalt.

54. The material as in the above item no. 33, wherein said binder matrix further comprises rhenium.

55. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy, rhenium and cobalt, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

56. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy and cobalt, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

57. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy and nickel, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

58. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy and iron, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

59. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy molybdenum, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

60. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy and chromium, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

61. The material as in the above item no. 33, wherein said binder matrix further comprises another alloy that is not a nickel-based alloy.

62. A material, comprising:

hard particles having a first material comprising TiC and TiN; and

a binder matrix having a second, different material comprising at least one of Ni, Mo, and Mo2C, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

63. A material, comprising:

hard particles comprising a first material which comprises TiC and TiN; and

a binder matrix comprising a second, different material which comprises Re and at least one of Ni, Mo, and Mo₂C, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

64. The material as in the above item no. 63, wherein said binder matrix further includes Co.

65. The material as in the above item no. 64, wherein said binder matrix further includes a Ni-based superalloy.

66. The material as in the above item no. 63, wherein said binder matrix further includes a Ni-based superalloy.

67. A material, comprising:

hard particles comprising a first material comprising TiC and TiN; and

a binder matrix comprising a second, different material which comprises a Ni-based superalloy, and at least one of Ni, Mo, and Mo₂C, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

68. A method comprising:

forming a grade powder by mixing a powder of hard particles with a binder matrix material comprising a nickel-based superalloy;

processing the grade powder to produce a solid hardmetal material by using the binder matrix material to bind the hard particles.

69. The method as in the above item no. 68, wherein said processing includes sequentially performing a pressing operation, a first sintering operation, a shaping operation, and a second sintering operation.

70. (The method as in the above item no. 68, further comprising: prior to the mixing, preparing the binder matrix material to further include rhenium.

71. The method as in the above item no. 68, further comprising: prior to the mixing, preparing the binder matrix material to further include cobalt.

72. The method as in the above item no. 68, wherein the processing includes a solid phase sintering in a hot isostatic pressing process.

73. The method as in the above item no. 68, wherein the processing includes (1) sintering the grade powder in a solid phase under a vacuum condition, and (2) sintering the grade power in a solid phase under a pressure in an inert gas medium.

74. The method as in the above item no. 68, further comprising: prior to the mixing, preparing the hard particles with a particle dimension less than 0.5 micron to reduce a temperature of the sintering operations.

75. A device, comprising a wear part that removes material from an object, said wear part having a material which comprises:

hard particles having a first material; and

a binder matrix having a second, different material comprising rhenium and a Ni-based super alloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

76. The device as in the above item no. 75, wherein said binder matrix further includes a cobalt.

77. A device, comprising a wear part having a material which comprises:

hard particles having a first material; and

a binder matrix of a second, different material comprising a nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

78. A material comprising:

hard particles having a first material selected from at least one from a group consisting of (1) a solid solution of WC, TiC, and TaC, (2) a solid solution of WC, TiC, and NbC, (3) a solid solution of WC, TiC, and at least one of TaC and NbC, and (4) a solid solution of WC, TiC, and at least one of HfC and NbC; and

79. The material as in the above item no. 78 or 87, wherein the hard particles comprise WC, TiC, and TaC, and the binder matrix is formed of pure Re.

80. The material as in the above item no. 79, wherein the hard particles are about 72% of and the Re is about 28% of the total weight of the material.

81. The material as in the above item no. 79, wherein the hard particles are about 85% of and the Re is about 15% of the total weight of the material.

82. The material as in the above item no. 79, wherein TiC and TaC are approximately equal in quantity and have a total quantity less than a quantity of the WC.

83. The material as in the above item no. 24, wherein the hard particles comprise WC, TiC, and TaC.

84. The material as in the above item no. 83, wherein each of TiC and TaC is from about 3% to less than about 6% in a total weight of the material, and WC is above 78% and below 89% in the total weight of the material.

85. The material as in the above item no. 83, wherein the binder matrix further includes Co.

86. The material as in the above item no. 83, wherein the Ni-based superalloy comprises mainly Ni and other elements including Co, Cr, Al, Ti, Mo, Nb, W, Zr, B, C, and V.

87. A material, comprising:

hard particles comprising a first material selected from at least one from a group consisting of (1) WC, TiC, and TaC, (2) WC, TiC, and NbC, (3) WC, TiC, and at least one of TaC and NbC, and (4) WC, TiC, and at least one of HfC and NbC; and

wherein the binder matrix includes Re and a Ni-based superalloy which includes Re.

88. The material as in the above item no. 21, wherein said Ni-based superalloy includes Re.

89. The material as in the above item no. 24, wherein said Ni-based superalloy includes Re.

90. The material as in the above item no. 21 or 47, wherein said Ni-based superalloy includes Re.

91. A material comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner,

wherein said Ni-based superalloy includes Re.

92. A material, comprising:

hard particles comprising a first material; and

wherein said Ni-based superalloy is in a γ-γ′ phase.

93. A material, comprising:

hard particles comprising a first material; and

a binder matrix comprising a second, different material which comprises a nickel-based superalloy which comprises nickel and other elements, said other elements comprising Co, Cr, Al, Ti, Mo, Nb, W, Zr, and Re, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

94. The material as in the above item no. 17, wherein said first material comprises a boride.

95. The material as in the above item no. 95, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

96. The material as in the above item no. 17, wherein said first material comprises a silicide.

97. The material as in the above item no. 96, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

98. The material as in the above item no. 17, wherein said first material comprises a carbide.

99. The material as in the above item no. 98, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

100. The material as in the above item no. 17, wherein said first material further comprises a nitride.

101. The material as in the above item no. 100, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

102. The material as in the above item no. 100, wherein said first material further comprises a carbide.

103. The material as in the above item no. 102, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

104. The material as in the above item no. 102, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

105. The material as in the above item no. 18, wherein said first material comprises a boride.

106. The material as in the above item no. 105, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

107. The material as in the above item no. 18, wherein said first material comprises a silicide.

108. The material as in the above item no. 107, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

109. The material as in the above item no. 18, wherein said first material comprises a carbide.

110. The material as in the above item no. 109, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

111. The material as in the above item no. 18, wherein said first material further comprises a nitride.

112. The material as in the above item no. 111, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

113. The material as in the above item no. 111, wherein said first material further comprises a carbide.

114. The material as in the above item no. 113, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

115. The material as in the above item no. 113, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

116. The material as in the above item no. 19, wherein said first material comprises a carbide.

117. The material as in the above item no. 116, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

118. The material as in the above item no. 19, wherein said first material comprises a boride.

119. The material as in the above item no. 118, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

120. The material as in the above item no. 19, wherein said first material comprises a silicide.

121. The material as in the above item no. 120, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

122. The material as in the above item no. 19, wherein said first material further comprises a nitride.

123. The material as in the above item no. 122, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

124. The material as in the above item no. 122, wherein said first material further comprises a carbide.

125. The material as in the above item no. 124, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

126. The material as in the above item no. 125, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

127. The material as in the above item no. 20, wherein said first material comprises a boride.

128. The material as in the above item no. 127, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

129. The material as in the above item no. 20, wherein said first material comprises a silicide.

130. The material as in the above item no. 129, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

131. The material as in the above item no. 20, wherein said first material comprises a carbide.

132. The material as in the above item no. 131, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

133. The material as in the above item no. 20, wherein said first material further comprises a nitride.

134. The material as in the above item no. 133, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

135. The material as in the above item no. 133, wherein said first material further comprises a carbide.

136. The material as in the above item no. 135, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

137. The material as in the above item no. 135, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

138. The material as in the above item no. 21, wherein said first material comprises a carbide.

139. The material as in the above item no. 138, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

140. The material as in the above item no. 21, wherein said first material comprises a boride.

141. The material as in the above item no. 140, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

142. The material as in the above item no. 21, wherein said first material comprises a silicide.

143. The material as in the above item no. 142, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

144. The material as in the above item no. 21, wherein said first material comprises a nitride.

145. The material as in the above item no. 144, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

146. The material as in the above item no. 144, wherein said first material further comprises a carbide.

147. The material as in the above item no. 146, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

148. The material as in the above item no. 147, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

149. The material as in the above item no. 22, wherein said first material comprises a boride.

150. The material as in the above item no. 149, wherein said boride is one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

151. The material as in the above item no. 22, wherein said first material comprises a silicide.

152. The material as in the above item no. 151, wherein said silicide is one of TaSi₂, Wsi₂, NbSi₂, and MoSi₂.

153. The material as in the above item no. 22, wherein said first material comprises a carbide.

154. The material as in the above item no. 153, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

155. The material as in the above item no. 22, wherein said first material further comprises a nitride.

156. The material as in the above item no. 155, wherein said nitride includes at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

157. The material as in the above item no. 155, wherein said first material further comprises a carbide.

158. The material as in the above item no. 157, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

159. The material as in the above item no. 157, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

160. The material as in the above item no. 24, wherein said first material further comprises a nitride.

161. The material as in the above item no. 160, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

162. The material as in the above item no. 24, wherein said binder matrix further comprises cobalt(Co).

163. The material as in the above item no. 24, wherein Re is from about 1.5% to about 24.4% of the total weight of the material, and said Ni-based superalloy is from about 0.86% to about 4.88% of the total weight of the material, and

- wherein the first material comprises TiC which is from about 3% to about 14.7% of the total weight of the material, TaC which is from about 3% to about 6.2% of the total weight of the material, and WC which is above about 64% and below about 88% of the total weight of the material.

164. The material as in the above item no. 26, wherein said binder matrix further comprises a Ni-based superalloy.

165. The material as in the above item no. 164, wherein said binder matrix further comprises Co.

166. The material as in the above item no. 27, wherein said binder matrix further comprises Co.

167. The material as in the above item no. 27, wherein said Re is from about 8.8% to about 23.8% of the total weight of the material, and said Ni-based superalloy is from about 3.0% to about 10.3% of the total weight of the material, and wherein said Mo₂C is from about 13.8% to about 15.2% of the total weight of the material, and said TiC is from about 59.4% to about 65.7% of the total weight of the material.

168. The material as in the above item no. 47, wherein said first material further comprises a carbide.

169. The material as in the above item no. 168, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

170. The material as in the above item no. 168, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

171. The material as in the above item no. 49, wherein said other elements comprise Cr, Co, Fe, Al, Ti, Mo, W, Nb, Ta, Hf, Zr, B, C, Re.

172. The material as in the above item no. 51, wherein said first material comprises a carbide.

173. The material as in the above item no. 172, wherein said first material further comprises a nitride.

174. The material as in the above item no. 50, wherein said other elements further comprise Fe, Ta, Hf, C, and Re.

175. The material as in the above item no. 51, wherein said first material comprises a nitride.

176. The material as in the above item no. 55, wherein Re is from about 0.4% to about 1.8% of the total weight of the material, said Ni-based superalloy from about 2.7% to about 4.5% of the total weight of the material, and said cobalt from about 3% to about 4.8% of the total weight of the material, and

wherein said first material comprises WC which is from about 90.4% to about 91.5% of the total weight of the material, and VC which is from about 0.3% to about 0.6% of the total weight of the material.

177. The material as in the above item no. 55, wherein said first material further comprises a nitride.

178. The material as in the above item no. 55, wherein said first material further comprises a carbide.

179. The material as in the above item no. 56, wherein said first material further comprises a nitride.

180. The material as in the above item no. 179, wherein said first material further comprises a carbide.

181. The material as in the above item no. 56, wherein said first material further comprises a carbide.

182. The material as in the above item no. 57, wherein said first material further comprises a nitride.

183. The material as in the above item no. 182, wherein said first material further comprises a carbide.

184. The material as in the above item no. 57, wherein said first material further comprises a carbide.

185. The material as in the above item no. 58, wherein said first material further comprises a nitride.

186. The material as in the above item no. 185, wherein said first material further comprises a carbide.

187. The material as in the above item no. 58, wherein said first material further comprises a carbide.

188. The material as in the above item no. 59, wherein said first material further comprises a nitride.

189. The material as in the above item no. 188, wherein said first material further comprises a carbide.

190. The material as in the above item no. 59, wherein said first material further comprises a carbide.

191. The material as in the above item no. 60, wherein said first material further comprises a nitride.

192. The material as in the above item no. 191, wherein said first material further comprises a carbide.

193. The material as in the above item no. 60, wherein said first material further comprises a carbide.

194. The device as in the above item no. 75, wherein said first material comprises a carbide.

195. The device as in the above item no. 194, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

196. The device as in the above item no. 75, wherein said first material further comprises a nitride.

197. The device as in the above item no. 196, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

198. The device as in the above item no. 196, wherein said first material further comprises a carbide.

199. The device as in the above item no. 198, wherein said first material comprises WC, TiC, TaC and Mo₂C.

200. The device as in the above item no. 198, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

201. The device as in the above item no. 198, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

202. The device as in the above item no. 75, wherein said first material further comprises a boride.

203. The device as in the above item no. 202, wherein said first material comprises at least one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

204. The device as in the above item no. 75, wherein said first material further comprises at least one boride and at least one carbide.

205. The device as in the above item no. 204, wherein said first material comprises WC, TiC, TaC, and B₄C.

206. The device as in the above item no. 75, wherein said first material comprises a silicide.

207. the device as in the above item no. 75, wherein said first material comprises at least one of TaSi₂, WSi₂, NbSi₂, and MoSi₂.

208. The device as in the above item no. 75, wherein said Re is from about 9.04% to about 9.32% of the total weight of the material, and said Ni-based superalloy is from about 3.53% to about 3.64% of the total weight of the material, and

wherein said first material comprises WC from about 67.24% to about 69.40% of the total weight of the material, TiC from about 6.35% to about 6.55% of the total weight of the material, TaC from about 6.24% to about 6.44% of, TiB₂from about 0.40% to about 7.39% of the total weight of the material, and B₄C from about 0.22% to about 4.25% of the total weight of the material.

209. The device as in the above item no. 75, wherein said Re is from about 8.96% to about 9.37% of the total weight of the material, and said Ni-based superalloy is from about 3.50% to about 3.66% of the total weight of the material, and

wherein said first material comprises WC from about 58.61% to about 66.67% of the total weight of the material, TiC from about 14.69% to about 15.37% of the total weight of the material, TaC from about 6.19% to about 6.47% of the total weight of the material, and Mo₂C from 0 to about 6.51% of the total weight of the material.

210. The device as in the above item no. 75, wherein said binder matrix further comprises Ni.

211. The device as in the above item no. 75, wherein said binder matrix further comprises Fe.

212. The device as in the above item no. 75, wherein said binder matrix further comprises Mo.

213. The device as in the above item no. 75, wherein said binder matrix further comprises Cr.

214. The material as in the above item no. 83, wherein the Ni-based superalloy comprises mainly Ni and other elements which comprise Cr, Co, Fe, Al, Ti, Mo, W, Nb, Ta, Hf, Zr, B, C, Re.

215. The material as in the above item no. 91, wherein said first material comprises a carbide.

216. The material as in the above item no. 215, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

217. The material as in the above item no. 91, wherein said first material further comprises a nitride.

218. The material as in the above item no. 217, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

219. The material as in the above item no. 217, wherein said first material further comprises a carbide.

220. The material as in the above item no. 219, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

221. The material as in the above item no. 91, wherein said first material further comprises a boride.

222. The material as in the above item no. 221, wherein said first material comprises at least one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

223. The material as in the above item no. 91, wherein said first material further comprises at least one boride and at least one carbide.

224. The material as in the above item no. 223, wherein said first material comprises WC, TiC, TaC, and B₄C.

225. The material as in the above item no. 91, wherein said first material comprises a silicide.

226. The material as in the above item no. 225, wherein said silicide comprises at least one of TaSi₂, WSi₂, NbSi₂, and MoSi₂.

227. The material as in the above item no. 91, wherein said binder matrix further comprises Ni.

228. The material as in the above item no. 91, wherein said binder matrix further comprises Fe.

229. The material as in the above item no. 91, wherein said binder matrix further comprises Mo.

230. The material as in the above item no. 91, wherein said binder matrix further comprises Cr.

231. The material as in the above item no. 92, wherein said first material comprises a carbide.

232. The material as in the above item no. 231, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

233. The material as in the above item no. 92, wherein said first material further comprises a nitride.

234. The material as in the above item no. 233, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

235. The material as in the above item no. 233, wherein said first material further comprises a carbide.

236. The material as in the above item no. 235, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

237. The material as in the above item no. 235, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

238. The material as in the above item no. 92, wherein said first material further comprises a boride.

239. The material as in the above item no. 238, wherein said first material comprises at least one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

240. The material as in the above item no. 92, wherein said first material comprises a silicide.

241. The material as in the above item no. 92, wherein said first material comprises at least one of TaSi₂, WSi₂, NbSi₂, and MoSi₂.

242. The material as in the above item no. 92, wherein said second material further comprises at least one of Re, Ni, Co, Fe, Mo, and Cr.

243. The material as in the above item no. 92, wherein said second material further comprises at least another different Ni-based superalloy.

244. The material as in the above item no. 92, wherein said first material comprises WC from about 91.9% to about 92.5% of the total weight of the material, and VC from about 0.3% to about 0.6% of the total weight of the material, and wherein said Ni-based superalloy is from about 7.2% to about 7.5% of the total weight of the material.

245. The material as in the above item no. 92, wherein said first material comprises TiC and Mo₂C which are about 69.44% and 16.09% of the total weight of the material, respectively, and wherein said Ni-based superalloy is about 14.47% of the total weight of the material.

246. The material as in the above item no. 93, wherein said first material comprises a carbide.

247. The material as in the above item no. 246, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

248. The material as in the above item no. 93, wherein said first material further comprises a nitride.

249. The material as in the above item no. 248, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

250. The material as in the above item no. 249, wherein said first material further comprises a carbide.

251. The material as in the above item no. 250, wherein said carbide comprises at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₂C₃, Mo₂C, and WC.

252. The material as in the above item no. 250, wherein said nitride comprises at least one of TiN, ZrN, HfN, VN, NbN, and TaN.

253. The material as in the above item no. 93, wherein said first material further comprises a boride.

254. The material as in the above item no. 253, wherein said first material comprises at least one of TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B.

255. The material as in the above item no. 93, wherein said first material comprises a silicide.

256. The material as in the above item no. 93, wherein said first material comprises at least one of TaSi₂, WSi₂, NbSi₂, and MoSi₂.

257. The material as in the above item no. 93, wherein said second material further comprises at least one of Re, Ni, Co, Fe, Mo, and Cr.

258. The material as in the above item no. 93, wherein said second material further comprises at least another different Ni-based superalloy.

259. The material as in the above item no. 93, wherein said other elements in said nickel-based superalloy further comprise Fe, Ta, Hf, B, and C.

260. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

hard particles having a first material, and

261. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

262. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

hard particles having a first material having a mixture of Mo2C and TiC; and

263. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

hard particles having a first material; and

a binder matrix having a second, different material comprising a nickel-based superalloy, wherein said hard particles are spatially dispersed in said binder matrix in a substantially uniform manner.

264. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

hard particles having a first material comprising TiC and TiN; and

265. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to coat a layer of a hardmetal layer over the metal surface,

wherein the hard metal layer comprises:

In addition, a second group of 288 specific implementations described in this application is as follows.

1. A material, comprising:

hard particles comprising at least one carbide selected from at least one of WC, TiC, and HfC; and

a binder matrix that binds the hard particles and comprises rhenium,

wherein the hard particles are less than 75% of a total weight of the material and rhenium is greater than 25% of the total weight of the material.

2. The material as in above item no. 1, wherein the at least one carbide is TiC which is greater than about 26% of the total weight of the material and the rhenium is less than about 74% of the total weight of the material.

3. The material as in above item no. 1, wherein the at least one carbide is WC which is greater than about 53% of the total weight of the material, and the rhenium is less than about 47% of the total weight of the material.

4. The material as in above item no. 1, wherein the at least one carbide is HfC which is greater than about 48% of the total weight of the material, and the rhenium is less than about 52% of the total weight of the material.

5. A material, comprising:

hard particles comprising at least one carbide selected from carbides that are formed from elements in IVb, Vb, and VIb columns of the periodic table of elements, exclusive of WC, TiC, and HfC; and

a binder matrix that binds the hard particles and comprises rhenium,

wherein the hard particles are less than 75% of a total weight of the material and rhenium is between 4% to 72% of the total weight of the material.

6. The material as in above item no. 5, wherein the at least one carbide is ZrC which is greater than about 32% of the total weight of the material, and the rhenium is less than about 68% of the total weight of the material.

7. The material as in above item no. 5, wherein the at least one carbide is VC which is greater than about 28% of the total weight of the material, and the rhenium is less than about 72% of the total weight of the material.

8. The material as in above item no. 5, wherein the at least one carbide is NbC which is greater than about 36% of the total weight of the material, and the rhenium is less than about 64% of the total weight of the material.

9. The material as in above item no. 5, wherein the at least one carbide is TaC which is greater than about 51% of the total weight of the material, and the rhenium is less than about 49% of the total weight of the material.

10. The material as in above item no. 5, wherein the at least one carbide is Cr₂C₃which is greater than about 32% of the total weight of the material, and the rhenium is less than about 68% of the total weight of the material.

11. The material as in above item no. 5, wherein the at least one carbide is Mo₂C which is greater than about 39% of the total weight of the material, and the rhenium is less than about 61% of the total weight of the material.

12. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVB and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium, wherein the rhenium is between about 4% to about 72% of the total weight of the material.

13. The material as in above item no. 12, wherein the at least one nitride is TiN which is between about 28% to about 89% of the total weight of the material.

14. The material as in above item no. 12, wherein the at least one nitride is ZrN which is between about 34% to about 92% of the total weight of the material, and the rhenium is between about 8% to about 66% of the total weight of the material.

15. The material as in above item no. 12, wherein the at least one nitride is HfN which is between about 50% to about 96% of the total weight of the material, and the rhenium is between about 4% to about 50% of the total weight of the material.

16. The material as in above item no. 12, wherein the at least one nitride is VN which is between about 30% to about 91% of the total weight of the material, and the rhenium is between about 9% to about 70% of the total weight of the material.

17. The material as in above item no. 12, wherein the at least one nitride is NbN which is between about 34% to about 92% of the total weight of the material, and the rhenium is between about 8% to about 66% of the total weight of the material.

18. The material as in above item no. 12, wherein the at least one nitride is TaN which is between about 51% to about 96% of the total weight of the material, and the rhenium is between about 4% to about 49% of the total weight of the material.

19. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVB and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises a Ni-based superalloy which is between about 1.7% to about 50% of a total weight of the material.

20. The material as in above item no. 19, wherein the at least one nitride is TiN between about 50% to about 96% of the total weight of the material and the Ni-based superalloy which is between about 4% to about 50% of the total weight of the material.

21. The material as in above item no. 19, wherein the at least one nitride is ZrN between about 58% to about 97% of the total weight of the material and the Ni-based superalloy which is between about 3% to about 42% of the total weight of the material.

22. The material as in above item no. 19, wherein the at least one nitride is HfN between about 72% to about 98.2% of the total weight of the material and the Ni-based superalloy which is between about 1.8% to about 28% of the total weight of the material.

23. The material as in above item no. 19, wherein the at least one nitride is VN between about 53% to about 96% of the total weight of the material and the Ni-based superalloy which is between about 4% to about 47% of the total weight of the material.

24. The material as in above item no. 19, wherein the at least one nitride is NbN between about 52% to about 97% of the total weight of the material and the Ni-based superalloy which is between about 3% to about 42% of the total weight of the material.

25. The material as in above item no. 19, wherein the at least one nitride is TaN between about 73% to about 98.3% of the total weight of the material and the Ni-based superalloy which is between about 1.7% to about 27% of the total weight of the material.

26. A material, comprising:

hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium and a Ni-based superalloy,

wherein the hard particles are between about 26.1% to about 98.4% of a total weight of the material.

27. The material as in above item no. 26, wherein the at least one carbide is TiC between about 26.1% to about 95.1% of the total weight of the material, the rhenium is not greater than about 73.6% of the total weight of the material, and the Ni-based superalloy is not greater than about 51.1% of the total weight of the material.

28. The material as in above item no. 26, wherein the at least one carbide is ZrC between about 32% to about 96% of the total weight of the material, the rhenium is not greater than about 67.7% of the total weight of the material, and the Ni-based superalloy is not greater than about 44.1% of the total weight of the material.

29. The material as in above item no. 26, wherein the at least one carbide is HfC between about 47.7% to about 98.1% of the total weight of the material, the rhenium is not greater about 52.1% of the total weight of the material, and the Ni-based superalloy is not greater about 29.2% of the total weight of the material.

30. The material as in above item no. 26, wherein the at least one carbide is VC between about 28.3% to about 95.6% of the total weight of the material, the rhenium does not exceed about 71.5% of the total weight of the material, and the Ni-based superalloy does exceed about 48.4% of the total weight of the material.

31. The material as in above item no. 26, wherein the at least one carbide is NbC between about 36% to about 96.9% of the total weight of the material, the rhenium is equal to or less than about 63.8% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 39.9% of the total weight of the material.

32. The material as in above item no. 26, wherein the at least one carbide is TaC between about 51% to about 98.3% of the total weight of the material, the rhenium is equal to or less than about 48.8% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 26.5% of the total weight of the material.

33. The material as in above item no. 26, wherein the at least one carbide is Cr₂C₃between about 32.4% to about 96.4% of the total weight of the material, the rhenium is equal to or less than about 67.3% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 43.6% of the total weight of the material.

34. The material as in above item no. 26, wherein the at least one carbide is Mo₂C between about 39.6% to about 97.3% of the total weight of the material, the rhenium is equal to or less than about 60.2% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 36.3% of the total weight of the material.

35. The material as in above item no. 26, wherein the at least one carbide is WC between about 52.9% to about 98.4% of the total weight of the material, the rhenium is equal to or less than about 46.9% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 25% of the total weight of the material.

36. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVb and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium and a Ni-based superalloy,

wherein the hard particles are between about 28% to about 98.3% of a total weight of the material.

37. The material as in above item no. 36, wherein the at least one nitride is TiN between about 28% to about 95.6% of the total weight of the material, the rhenium is equal to or less than about 71.7% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 48.7% of the total weight of the material.

38. The material as in above item no. 36, wherein the at least one nitride is ZrN between about 34.5% to about 96.7% of the total weight of the material, the rhenium is equal to or less than about 65.3% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 41.4% of the total weight of the material.

39. The material as in above item no. 36, wherein the at least one nitride is HfN between about 49.8% to about 98.2% of the total weight of the material, the rhenium is equal to or less than about 50% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 27.5% of the total weight of the material.

40. The material as in above item no. 36, wherein the at least one nitride is VN between about 30% to about 96% of the total weight of the material, the rhenium is equal to or less than about 69.6% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 46.2% of the total weight of the material.

41. The material as in above item no. 36, wherein the at least one nitride is NbN between about 34.4% to about 96.7% of the total weight of the material, the rhenium is equal to or less than about 65.3% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 41.5% of the total weight of the material.

42. The material as in above item no. 36, wherein the at least one nitride is TaN between about 50.7% to about 98.3% of the total weight of the material, the rhenium is equal to or less than about 49.1% of the total weight of the material, and the Ni-based superalloy is equal to or less than about 26.8% of the total weight of the material.

43. A material, comprising:

hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt,

wherein the hard particles are between about 26.1% to about 98.2% of a total weight of the material.

44. The material as in above item no. 43, wherein the at least one carbide is TiC between about 26.1% to about 94.6% of the total weight of the material, the rhenium is equal to or less than about 73.6% of the total weight of the material, and the cobalt is equal to or less than about 54.1% of the total weight of the material.

45. The material as in above item no. 43, wherein the at least one carbide is ZrC between about 32% to about 96% of the total weight of the material, the rhenium is equal to or less than about 67.7% of the total weight of the material, and cobalt is equal to or less than about 47.1% of the total weight of the material.

46. The material as in above item no. 43, wherein the at least one carbide is HfC between about 47.6% to about 97.8% of the total weight of the material, the rhenium is equal to or less than about 52.1% of the total weight of the material, and the cobalt is equal to or less than about 31.8% of the total weight of the material.

47. The material as in above item no. 43, wherein the at least one carbide is VC between about 28.3% to about 95.1% of the total weight of the material, the rhenium is equal to or less than about 71.4% of the total weight of the material, and the cobalt is equal to or less than about 51.5% of the total weight of the material.

48. The material as in above item no. 43, wherein the at least one carbide is NbC between about 36% to about 96.5% of the total weight of the material, the rhenium is equal to or less than about 63.8% of the total weight of the material, and the cobalt is equal to or less than about 42.8% of the total weight of the material.

49. The material as in above item no. 43, wherein the at least one carbide is TaC between about 51% to about 98% of the total weight of the material, the rhenium is equal to or less than about 48.8% of the total weight of the material, and the cobalt is equal to or less than about 28.9% of the total weight of the material.

50. The material as in above item no. 43, wherein the at least one carbide is Cr₂C₃between about 32.4% to about 96% of the total weight of the material, the rhenium is equal to or less than about 67.3% of the total weight of the material, and the cobalt is equal to or less than about 46.6% of the total weight of the material.

51. The material as in above item no. 43, wherein the at least one carbide is Mo₂C between about 39.6% to about 97% of the total weight of the material, the rhenium is equal to or less than about 60.2% of the total weight of the material, and the cobalt is equal to or less than about 39.2% of the total weight of the material.

52. The material as in above item no. 43, wherein the at least one carbide is WC between about 52.9% to about 98.2% of the total weight of the material, the rhenium is equal to or less than about 46.9% of the total weight of the material, and the cobalt is equal to or less than about 27.4% of the total weight of the material.

53. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVb and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt,

wherein the hard particles are between about 28% to about 98% of a total weight of the material.

54. The material as in above item no. 53, wherein the at least one nitride is TiN between about 28% to about 95% of the total weight of the material, the rhenium is up to about 71.6% of the total weight of the material, and the cobalt is up to about 51.7% of the total weight of the material.

55. The material as in above item no. 53, wherein the at least one nitride is ZrN between about 34.5% to about 96.3% of the total weight of the material, the rhenium is up to about 65.3% of the total weight of the material, and the cobalt is up to about 44.4% of the total weight of the material.

56. The material as in above item no. 53, wherein the at least one nitride is HfN between about 49.8% to about 98% of the total weight of the material, the rhenium is up to about 50% of the total weight of the material, and the cobalt is up to about 30% of the total weight of the material.

57. The material as in above item no. 53, wherein the at least one nitride is VN between about 30% to about 95.5% of the total weight of the material, the rhenium is up to about 69.6% of the total weight of the material, and the cobalt is up to about 49.3% of the total weight of the material.

58. The material as in above item no. 53, wherein the at least one nitride is NbN between about 34.4% to about 96.3% of the total weight of the material, the rhenium is up to about 65.3% of the total weight of the material, and the cobalt is up to about 44.5% of the total weight of the material.

59. The material as in above item no. 53, wherein the at least one nitride is TaN between about 50.7% to about 98% of the total weight of the material, the rhenium is up to d about 49.1% of the total weight of the material, and the cobalt is up to about 29.2% of the total weight of the material.

60. A material, comprising:

hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises a Ni-based superalloy and cobalt,

wherein the hard particles are between about 45% to about 98% of a total weight of the material.

61. The material as in above item no. 60, wherein the at least one carbide is TiC between about 45% to about 95% of the total weight of the material, the Ni-based superalloy is up to about 51.5% of the total weight of the material, and the cobalt is up to about 54.5% of the total weight of the material.

62. The material as in above item no. 60, wherein the at least one carbide is ZrC between about 52% to about 96% of the total weight of the material, the Ni-based superalloy is up to about 44.4% of the total weight of the material, and cobalt is up to about 47.4% of the total weight of the material.

63. The material as in above item no. 60, wherein the at least one carbide is HfC between about 68% to about 98% of the total weight of the material, the Ni-based superalloy is up to about 29% of the total weight of the material, and the cobalt is up to about 32% of the total weight of the material.

64. The material as in above item no. 60, wherein the at least one carbide is VC between about 48% to about 96% of the total weight of the material, the Ni-based superalloy is up to about 49% of the total weight of the material, and the cobalt is up to about 52% of the total weight of the material.

65. The material as in above item no. 60, wherein the at least one carbide is NbC between about 57% to about 97% of the total weight of the material, the Ni-based superalloy is up to about 40% of the total weight of the material, and the cobalt is up to about 43% of the total weight of the material.

66. The material as in above item no. 60, wherein the at least one carbide is TaC between about 71% to about 98% of the total weight of the material, the Ni-based superalloy is up to about 27% of the total weight of the material, and the cobalt is up to about 29% of the total weight of the material.

67. The material as in above item no. 60, wherein the at least one carbide is Cr₂C₃between about 53% to about 96% of the total weight of the material, the Ni-based superalloy is up to about 67.3% of the total weight of the material, and the cobalt is up to about 44% of the total weight of the material.

68. The material as in above item no. 60, wherein the at least one carbide is Mo₂C between about 60% to about 97% of the total weight of the material, the Ni-based superalloy is up to about 36.5% of the total weight of the material, and the cobalt is up to about 39% of the total weight of the material.

69. The material as in above item no. 60, wherein the at least one carbide is WC between about 72% to about 98% of the total weight of the material, the Ni-based superalloy is up to about 46.9% of the total weight of the material, and the cobalt is up to about 27.5% of the total weight of the material.

70. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVb and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises a Ni-based superalloy and cobalt,

wherein the hard particles are between about 47% to about 98% of a total weight of the material.

71. The material as in above item no. 70, wherein the at least one nitride is TiN between about 47% to about 96% of the total weight of the material, the Ni-based superalloy is up to about 49% of the total weight of the material, and the cobalt is up to about 52% of the total weight of the material.

72. The material as in above item no. 70, wherein the at least one nitride is ZrN between about 55% to about 97% of the total weight of the material, the Ni-based superalloy is up to about 42% of the total weight of the material, and the cobalt is up to about 45% of the total weight of the material.

73. The material as in above item no. 70, wherein the at least one nitride is HfN between about 70% to about 98% of the total weight of the material, the Ni-based superalloy is up to about 31% of the total weight of the material, and the cobalt is up to about 27% of the total weight of the material.

74. The material as in above item no. 70, wherein the at least one nitride is VN between about 50% to about 96% of the total weight of the material, the Ni-based superalloy is up to about 53% of the total weight of the material, and the cobalt is up to about 44% of the total weight of the material.

75. The material as in above item no. 70, wherein the at least one nitride is NbN between about 55% to about 97% of the total weight of the material, the Ni-based superalloy is up to about 47% of the total weight of the material, and the cobalt is up to about 40% of the total weight of the material.

76. The material as in above item no. 70, wherein the at least one nitride is TaN between about 70% to about 98% of the total weight of the material, the Ni-based superalloy is up to about 30% of the total weight of the material, and the cobalt is up to about 26% of the total weight of the material.

77. A material, comprising:

hard particles comprising at least one carbide from carbides of IVb, Vb, and VIb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium, a Ni-based superalloy and cobalt,

wherein the hard particles are between about 26% to about 98.3% of a total weight of the material.

78. The material as in above item no. 77, wherein the at least one carbide is TiC between about 26% to about 95% of the total weight of the material, the rhenium is up to about 73.6% of the total weight of the material, the Ni-based superalloy is up to about 51.3% of the total weight of the material, and the cobalt is up to about 54.3% of the total weight of the material.

79. The material as in above item no. 77, wherein the at least one carbide is ZrC between about 32% to about 96% of the total weight of the material, the rhenium is up to about 67.7% of the total weight of the material, the Ni-based superalloy is up to about 44.2% of the total weight of the material, and the cobalt is up to about 47.2% of the total weight of the material.

80. The material as in above item no. 77, wherein the at least one carbide is HfC between about 48% to about 98% of the total weight of the material, the rhenium is up to about 52.1% of the total weight of the material, the Ni-based superalloy is up to about 29.3% of the total weight of the material, and the cobalt is up to about 31.8% of the total weight of the material.

81. The material as in above item no. 77, wherein the at least one carbide is VC between about 28% to about 96% of the total weight of the material, the rhenium is up to about 71.5% of the total weight of the material, the Ni-based superalloy is up to about 48.6% of the total weight of the material, and the cobalt is up to about 51.7% of the total weight of the material.

82. The material as in above item no. 77, wherein the at least one carbide is NbC between about 36% to about 97% of the total weight of the material, the rhenium is up to about 63.8% of the total weight of the material, the Ni-based superalloy is up to about 40% of the total weight of the material, and the cobalt is up to about 43% of the total weight of the material.

83. The material as in above item no. 77, wherein the at least one carbide is TaC between about 51% to about 98.3% of the total weight of the material, the rhenium is up to about 48.8% of the total weight of the material, the Ni-based superalloy is up to about 26.6% of the total weight of the material, and the cobalt is up to about 29% of the total weight of the material.

84. The material as in above item no. 77, wherein the at least one carbide is Cr₂C₃between about 32% to about 96% of the total weight of the material, the rhenium is up to about 67.3% of the total weight of the material, the Ni-based superalloy is up to about 43.8% of the total weight of the material, and the cobalt is up to about 46.8% of the total weight of the material.

85. The material as in above item no. 77, wherein the at least one carbide is Mo₂C between about 39% to about 97% of the total weight of the material, the rhenium is up to about 60.2% of the total weight of the material, the Ni-based superalloy is up to about 36.4% of the total weight of the material, and the cobalt is up to about 39.3% of the total weight of the material.

86. The material as in above item no. 77, wherein the at least one carbide is WC between about 53% to about 98% of the total weight of the material, the rhenium is up to about 46.9% of the total weight of the material, the Ni-based superalloy is up to about 25.1% of the total weight of the material, and the cobalt is up to about 27.5% of the total weight of the material.

87. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVb and Vb columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium, a Ni-based superalloy, and cobalt,

wherein the hard particles are between about 28% to about 98.3% of a total weight of the material.

88. The material as in above item no. 87, wherein the at least one nitride is TiN between about 28% to about 96% of the total weight of the material, the rhenium is up to about 71.6% of the total weight of the material, the Ni-based superalloy is up to about 48.8% of the total weight of the material, and the cobalt is up to about 51.9% of the total weight of the material.

89. The material as in above item no. 87, wherein the at least one nitride is ZrN between about 34% to about 97% of the total weight of the material, the rhenium is up to about 65.3% of the total weight of the material, the Ni-based superalloy is up to about 41.6% of the total weight of the material, and the cobalt is up to about 44.6% of the total weight of the material.

90. The material as in above item no. 87, wherein the at least one nitride is HfN between about 50% to about 98% of the total weight of the material, the rhenium is up to about 50% of the total weight of the material, the Ni-based superalloy is up to about 27.5% of the total weight of the material, and the cobalt is up to about 30% of the total weight of the material.

91. The material as in above item no. 87, wherein the at least one nitride is VN between about 30% to about 96% of the total weight of the material, the rhenium is up to about 60% of the total weight of the material, the Ni-based superalloy is up to about 46.4% of the total weight of the material, and the cobalt is up to about 49% of the total weight of the material.

92. The material as in above item no. 87, wherein the at least one nitride is NbN between about 34% to about 97% of the total weight of the material, the rhenium is up to about 65% of the total weight of the material, the Ni-based superalloy is up to about 42% of the total weight of the material, and the cobalt is up to about 45% of the total weight of the material.

93. The material as in above item no. 87, wherein the at least one nitride is TaN between about 51% to about 98.3% of the total weight of the material, the rhenium is up to about 49% of the total weight of the material, the Ni-based superalloy is up to about 27% of the total weight of the material, and the cobalt is up to about 29% of the total weight of the material.

94. A material, comprising:

hard particles comprising WC and TiC which are between about 40% to about 96% and between about 0.3% to about 21% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium which is between about 4% to about 54% of the total weight of the material.

95. A material, comprising:

hard particles comprising WC between about 44% to about 96% and TaC up to about 21% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium which is between about 4% to about 48% of the total weight of the material.

96. A material, comprising:

hard particles comprising WC, TiC and TaC which are between about 36% to about 95%, up to about 22%, and up to about 25% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium which is between about 4% to about 48% of a total weight of the material.

97. A material, comprising:

hard particles comprising WC and TiC which are between about 60% to about 98%, and up to about 25% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a Nickel-based superalloy which is between about 1.5% to about 31% of the total weight of the material.

98. A material, comprising:

hard particles comprising WC and TaC which are between about 63% to about 98%, and up to about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a Nickel-based superalloy which is between about 1.5% to about 26% of the total weight of the material.

99. A material, comprising:

hard particles comprising WC, Tic and TaC which are between about 51% to about 98%, up to about 23%, and up to about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a Nickel-based superalloy which is between about 1.5% to about 26% of the total weight of the material.

100. A material, comprising:

hard particles comprising WC and TiC which are between about 40% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and a Nickel-based superalloy which are up to about 52% and 29% of the total weight of the material, respectively.

101. A material, comprising:

hard particles comprising WC and TaC which are between about 44% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and a Nickel-based superalloy which are up to about 47% and about 25% of the total weight of the material, respectively.

102. A material, comprising:

hard particles comprising WC, TiC and TaC which are between about 40% to about 98%, up to about 23%, and up about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and a Nickel-based superalloy which are up to about 53% and about 30% of the total weight of the material, respectively.

103. A material, comprising:

hard particles comprising WC and TiC which are between about 40% to about 98%, and up to about 23% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt which are up to about 53% and about 31% of the total weight of the material, respectively.

104. A material, comprising:

hard particles comprising WC and TaC which are between about 44% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt which are up to about 47% and about 28% of the total weight of the material, respectively.

105. A material, comprising:

hard particles comprising WC, Tic and TaC which are between about 40% to about 98%, up to about 23%, and up to about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt which are up to about 53% and about 33% of the total weight of the material, respectively.

106. A material, comprising:

hard particles comprising WC and TiC which are between about 58% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt and a nickel-based superalloy which are up to about 33% and about 29% of the total weight of the material, respectively.

107. A material, comprising:

hard particles comprising WC and TaC which are between about 61% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt and a nickel-based superalloy which are up to about 28% and about 25% of the total weight of the material, respectively.

108. A material, comprising:

hard particles comprising WC, TiC and TaC which are between about 57% to about 98%, up to about 23%, and up to about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt and a nickel-based superalloy which are up to about 33% and about 30% of the total weight of the material, respectively.

109. A material, comprising:

hard particles comprising WC and TiC which are between about 40% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt up to about 32% of the total weight of the material, rhenium and a nickel-based superalloy which are up to about 54% and about 29% of the total weight of the material, respectively.

110. A material, comprising:

hard particles comprising WC and TaC which are between about 45% to about 98%, and up to about 24% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt up to about 28% of the total weight of the material, rhenium and a nickel-based superalloy which are up to about 47% and about 26% of the total weight of the material, respectively.

111. A material, comprising:

hard particles comprising WC, TiC and TaC which are between about 35% to about 93%, up to about 25%, and up to about 26% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises cobalt up to about 44% of the total weight of the material, rhenium and a nickel-based superalloy which are up to about 65% and about 41% of the total weight of the material, respectively.

112. A material, comprising:

hard particles comprising TiC between about 19% to about 88% of a total weight of the material and Mo₂C up to about 38% of the total weight of the material; and

a binder matrix that binds the hard particles and comprises rhenium between about 9.5% to about 65% of the total weight of the material.

113. A material, comprising:

hard particles comprising TiN between about 21% to about 89% of a total weight of the material and Mo₂C up to about 36% of the total weight of the material; and

a binder matrix that binds the hard particles and comprises rhenium between about 9% to about 63% of the total weight of the material.

114. A material, comprising:

hard particles comprising TiC up to about 84% of a total weight of the material, TiN up to about 85% of the total weight of the material, and Mo₂C up to about 36% of the total weight of the material; and

a binder matrix that binds the hard particles and comprises rhenium between about 9% to about 64% of the total weight of the material.

115. A material, comprising:

hard particles comprising TiC up to about 83% of a total weight of the material, TiN up to about 85% of the total weight of the material, Mo₂C up to about 25% of the total weight of the material, WC up to about 39% of the total weight of the material, TaC up to about 30% of the total weight of the material, VC up to about 11% of the total weight of the material, and Cr₂C₃up to about 16% of the total weight of the material; and

a binder matrix that binds the hard particles and comprises rhenium between about 6% to about 65% of the total weight of the material.

116. A material, comprising:

hard particles comprising TiC and Mo₂C which are between about 30% to about 90% and up to about 40% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel based superalloy which is between about 4% to about 41% of the total weight of the material.

117. A material, comprising:

hard particles comprising TiN and Mo₂C which are up to about 91% and up to about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel based superalloy which is between about 4% to about 38% of the total weight of the material.

118. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel based superalloy which is between about 4% to about 40% of the total weight of the material.

119. A material, comprising:

hard particles comprising TiC, TiN, Mo₂C, WC, and TaC which are up to about 90%, about 90%, about 25%, about 42%, and about 36% of a total weight of the material, respectively, the hard particles further comprising VC and Cr₂C₃up to about 14% and 18% of the total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel based superalloy which is between about 2% to about 40% of the total weight of the material.

120. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and a nickel based superalloy which are up to about 64% and about 40% of the total weight of the material, respectively.

121. A material, comprising:

hard particles comprising TiC, TiN, Mo₂C, WC, and TaC which are up to about 89%, about 90%, about 26%, about 42%, and about 33% of a total weight of the material, respectively, the hard particles further comprising VC and Cr₂C₃up to about 16% and 18% of the total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and a nickel based superalloy which are up to about 64% and about 40% of the total weight of the material, respectively.

122. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and nickel which are up to about 64% and about 42% of the total weight of the material, respectively.

123. A material, comprising:

a binder matrix that binds the hard particles and comprises rhenium and nickel which are up to about 64% and about 42% of the total weight of the material, respectively.

124. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt which are up to about 64% and about 43% of the total weight of the material, respectively.

125. A material, comprising:

hard particles comprising TiC, TiN, Mo₂C, WC, and TaC which are up to about 89%, about 90%, about 26%, about 42%, and about 32% of a total weight of the material, respectively, the hard particles further comprising VC and Cr₂C₃up to about 16% and 18% of the total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium and cobalt which are up to about 64% and about 43% of the total weight of the material, respectively.

126. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel-based superalloy and cobalt which are up to about 40% and about 43% of the total weight of the material, respectively.

127. A material, comprising:

hard particles comprising TiC, TiN, Mo₂C, WC, and TaC which are up to about 89%, about 90%, about 26%, between about 42%, and about 33% of a total weight of the material, respectively, the hard particles further comprising VC and Cr₂C₃up to about 16% and 18% of the total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel-based superalloy and cobalt which are up to about 40% and about 43% of the total weight of the material, respectively.

128. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel-based superalloy and nickel which are up to about 40% and about 43% of the total weight of the material, respectively.

129. A material, comprising:

a binder matrix that binds the hard particles and comprises a nickel-based superalloy and nickel which are up to about 40% and about 43% of the total weight of the material, respectively.

130. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy and cobalt which are up to about 64%, about 40% and about 42% of the total weight of the material, respectively.

131. A material, comprising:

a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy and cobalt which are up to about 63%, about 39% and about 42% of the total weight of the material, respectively.

132. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy and nickel which are up to about 63%, about 40% and about 42% of the total weight of the material, respectively.

133. A material, comprising:

a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy and nickel which are up to about 63%, about 39% and about 42% of the total weight of the material, respectively.

134. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium, nickel and cobalt which are up to about 63%, about 42% and about 42% of the total weight of the material, respectively.

135. A material, comprising:

a binder matrix that binds the hard particles and comprises rhenium, a nickel and cobalt which are up to about 63%, about 42% and about 42% of the total weight of the material, respectively . . .

136. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises a nickel-based superalloy, nickel and cobalt which are up to about 40%, about 42% and about 43% of the total weight of the material, respectively.

137. A material, comprising:

a binder matrix that binds the hard particles and comprises a nickel-based superalloy, nickel and cobalt which are up to about 40%, about 42% and about 42% of the total weight of the material, respectively.

138. A material, comprising:

hard particles comprising TiC, TiN and Mo₂C which are up to about 90%, about 91% and about 38% of a total weight of the material, respectively; and

a binder matrix that binds the hard particles and comprises rhenium, a nickel-based superalloy, nickel and cobalt which are up to about 63%, about 39%, about 42% and about 42% of the total weight of the material, respectively.

139. A material, comprising:

140. A material, comprising:

hard particles comprising at least one boride from borides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium, wherein the rhenium is between about 4% to about 76% of the total weight of the material.

141. The material as in above item no. 140, wherein the at least one boride is TiB₂which is between about 24% to about 87.5% of the total weight of the material, and the rhenium is between about 12.5% to about 76% of the total weight of the material.

142. The material as in above item no. 140, wherein the at least one boride is ZrB₂which is between about 30% to about 90.5% of the total weight of the material, and the rhenium is between about 9.5% to about 70% of the total weight of the material.

143. The material as in above item no. 140, wherein the at least one boride is HfB₂which is between about 44.5% to about 94.5% of the total weight of the material, and the rhenium is between about 5.5% to about 55.5% of the total weight of the material.

144. The material as in above item no. 140, wherein the at least one boride is VB₂which is between about 27% to about 89% of the total weight of the material, and the rhenium is between about 11% to about 73% of the total weight of the material.

145. The material as in above item no. 140, wherein the at least one boride is NbB₂which is between about 34% to about 92% of the total weight of the material, and the rhenium is between about 8% to about 66% of the total weight of the material.

146. The material as in above item no. 140, wherein the at least one boride is TaB₂which is between about 47% to about 95% of the total weight of the material, and the rhenium is between about 5% to about 53% of the total weight of the material.

147. The material as in above item no. 140, wherein the at least one boride is Cr₃B₂which is between about 30.5% to about 90.5% of the total weight of the material, and the rhenium is between about 9.5% to about 69.5% of the total weight of the material.

148. The material as in above item no. 140, wherein the at least one boride is MoB₂which is between about 36% to about 92.5% of the total weight of the material, and the rhenium is between about 7.5% to about 64% of the total weight of the material.

149. The material as in above item no. 140, wherein the at least one boride is WB which is between about 53% to about 96% of the total weight of the material, and the rhenium is between about 4% to about 47% of the total weight of the material.

150. The material as in above item no. 140, wherein the at least one boride is W₂B which is between about 53% to about 96% of the total weight of the material, and the rhenium is between about 4% to about 47% of the total weight of the material.

151. A material, comprising:

hard particles comprising at least one silicide from silicides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium, wherein the rhenium is between about 6% to about 77% of the total weight of the material.

152. The material as in above item no. 151, wherein the at least one silicide is Ti₅Si₃which is between about 23% to about 87% of the total weight of the material, and the rhenium is between about 13% to about 77% of the total weight of the material.

153. The material as in above item no. 151, wherein the at least one silicide is Zr₆Si₅which is between about 28% to about 90% of the total weight of the material, and the rhenium is between about 10% to about 72% of the total weight of the material.

154. The material as in above item no. 151, wherein the at least one silicide is NbSi₂which is between about 31% to about 91% of the total weight of the material, and the rhenium is between about 9% to about 69% of the total weight of the material.

155. The material as in above item no. 151, wherein the at least one silicide is TaSi₂which is between about 38% to about 93% of the total weight of the material, and the rhenium is between about 7% to about 62% of the total weight of the material.

156. The material as in above item no. 151, wherein the at least one silicide is MoSi₂which is between about 31% to about 91% of the total weight of the material, and the rhenium is between about 9% to about 69% of the total weight of the material.

157. The material as in above item no. 151, wherein the at least one silicide is WSi₂which is between about 40% to about 94% of the total weight of the material, and the rhenium is between about 6% to about 60% of the total weight of the material.

158. A material, comprising:

hard particles; and

a binder matrix that binds the hard particles and comprises tungsten.

159. The material as in above item no. 158, wherein the hard particles comprise at least one carbide from carbides of IVB, VB and VIB columns in the periodic table and the tungsten is between about 4% to about 72% of the total weight of the material.

160. The material as in above item no. 159, wherein the at least one carbide is TiC which is between about 28% and about 89% of the total weight of the material, and the tungsten is between about 11% and about 72% of the total weight of the material.

161. The material as in above item no. 159, wherein the at least one carbide is ZrC which is between about 34% and about 92% of the total weight of the material, and the tungsten is between about 8% and about 66% of the total weight of the material.

162. The material as in above item no. 159, wherein the at least one carbide is HfC which is between about 50% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 50% of the total weight of the material.

163. The material as in above item no. 159, wherein the at least one carbide is VC which is between about 30% and about 90% of the total weight of the material, and the tungsten is between about 10% and about 70% of the total weight of the material.

164. The material as in above item no. 159, wherein the at least one carbide is NbC which is between about 38% and about 93% of the total weight of the material, and the tungsten is between about 7% and about 62% of the total weight of the material.

165. The material as in above item no. 159, wherein the at least one carbide is TaC which is between about 53% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 47% of the total weight of the material.

166. The material as in above item no. 159, wherein the at least one carbide is Cr₂C₃which is between about 34% and about 92% of the total weight of the material, and the tungsten is between about 8% and about 66% of the total weight of the material.

167. The material as in above item no. 159, wherein the at least one carbide is Mo₂C which is between about 41% and about 94% of the total weight of the material, and the tungsten is between about 6% and about 59% of the total weight of the material.

168. The material as in above item no. 159, wherein the at least one carbide is WC which is between about 55% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 45% of the total weight of the material.

169. The material as in above item no. 158, wherein the hard particles comprise at least one nitride from nitrides of IVB and VB columns in the periodic table and the tungsten is between about 4% and about 72% of the total weight of the material.

170. The material as in above item no. 169, wherein the at least one nitride is TiN which is between about 28% and about 89% of the total weight of the material, and the tungsten is between about

11% and about 72% of the total weight of the material. 171. The material as in above item no. 169, wherein the at least one nitride is ZrN which is between about 36% and about 92% of the total weight of the material, and the tungsten is between about 8% and about 64% of the total weight of the material.

172. The material as in above item no. 169, wherein the at least one nitride is HfN which is between about 52% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 48% of the total weight of the material.

173. The material as in above item no. 169, wherein the at least one nitride is VN which is between about 32% and about 91% of the total weight of the material, and the tungsten is between about 9% and about 68% of the total weight of the material.

174. The material as in above item no. 169, wherein the at least one nitride is NbN which is between about 36% and about 92% of the total weight of the material, and the tungsten is between about 8% and about 64% of the total weight of the material.

175. The material as in above item no. 169, wherein the at least one nitride is TaN which is between about 53% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 47% of the total weight of the material.

176. The material as in above item no. 158, wherein the hard particles comprise at least one boride from borides of IVB, VB and VIB columns in the periodic table and the tungsten is between about 3% and about 74% of the total weight of the material.

177. The material as in above item no. 176, wherein the at least one boride is TiB₂which is between about 26% and about 88% of the total weight of the material, and the tungsten is between about 12% and about 74% of the total weight of the material.

178. The material as in above item no. 176, wherein the at least one boride is ZrB₂which is between about 32% and about 91% of the total weight of the material, and the tungsten is between about 9% and about 68% of the total weight of the material.

179. The material as in above item no. 176, wherein the at least one boride is HfB₂which is between about 46% and about 95% of the total weight of the material, and the tungsten is between about 5% and about 54% of the total weight of the material.

180. The material as in above item no. 176, wherein the at least one boride is VB₂which is between about 28% and about 90% of the total weight of the material, and the tungsten is between about 10% and about 72% of the total weight of the material.

181. The material as in above item no. 176, wherein the at least one boride is NbB₂which is between about 36% and about 92% of the total weight of the material, and the tungsten is between about 8% and about 64% of the total weight of the material.

182. The material as in above item no. 176, wherein the at least one boride is TaB₂which is between about 49% and about 95% of the total weight of the material, and the tungsten is between about 5% and about 51% of the total weight of the material.

183. The material as in above item no. 176, wherein the at least one boride is Cr₃B₂which is between about 32% and about 91% of the total weight of the material, and the tungsten is between about 9% and about 68% of the total weight of the material.

184. The material as in above item no. 176, wherein the at least one boride is MoB₂which is between about 38% and about 93% of the total weight of the material, and the tungsten is between about 7% and about 62% of the total weight of the material.

185. The material as in above item no. 176, wherein the at least one boride is WB which is between about 55% and about 96% of the total weight of the material, and the tungsten is between about 4% and about 45% of the total weight of the material.

186. The material as in above item no. 176, wherein the at least one boride is W₂B which is between about 56% and about 97% of the total weight of the material, and the tungsten is between about 3% and about 44% of the total weight of the material.

187. The material as in above item no. 158, wherein the hard particles comprise at least one silicide from silicides of IVB, VB and VIB columns in the periodic table and the tungsten is between about 6% and about 75% of the total weight of the material.

188. The material as in above item no. 187, wherein the at least one silicide is Ti₅Si₃which is between about 25% and about 88% of the total weight of the material, and the tungsten is between about 12% and about 75% of the total weight of the material.

189. The material as in above item no. 187, wherein the at least one silicide is Zr₆Si₅which is between about 30% and about 90% of the total weight of the material, and the tungsten is between about 10% and about 70% of the total weight of the material.

190. The material as in above item no. 187, wherein the at least one silicide is NbSi₂which is between about 33% and about 91% of the total weight of the material, and the tungsten is between about 9% and about 67% of the total weight of the material.

191. The material as in above item no. 187, wherein the at least one silicide is TaSi₂which is between about 40% and about 93% of the total weight of the material, and the tungsten is between about 7% and about 60% of the total weight of the material.

192. The material as in above item no. 187, wherein the at least one silicide is MoSi₂which is between about 31% and about 91% of the total weight of the material, and the tungsten is between about 9% and about 67% of the total weight of the material.

193. The material as in above item no. 187, wherein the at least one silicide is WSi₂which is between about 42% and about 94% of the total weight of the material, and the tungsten is between about 6% and about 58% of the total weight of the material.

194. The material as in above item no. 158, wherein the binder matrix material further comprises rhenium in addition to tungsten.

195. The material as in above item no. 194, wherein the hard particles comprise at least one carbide from carbides of IVB, VB and VIB columns in the periodic table, and

wherein the rhenium is less than about 73% and tungsten is less than about 72% of the total weight of the material.

196. The material as in above item no. 195, wherein the at least one carbide is TiC which is between about 26% and about 89% of the total weight of the material.

197. The material as in above item no. 195, wherein the at least one carbide is ZrC which is between about 32% and about 92% of the total weight of the material.

198. The material as in above item no. 195, wherein the at least one carbide is HfC which is between about 48% and about 95% of the total weight of the material.

199. The material as in above item no. 195, wherein the at least one carbide is VC which is between about 28% and about 90% of the total weight of the material.

200. The material as in above item no. 195, wherein the at least one carbide is NbC which is between about 36% and about 93% of the total weight of the material.

201. The material as in above item no. 195, wherein the at least one carbide is TaC which is between about 51% and about 96% of the total weight of the material.

202. The material as in above item no. 195, wherein the at least one carbide is Cr₂C₃which is between about 32% and about 92% of the total weight of the material.

203. The material as in above item no. 195, wherein the at least one carbide is Mo₂C which is between about 39% and about 94% of the total weight of the material.

204. The material as in above item no. 195, wherein the at least one carbide is WC which is between about 53% and about 96% of the total weight of the material.

205. The material as in above item no. 194, wherein the hard particles comprise at least one nitride from nitrides of IVB and VB columns in the periodic table, and

wherein the rhenium is less than about 71% and tungsten is less than about 70% of the total weight of the material.

206. The material as in above item no. 205, wherein the at least one nitride is TiN which is between about 28% and about 90% of the total weight of the material.

207. The material as in above item no. 205, wherein the at least one nitride is ZrN which is between about 34% and about 92% of the total weight of the material.

208. The material as in above item no. 205, wherein the at least one nitride is HfN which is between about 50% and about 96% of the total weight of the material.

209. The material as in above item no. 205, wherein the at least one nitride is VN which is between about 30% and about 91% of the total weight of the material.

210. The material as in above item no. 205, wherein the at least one nitride is NbN which is between about 35% and about 92% of the total weight of the material.

211. The material as in above item no.205, wherein the at least one nitride is TaN which is between about 51% and about 96% of the total weight of the material.

212. The material as in above item no. 194, wherein the hard particles comprise at least one boride from borides of IVB, VB and VIB columns in the periodic table, and

wherein the rhenium is less than about 75% and tungsten is less than about 73% of the total weight of the material.

213. The material as in above item no. 212, wherein the at least one boride is TiB₂which is between about 24% and about 88% of the total weight of the material.

214. The material as in above item no. 212, wherein the at least one boride is ZrB₂which is between about 30% and about 91% of the total weight of the material.

215. The material as in above item no. 212, wherein the at least one boride is HfB₂which is between about 44% and about 95% of the total weight of the material.

215A. The material as in above item no. 212, wherein the at least one boride is VB₂which is between about 27% and about 90% of the total weight of the material.

216. The material as in above item no. 212, wherein the at least one boride is NbrB₂which is between about 34% and about 92% of the total weight of the material.

217. The material as in above item no. 212, wherein the at least one boride is TaB₂which is between about 47% and about 96% of the total weight of the material.

218. The material as in above item no. 212, wherein the at least one boride is Cr₃B₂which is between about 32% and about 91% of the total weight of the material.

219. The material as in above item no. 212, wherein the at least one boride is MoB₂which is between about 36% and about 93% of the total weight of the material.

220. The material as in above item no. 212, wherein the at least one boride is WB which is between about 53% and about 96% of the total weight of the material.

221. The material as in above item no. 212, wherein the at least one boride is W₂B which is between about 54% and about 97% of the total weight of the material.

223. The material as in above item no. 194, wherein the hard particles comprise at least one silicide from silicides of IVB, VB and VIB columns in the periodic table, and

wherein the rhenium is less than about 76% and tungsten is less than about 74% of the total weight of the material.

224. The material as in above item no. 223, wherein the at least one silicide is Ti₅Si₃which is between about 24% and about 88% of the total weight of the material.

225. The material as in above item no. 223, wherein the at least one silicide is Zr₆Si₅which is between about 28% and about 90% of the total weight of the material.

226. The material as in above item no. 223, wherein the at least one silicide is NbSi₂which is between about 31% and about 91% of the total weight of the material.

227. The material as in above item no. 223, wherein the at least one silicide is TaSi₂which is between about 38% and about 93% of the total weight of the material.

228. The material as in above item no. 223, wherein the at least one silicide is MoSi₂which is between about 31% and about 91% of the total weight of the material.

229. The material as in above item no. 223, wherein the at least one silicide is WSi₂which is between about 40% and about 94% of the total weight of the material.

230. A material, comprising:

hard particles comprising at least one nitride from nitrides of IVB and VB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 71% of a total weight of the material and cobalt which is less than 52% of the total weight of the material.

231. The material as in above item no. 230, wherein the at least one nitride is TiN which is between about 28% and about 95% of the total weight of the material.

232. The material as in above item no. 230, wherein the at least one nitride is ZrN which is between about 34% and about 96% of the total weight of the material.

233. The material as in above item no. 230, wherein the at least one nitride is HfN which is between about 50% and about 98% of the total weight of the material.

234. The material as in above item no. 230, wherein the at least one nitride is VN which is between about 30% and about 96% of the total weight of the material.

235. The material as in above item no. 230, wherein the at least one nitride is NbN which is between about 34% and about 96% of the total weight of the material.

236. The material as in above item no. 230, wherein the at least one nitride is TaN which is between about 51% and about 98% of the total weight of the material.

237. A material, comprising:

hard particles comprising at least one boride from borides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 75% of a total weight of the material and cobalt which is less than 56% of the total weight of the material.

238. The material as in above item no. 237, wherein the at least one boride is TiB₂which is between about 24% and about 34% of the total weight of the material.

239. The material as in above item no. 237, wherein the at least one boride is ZrB₂which is between about 30% and about 96% of the total weight of the material.

240. The material as in above item no. 237, wherein the at least one boride is HfB₂which is between about 45% and about 98% of the total weight of the material.

241. The material as in above item no. 237, wherein the at least one boride is VB₂which is between about 27% and about 95% of the total weight of the material.

242. The material as in above item no. 237, wherein the at least one boride is NbB₂which is between about 34% and about 96% of the total weight of the material.

243. The material as in above item no. 237, wherein the at least one boride is TaB₂which is between about 48% and about 98% of the total weight of the material.

244. The material as in above item no. 237, wherein the at least one boride is Cr₃B₂which is between about 30% and about 96% of the total weight of the material.

245. The material as in above item no. 237, wherein the at least one boride is MoB₂which is between about 36% and about 97% of the total weight of the material.

246. The material as in above item no. 237, wherein the at least one boride is WB which is between about 53% and about 98% of the total weight of the material.

247. The material as in above item no. 237, wherein the at least one boride is W₂B which is between about 55% and about 98% of the total weight of the material.

248. A material, comprising:

hard particles comprising at least one silicide from silicides of IVB and VB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 76% of a total weight of the material and cobalt which is less than 57% of the total weight of the material.

249. The material as in above item no. 248, wherein the at least one silicide is Ti₅Si₃which is between about 24% and about 94% of the total weight of the material.

250. The material as in above item no. 248, wherein the at least one silicide is Zr₆Si₃which is between about 28% and about 95% of the total weight of the material.

251. The material as in above item no. 248, wherein the at least one silicide is NbSi₂which is between about 31% and about 96% of the total weight of the material.

252. The material as in above item no. 248, wherein the at least one silicide is TaSi₂which is between about 38% and about 97% of the total weight of the material.

253. The material as in above item no. 248, wherein the at least one silicide is MoSi₂which is between about 31% and about 96% of the total weight of the material.

254. The material as in above item no. 248, wherein the at least one silicide is WSi₂which is between about 40% and about 97% of the total weight of the material.

255. A material, comprising:

hard particles comprising at least one carbide from carbides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 74% of a total weight of the material and molybdenum which is less than 57% of the total weight of the material.

256. The material as in above item no. 255, wherein the at least one carbide is TiC which is between about 26% and about 94% of the total weight of the material.

257. The material as in above item no. 255, wherein the at least one carbide is ZrC which is between about 32% and about 95% of the total weight of the material.

258. The material as in above item no. 255, wherein the at least one carbide is HfC which is between about 48% and about 98% of the total weight of the material.

259. The material as in above item no. 255, wherein the at least one carbide is VC which is between about 28% and about 95% of the total weight of the material.

260. The material as in above item no. 255, wherein the at least one carbide is NbC which is between about 36% and about 98% of the total weight of the material.

261. The material as in above item no. 255, wherein the at least one carbide is TaC which is between about 51% and about 98% of the total weight of the material.

262. The material as in above item no. 255, wherein the at least one carbide is Cr₂C₃which is between about 32% and about 95% of the total weight of the material.

263. The material as in above item no. 255, wherein the at least one carbide is Mo₂C which is between about 40% and about 97% of the total weight of the material.

264. The material as in above item no. 255, wherein the at least one carbide is WC which is between about 53% and about 98% of the total weight of the material.

265. A material, comprising:

hard particles comprising at least one carbide from carbides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 74% of a total weight of the material and nickel which is less than 54% of the total weight of the material.

266. The material as in above item no. 265, wherein the at least one carbide is TiC which is between about 26% and about 95% of the total weight of the material.

267. The material as in above item no. 265, wherein the at least one carbide is ZrC which is between about 32% and about 96% of the total weight of the material.

268. The material as in above item no. 265, wherein the at least one carbide is HfC which is between about 48% and about 98% of the total weight of the material.

269. The material as in above item no. 265, wherein the at least one carbide is VC which is between about 28% and about 95% of the total weight of the material.

270. The material as in above item no. 265, wherein the at least one carbide is NbC which is between about 36% and about 97% of the total weight of the material.

271. The material as in above item no. 265, wherein the at least one carbide is TaC which is between about 51% and about 98% of the total weight of the material.

272. The material as in above item no. 265, wherein the at least one carbide is Cr₂C₃which is between about 32% and about 96% of the total weight of the material.

273. The material as in above item no. 265, wherein the at least one carbide is Mo₂C which is between about 40% and about 97% of the total weight of the material.

274. The material as in above item no. 265, wherein the at least one carbide is WC which is between about 53% and about 98% of the total weight of the material.

275. A material, comprising:

hard particles comprising at least one carbide from carbides of IVB, VB and VIB columns in the periodic table; and

a binder matrix that binds the hard particles and comprises rhenium which is less than 74% of a total weight of the material and chromium which is less than 48% of the total weight of the material.

276. The material as in above item no. 275, wherein the at least one carbide is TiC which is between about 26% and about 96% of the total weight of the material.

277. The material as in above item no. 275, wherein the at least one carbide is ZrC which is between about 32% and about 97% of the total weight of the material.

278. The material as in above item no. 275, wherein the at least one carbide is HfC which is between about 48% and about 98% of the total weight of the material.

279. The material as in above item no. 275, wherein the at least one carbide is VC which is between about 28% and about 95% of the total weight of the material.

280. The material as in above item no. 275, wherein the at least one carbide is NbC which is between about 36% and about 97% of the total weight of the material.

281. The material as in above item no. 275, wherein the at least one carbide is TaC which is between about 51% and about 98% of the total weight of the material.

282. The material as in above item no. 275, wherein the at least one carbide is Cr₂C₃which is between about 32% and about 97% of the total weight of the material.

283. The material as in above item no. 275, wherein the at least one carbide is Mo₂C which is between about 40% and about 98% of the total weight of the material.

284. The material as in above item no. 275, wherein the at least one carbide is WC which is between about 53% and about 98.6% of the total weight of the material.

285. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to deposit a hardmetal over the metal surface,

wherein the hard metal comprises:

hard particles comprising at least a material made of a carbide, nitride, boride, or silicide; and

a binder matrix to bind the hard particles and comprising at least rhenium.

286. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to deposit a hardmetal over the metal surface,

wherein the hard metal comprises:

hard particles comprising at least a material made of a carbide, nitride, boride, or silicide; and

a binder matrix to bind the hard particles and comprising at least a Ni-based superalloy.

287. A method, comprising:

preparing a metal surface for a thermal spray process; and

performing the thermal spray process to deposit a hardmetal over the metal surface,

wherein the hard metal comprises:

hard particles comprising at least a material made of a carbide, nitride, boride, or silicide; and

a binder matrix to bind the hard particles and comprising at least tungsten.

These and other features, implementations, and advantages are now described in details with respect to the drawings, the detailed description, and the claims.

DRAWING DESCRIPTION

FIG. 1 shows one exemplary fabrication flow in making a hardmetal according to one implementation.

FIG. 2 shows an exemplary two-step sintering process for processing hardmetals in a solid state.

FIGS. 3, 4, 5, 6, 7, and 8 show various measured properties of selected exemplary hardmetals.

FIGS. 9 and 10 illustrate examples of the thermal spray methods.

FIG. 11 shows one example of a friction stir welding tool system with a friction stir welding head that uses a material described in this application.

DETAILED DESCRIPTION

Friction stir welding is a solid-state welding process to join metal components without melting and to avoid various adverse effects associated with traditional welding techniques that melt the metal pieces. Notably, the friction stir welding can be used to produce large welds in a variety of geometric configurations, where a rotating cylindrical tool head is plunged into a rigidly clamped workpiece, and then traversed along the joint between two metal piences to be welded. The tool is specially designed to provide a combination of frictional heat and thermo-mechanical working to the workpiece material as the tool traverses along the joint. A strong, solid-state bond is formed in the wake of the tool.

FIG. 11 illustrates one example of a FSW system. A FSW head 102 is engaged to a shank 108 which is in turn fixed to a rotor can include a pin and a shoulder to which the pin is engaged. A chuck may be used to hold the shank so that the rotor rotates the shank 108 which spins the head 102 during welding. In operation, the spinning head is pressed to the interface of two metal pieces 1 and 2 to be welded together and is moved along the joint interface. The head 102 includes a shoulder 104 that is engaged to the shank 108 and a pin 106 that is engaged to the shoulder 104. The pin 106 and the shoulder 104 are in direct contact with the two pieces to weld them together. In some implementations, the pin 106 and the shoulder 104 are made of a hardmetal material described in this application. In other implementations, the surfaces of the pin and shoulder may be made of a material described in this application while the inner parts of the pin and shoulder may be made of a different material. Various materials described here exhibit high hardness and toughness under a high temoperature experienced by the pin and shoulder during the friction stir welding and thus can be used for constructing the head.

Examples of the FSW head designs are also described in U.S. Pat. No. 6, 648,206 entitled “Frication stir welding using a superabrasive tool” and U.S. Patent Publication No. US2004/0238599(A1) entitled “Apparatus and method for friction stir welding of high strength materials and articles made thereform.” The above two U.S. patent documents are incorporated by reference as part of the specification of this application.

In some implementations, the whole FSW tool or pin and shoulder of the FSW tool may be made from a material such as a cermet described in this application. For example, a cermet may a metal bound ceramic particles from at least one ccerameic material. Examples of the ceramics include Carbides, Nitrides, Borides, and Silicides. Carbide may include at least one of TiC, ZrC, HfC, VC, NbC, TaC, Cr₃C₂, MoC, Mo₂C, WC, W₂C. The nitride may include at least one of TiN, ZrN, HfN, VN, NbN. The boride may include at least one of TiB₂, ZrB₂, HfB₂, VB₂, NbB₂, TaB₂, Cr₃C₂, CrB₂, Mo₂C, MoB, MoB₂, W₂C, WB. The silicide may include at least one of Ti₅Si₃, Zr₆Si₅, Zr₃Si₂, Zr₄Si₃, ZrSi, HfSi₂, NbSi₂, TaSi₂, Mo₃Si₂, MoSi₂, W₃Si₂, WSi₂. At least one or more metal binder matesrials may be used to bind the pargicles, e.g., Re, a Ni based superalloy, Re—Ni based superalloy, Re—Co, Re—Ni, Re—Fe, Re—Cr, Re—Mo, Ni based superalloy-Fe, Ni based superalloy-Ni, Ni based superalloy-Co, Ni based superalloy-Cr, Ni based superalloy-Mo, Ni based superalloy-Ni based superalloy, Re—Ni based superalloy-Ni, Re—Ni based superalloy-Co, Re—Ni based superalloy-Fe, Re—Ni based superalloy-Cr, and Re—Ni based superalloy-Mo.

More examples of the materials for the shoulder and the pin are described below.

Compositions of hardmetals are important in that they directly affect the technical performance of the hardmetals in their intended applications, and processing conditions and equipment used during fabrication of such hardmetals. The hardmetal compositions also can directly affect the cost of the raw materials for the hardmetals, and the costs associated with the fabrication processes. For these and other reasons, extensive efforts have been made in the hardmetal industry to develop technically superior and economically feasible compositions for hardmetals. This application describes, among other features, material compositions for hardmetals with selected binder matrix materials that, together, provide performance advantages.

Material compositions for hardmetals of interest include various hard particles and various binder matrix materials. In general, the hard particles may be formed from carbides of the metals in columns IVB (e.g., TiC, ZrC, HfC), VB (e.g., VC, NbC, TaC), and VIB (e.g., Cr₃C₂, Mo₂C, WC) in the Periodic Table of Elements. In addition, nitrides formed by metals elements in columns IVB (e.g., TiN, ZrN, HfN) and VB (e.g., VN, NbN, and TaN) in the Periodic Table of Elements may also be used. For example, one material composition for hard particles that is widely used for many hardmetals is a tungsten carbide, e.g., the mono tungsten carbide (WC). Various nitrides may be mixed with carbides to form the hard particles. Two or more of the above and other carbides and nitrides may be combined to form WC-based hardmetals or WC-free hardmetals. Examples of mixtures of different carbides include but are not limited to a mixture of WC and TiC, and a mixture of WC, TiC, and TaC. In addition to various carbides, nitrides, carbonitrides, borides, and silicides may also be used as hard particles for hardmetals. Examples of various suitable hard particles are described in this application.

The material composition of the binder matrix, in addition to providing a matrix for bonding the hard particles together, can significantly affect the hard and refractory properties of the resulting hardmetals. In general, the binder matrix may include one or more transition metals in the eighth column of the Periodic Table of Elements, such as cobalt (Co), nickel (Ni), and iron (Fe), and the metals in the 6B column such as molybdenum (Mo) and chromium (Cr). Two or more of such and other binder metals may be mixed together to form desired binder matrices for bonding suitable hard particles. Some binder matrices, for example, use combinations of Co, Ni, and Mo with different relative weights.

The hardmetal compositions described here were developed in part based on a recognition that the material composition of the binder matrix may be specially configured and tailored to provide high-performance hardmetals to meet specific needs of various applications. In particular, the material composition of the binder matrix has significant effects on other material properties of the resulting hardmetals, such as the elasticity, the rigidity, and the strength parameters (including the transverse rupture strength, the tensile strength, and the impact strength). Hence, the inventor recognized that it was desirable to provide the proper material composition for the binder matrix to better match the material composition of the hard particles and other components of the hardmetals in order to enhance the material properties and the performance of the resulting hardmetals.

More specifically, these hardmetal compositions use binder matrices that include rhenium, a nickel-based superalloy or a combination of at least one nickel-based superalloy and other binder materials. Other suitable binder materials may include, among others, rhenium (Re) or cobalt. A Ni-based superalloy exhibits a high material strength at a relatively high temperature. The resulting hardmetal formed with such a binder material can benefit from the high material strength at high temperatures of rhenium and Ni-superalloy and exhibit enhanced performance at high temperatures. In addition, a Ni-based superalloy also exhibits superior resistance to corrosion and oxidation, and thus, when used as a binder material, can improve the corresponding resistance of the hardmetals.

The compositions of the hardmetals described in this application may include the binder matrix material from about 3% to about 40% by volume of the total materials in the hardmetals so that the corresponding volume percentage of the hard particles is about from 97% to about 60%, respectively. Within the above volume percentage range, the binder matrix material in certain implementations may be from about 4% to about 35% by volume out of the volume of the total hardmetal materials. More preferably, some compositions of the hardmetals may have from about 5% to about 30% of the binder matrix material by volume out of the volume of the total hardmetal materials. The weight percentage of the binder matrix material in the total weight of the resulting hardmetals may be derived from the specific compositions of the hardmetals.

In various implementations, the binder matrices may be formed primarily by a nickel-based superalloy, and by various combinations of the nickel-based superalloy with other elements such as Re, Co, Ni, Fe, Mo, and Cr. A Ni-based superalloy of interest may comprise, in addition to Ni, elements Co, Cr, Al, Ti, Mo, W, and other elements such as Ta, Nb, B, Zr and C. For example, Ni-based superalloys may include the following constituent metals in weight percentage of the total weight of the superalloy: Ni from about 30% to about 70%, Cr from about 10% to about 30%, Co from about 0% to about 25%, a total of Al and Ti from about 4% to about 12%, Mo from about 0% to about 10%, W from about 0% to about 10%, Ta from about 0% to about 10%, Nb from about 0% to about 5%, and Hf from about 0% to about 5%. Ni-based superalloys may also include either or both of Re and Hf. e.g., Re from 0% to about 10%, and Hf from 0% to about 5%. Ni-based superalloy with Re may be used in applications under high temperatures. A Ni-based super alloy may further include other elements, such as B, Zr, and C, in small amounts.

Compounds TaC and NbC have similar properties to a certain extent and may be used to partially or completely substitute or replace each other in hardmetal compositions in some implementations. Either one or both of HfC and NbC also may be used to substitute or replace a part or all of TaC in hardmetal designs. Compounds WC, TiC, TaC may be produced individually and then mixed to form a mixture or may be produced in a form of a solid solution. When a mixture is used, the mixture may be selected from at least one from a group consisting of (1) a mixture of WC, TiC, and TaC, (2) a mixture of WC, TiC, and NbC, (3) a mixture of WC, TiC, and at least one of TaC and NbC, and (4) a mixture of WC, TiC, and at least one of HfC and NbC. A solid solution of multiple carbides may exhibit better properties and performances than a mixture of several carbides. Hence, hard particles may be selected from at least one from a group consisting of (1) a solid solution of WC, TiC, and TaC, (2) a solid solution of WC, TiC, and NbC, (3) a solid solution of WC, TiC, and at least one of TaC and NbC, and (4) a solid solution of WC, TiC, and at least one of HfC and NbC.

The nickel-based superalloy as a binder material may be in a γ-γ′ phase where the γ′ phase with a FCC structure mixes with the γ phase. The strength increases with temperature within a certain extent. Another desirable property of such a Ni-based superalloy is its high resistance to oxidation and corrosion. The nickel-based superalloy may be used to either partially or entirely replace Co in various Co-based binder compositions. As demonstrated by examples disclosed in this application, the inclusion of both of rhenium and a nickel-based superalloy in a binder matrix of a hardmetal can significantly improve the performance of the resulting hardmetal by benefiting from the superior performance at high temperatures from presence of Re while utilizing the relatively low-sintering temperature of the Ni-based superalloy to maintain a reasonably low sintering temperature for ease of fabrication. In addition, the relatively low content of Re in such binder compositions allows for reduced cost of the binder materials so that such materials be economically feasible.

Such a nickel-based superalloy may have a percentage weight from several percent to 100% with respect to the total weight of all material components in the binder matrix based on the specific composition of the binder matrix. A typical nickel-based superalloy may primarily comprise nickel and other metal components in a γ-γ′ phase strengthened state so that it exhibits an enhanced strength which increases as temperature rises.

Various nickel-based superalloys may have a melting point lower than the common binder material cobalt, such as alloys under the trade names Rene-95, Udimet-700, Udimet-720 from Special Metals which comprise primarily Ni in combination with Co, Cr, Al, Ti, Mo, Nb, W, B, and Zr. Hence, using such a nickel-based superalloy alone as a binder material may not increase the melting point of the resulting hardmetals in comparison with hardmetals using binders with Co.

However, in one implementation, the nickel-based superalloy can be used in the binder to provide a high material strength and to improve the material hardness of the resulting hardmetals, at high temperatures near or above 500° C. Tests of some fabricated samples have demonstrated that the material hardness and strength for hardmetals with a Ni-based superalloy in the binder can improve significantly, e.g., by at least 10%, at low operating temperatures in comparison with similar material compositions without Ni-based superalloy in the binder. The following table show measured hardness parameters of samples P65 and P46A with Ni-based superalloy in the binder in comparison with samples P49 and P47A with pure Co as the binder, where the compositions of the samples are listed in Table 4.

Effects of Ni-based Superalloy (NS) in BinderSampleHv at RoomKsc at roomCodeCo or NSTemperaturetemperatureNameBinder(Kg/mm²)(×10⁶Pa · m^1/2)ComparisonP49Co: 1021866.5volume %P65NS: 1025326.7Hv is about 16%volume %greater than thatof P49P47ACo: 1521606.4volume %P46ANS: 1523646.4Hv is about 10%volume %greater than thatof P47A

Notably, at high operating temperatures above 500° C., hardmetal samples with Ni-based superalloy in the binder can exhibit a material hardness that is significantly higher than that of similar hardmetal samples without having a Ni-based superalloy in the binder. In addition, Ni-based superalloy as a binder material can also improve the resistance to corrosion of the resulting hardmetals or cermets in comparison with hardmetals or cermets using the conventional cobalt as the binder.

A nickel-based superalloy may be used alone or in combination with other elements to form a desired binder matrix. Other elements that may be combined with the nickel-based superalloy to form a binder matrix include but are not limited to, another nickel-based superalloy, other non-nickel-based alloys, Re, Co, Ni, Fe, Mo, and Cr.

Rhenium as a binder material may be used to provide strong bonding of hard particles and in particular can produce a high melting point for the resulting hardmetal material. The melting point of rhenium is about 3180° C., much higher than the melting point of 1495° C. of the commonly-used cobalt as a binder material. This feature of rhenium partially contributes to the enhanced performance of hardmetals with binders using Re, e.g., the enhanced hardness and strength of the resulting hardmetals at high temperatures. Re also has other desired properties as a binder material. For example, the hardness, the transverse rapture strength, the fracture toughness, and the melting point of the hardmetals with Re in their binder matrices can be increased significantly in comparison with similar hardmetals without Re in the binder matrices. A hardness Hv over 2600 Kg/mm²has been achieved in exemplary WC-based hardmetals with Re in the binder matrices. The melting point of some exemplary WC-based hardmetals, i.e., the sintering temperature, has shown to be greater than 2200° C. In comparison, the sintering temperature for WC-based hardmetals with Co in the binders in Table 2.1 in the cited Brookes is below 1500° C. A hardmetal with a high sintering temperature allows the material to operate at a high temperature below the sintering temperature. For example, tools based on such Re-containing hardmetal materials may operate at high speeds to reduce the processing time and the overall throughput of the processing.

The use of Re as a binder material in hardmetals, however, may present limitations in practice. For example, the desirable high-temperature property of Re generally leads to a high sintering temperature for fabrication. Thus, the oven or furnace for the conventional sintering process needs to operate at or above the high sintering temperature. Ovens or furnaces capable of operating at such high temperatures, e.g., above 2200° C., can be expensive and may not be widely available for commercial use. U.S. Pat. No. 5,476,531 discloses a use of a rapid omnidirectional compaction (ROC) method to reduce the processing temperature in manufacturing WC-based hardmetals with pure Re as the binder material from 6% to 18% of the total weight of each hardmetal. This ROC process, however, is still expensive and is generally not suitable for commercial fabrication.

One potential advantage of the hardmetal compositions and the composition methods described here is that they may provide or allow for a more practical fabrication process for fabricating hardmetals with either Re or mixtures of Re with other binder materials in the binder matrices. In particular, this two-step process makes it possible to fabricate hardmetals where Re is at or more than 25% of the total weight of the binder matrix of the resulting hardmetal. Such hardmetals with Re at or more than 25% may be used to achieve a high hardness and a high material strength at high temperatures.

Another limitation of using pure Re as a binder material for hardmetals is that Re oxidizes severely in air at or above about 350° C. This poor oxidation resistance may dramatically reduce the use of pure Re as binder for any application above about 300° C. Since Ni-based superalloy has exceptionally strength and oxidation resistance under 1000° C., a mixture of a Ni-based superalloy and Re where Re is the dominant material in the binder may be used to improve the strength and oxidation resistance of the resulting hardmetal using such a mixture as the binder. On the other hand, the addition of Re into a binder primarily comprised of a Ni-based superalloy can increase the melting range of the resulting hardmetal, and improve the high temperature strength and creep resistance of the Ni-based superalloy binder.

In general, the percentage weight of the rhenium in the binder matrix should be between a several percent to essentially 100% of the total weight of the binder matrix in a hardmetal. Preferably, the percentage weight of rhenium in the binder matrix should be at or above 5%. In particular, the percentage weight of rhenium in the binder matrix may be at or above 10% of the binder matrix. In some implementations, the percentage weight of rhenium in the binder matrix may be at or above 25% of the total weight of the binder matrix of the resulting hardmetal. Hardmetals with such a high concentration of Re may be fabricated at relatively low temperatures with a two-step process described in this application.

Since rhenium is generally more expensive than other materials used in hardmetals, cost should be considered in designing binder matrices that include rhenium. Some of the examples given below reflect this consideration. In general, according to one implementation, a hardmetal composition includes dispersed hard particles having a first material, and a binder matrix having a second, different material that includes rhenium, where the hard particles are spatially dispersed in the binder matrix in a substantially uniform manner. The binder matrix may be a mixture of Re and other binder materials to reduce the total content of Re to in part reduce the overall cost of the raw materials and in part to explore the presence of other binder materials to enhance the performance of the binder matrix. Examples of binder matrices having mixtures of Re and other binder materials include, mixtures of Re and at least one Ni-based superalloy, mixtures of Re, Co and at least one Ni-based superalloy, mixtures of Re and Co, and others.

TABLE 1 lists some examples of hardmetal compositions of interest. In this table, WC-based compositions are referred to as “hardmetals” and the TiC-based compositions are referred to as “cermets.” Traditionally, TiC particles bound by a mixture of Ni and Mo or a mixture of Ni and Mo₂C are cermets. Cermets as described here further include hard particles formed by mixtures of TiC and TiN, of TiC, TiN, WC, TaC, and NbC with the binder matrices formed by the mixture of Ni and Mo or the mixture of Ni and Mo₂C. For each hardmetal composition, three different weight percentage ranges for the given binder material in the are listed. As an example, the binder may be a mixture of a Ni-based superalloy and cobalt, and the hard particles may a mixture of WC, TiC, TaC, and NbC. In this composition, the binder may be from about 2% to about 40% of the total weight of the hardmetal. This range may be set to from about 3% to about 35% in some applications and may be further limited to a smaller range from about 4% to about 30% in other applications.

TABLE 1(NS: Ni-based superalloy)BinderComposition for1^stBinder Wt. %2^ndBinder Wt. %3^rdBinder Wt. %CompositionHard ParticlesRangeRangeRangeHardmetalsReWC4 to 405 to 356 to 30WC—TiC—TaC—NbC4 to 405 to 356 to 30NSWC2 to 303 to 254 to 20WC—TiC—TaC—NbC2 to 303 to 254 to 20NS-ReWC2 to 403 to 354 to 30WC—TiC—TaC—NbC2 to 403 to 354 to 30Re—CoWC2 to 403 to 354 to 30WC—TiC—TaC—NbC2 to 403 to 354 to 30NS-Re—CoWC2 to 403 to 354 to 30WC—TiC—TaC—NbC2 to 403 to 354 to 30CermetsNSMo₂C—TiC5 to 406 to 358 to 40Mo₂C—TiC—TiN—WC—TaC—NbC5 to 406 to 358 to 40ReMo₂C—TiC10 to 55 12 to 50 15 to 45 Mo₂C—TiC—TiN—WC—TaC—NbC10 to 55 12 to 50 15 to 45 NS-ReMo₂C—TiC5 to 556 to 508 to 45Mo₂C—TiC—TiN—WC—TaC—NbC5 to 556 to 508 to 45

Fabrication of hardmetals with Re or a nickel-based superalloy in binder matrices may be carried out as follows. First, a powder with desired hard particles such as one or more carbides or carbonitrides is prepared. This powder may include a mixture of different carbides or a mixture of carbides and nitrides. The powder is mixed with a suitable binder matrix material that includes Re or a nickel-based superalloy. In addition, a pressing lubricant, e.g., a wax, may be added to the mixture.

The mixture of the hard particles, the binder matrix material, and the lubricant is mixed through a milling or attriting process by milling or attriting over a desired period, e.g., hours, to fully mix the materials so that each hard particle is coated with the binder matrix material to facilitate the binding of the hard particles in the subsequent processes. The hard particles should also be coated with the lubricant material to lubricate the materials to facilitate the mixing process and to reduce or eliminate oxidation of the hard particles. Next, pressing, presintering, shaping, and final sintering are subsequently performed to the milled mixture to form the resulting hardmetal. The sintering process is a process for converting a powder material into a continuous mass by heating to a temperature that is below the melting temperature of the hard particles and may be performed after preliminary compacting by pressure. During this process, the binder material is densified to form a continuous binder matrix to bind hard particles therein. One or more additional coatings may be further formed on a surface of the resulting hardmetal to enhance the performance of the hardmetal. FIG. 1 is a flowchart for this implementation of the fabrication process.

In one implementation, the manufacture process for cemented carbides includes wet milling in solvent, vacuum drying, pressing, and liquid-phase sintering in vacuum. The temperature of the liquid-phase sintering is between melting point of the binder material (e.g., Co at 1495° C.) and the eutectic temperature of the mixture of hardmetal (e.g., WC—Co at 1320° C.). In general, the sintering temperature of cemented carbide is in a range of 1360 to 1480° C. For new materials with low concentration of Re or a Ni-based superalloy in binder alloy, manufacture process is same as conventional cemented carbide process. The principle of liquid phase sintering in vacuum is applied in here. The sintering temperature is slightly higher than the eutectic temperature of binder alloy and carbide. For example, the sintering condition of P17 (25% of Re in binder alloy, by weight ) is at 1700° C. for one hour in vacuum.

FIG. 2 shows a two-step fabrication process based on a solid-state phase sintering for fabricating various hardmetals described in this application. Examples of hardmetals that can be fabricated with this two-step sintering method include hardmetals with a high concentration of Re in the binder matrix that would otherwise require the liquid-phase sintering at high temperatures. This two-step process may be implemented at relatively low temperatures, e.g., under 2200° C., to utilize commercially feasible ovens and to produce the hardmetals at reasonably low costs. The liquid phase sintering is eliminated in this two-step process because the liquid phase sintering may not be practical due to the generally high eutectic temperatures of the binder alloy and carbide. As discussed above, sintering at such high temperatures requires ovens operating at high temperatures which may not be commercially feasible.

The first step of this two-step process is a vacuum sintering where the mixture materials for the binder matrix and the hard particles are sintered in vacuum. The mixture is initially processed by, e.g., wet milling, drying, and pressing, as performed in conventional processes for fabricating cemented carbides. This first step of sintering is performed at a temperature below the eutectic temperature of the binder alloy and the hard particle materials to remove or eliminate the interconnected porosity. The second step is a solid phase sintering at a temperature below the eutectic temperature and under a pressured condition to remove and eliminate the remaining porosities and voids left in the sintered mixture after the first step. A hot isostatic pressing (HIP) process may be used as this second step sintering. Both heat and pressure are applied to the material during the sintering to reduce the processing temperature which would otherwise be higher in absence of the pressure. A gas medium such as an inert gas may be used to apply and transmit the pressure to the sintered mixture. The pressure may be at or over 1000 bar. Application of pressure in the HIP process lowers the required processing temperature and allows for use of conventional ovens or furnaces. The temperatures of solid phase sintering and HIPping for achieving fully condensed materials are generally significantly lower than the temperatures for liquid phase sintering. For example, the sample P62 which uses pure Re as the binder may be fully densified by vacuum sintering at 2200° C. for one to two hours and then HIPping at about 2000° C. under a pressure of 30,000 PSI in the inert gas such as Ar for about one hour. Notably, the use of ultra fine hard particles with a particulate dimension less than 0.5 micron can reduce the sintering temperature for fully densifying the hardmetals (fine particles are several microns in size). For example, in making the samples P62 and P63, the use of such ultra fine WC allows for sintering temperatures to be low, e.g., around 2000° C. This two-step process is less expensive than the ROC method and may be used to commercial production.

The following sections describe exemplary hardmetal compositions and their properties based on various binder matrix materials that include at least rhenium or a nickel-based superalloy.

TABLE 2 provides a list of code names (lot numbers) for some of the constituent materials used to form the exemplary hardmetals, where H1 represents rhenium, and L1, L2, and L3 represent three exemplary commercial nickel-based superalloys. TABLE 3 further lists compositions of the above three exemplary nickel-based superalloys, Udimet720(U720), Rene+ 95(R-95), and Udimet700(U700), respectively. TABLE 4 lists compositions of exemplary hardmetals, both with and without rhenium or a nickel-based superalloy in the binder matrices. For example, the material composition for Lot P17 primarily includes 88 grams of T32 (WC), 3 grams of I32 (TiC), 3 grams of A31 (TaC), 1.5 grams of H1 (Re) and 4.5 grams of L2 (R-95) as binder, and 2 grams of a wax as lubricant. Lot P58 represents a hardmetal with a nickel-based superalloy L2 as the only binder material without Re. These hardmetals were fabricated and tested to illustrate the effects of either or both of rhenium and a nickel-based superalloy as binder materials on various properties of the resulting hardmetals. TABLES 5-8 further provide summary information of compositions and properties of different sample lots as defined above.

FIGS. 3 through 8 show measurements of selected hardmetal samples of this application. FIGS. 3 and 4 show measured toughness and hardness parameters of some exemplary hardmetals for the steel cutting grades. FIGS. 5 and 6 show measured toughness and hardness parameters of some exemplary hardmetals for the non-ferrous cutting grades. Measurements were performed before and after the solid-phase sintering HIP process and the data suggests that the HIP process significantly improves both the toughness and the hardness of the materials. FIG. 7 shows measurements of the hardness as a function of temperature for some samples. As a comparison, FIGS. 7 and 8 also show measurements of commercial C2 and C6 carbides under the same testing conditions, where FIG. 7 shows the measured hardness and FIG. 8 shows measured change in hardness from the value at the room temperature (RT). Clearly, the hardmetal samples based on the compositions described here outperform the commercial grade materials in terms of the hardness at high temperatures. These results demonstrate that the superior performance of binder matrices with either or both of Re and a nickel-based superalloy as binder materials in comparison with Co-based binder matrix materials.

TABLE 2PowderCodeCompositionNoteT32WCParticle size 1.5 μm, from AlldyneT35WCParticle size 15 μm, from AlldyneY20MoParticle size 1.7-2.2 μm, from AlldyneL3U-700−325 Mesh, special metal Udimet 700L1U-720−325 Mesh, Special Metal, Udimet 720L2Re-95−325 Mesh, Special Metal, Rene 95H1Re−325 Mesh, Rhenium Alloy Inc.I32TiCfrom AEE, Ti-302I21TiB₂from AEE, Ti-201, 1-5 μmA31TaCfrom AEE, TA-301Y31Mo₂Cfrom AEE, MO-301D31VCfrom AEE, VA-301B1Cofrom AEE, CO-101K1Nifrom AEE, Ni-101K2Nifrom AEE, Ni-102I13TiNfrom Cerac, T-1153C21ZrB2from Cerac, Z-1031Y6Mofrom AEE Mo + 100, 1-2 μmL6Alfrom AEE Al − 100, 1-5 μmR31B₄Cfrom AEE Bo-301, 3 μmT3.8WCParticle size 0.8 μm, AlldyneT3.4WCParticle size 0.4 μm, OMGT3.2WCParticle size 0.2 μm, OMG

TABLE 3

Ni
Co
Cr
Al
Ti
Mo
Nb
W
Zr
B
C
V

R95
61.982
8.04
13.16
3.54
2.53
3.55
3.55
3.54
0.049

0.059

U700
54.331
17.34
15.35
4.04
3.65
5.17
.028
.008
.04
.019
.019
.005

U720
56.334
15.32
16.38
3.06
5.04
3.06
0.01
1.30
.035
.015
.012
.004

TABLE 4

Lot No
Composition (units in grams)

P17
H1 = 1.5, L2 = 4.5, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P18
H1 = 3, L2 = 3, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P19
H1 = 1.5, L3 = 4.5, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P20
H1 = 3, L3 = 3, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P25
H1 = 3.75, L2 = 2.25, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P25A
H1 = 3.75, L2 = 2.25, I32 = 3, A31 = 3, T32 = 88, Wax = 2

P31
H1 = 3.44, B1 = 4.4, T32 = 92.16, Wax = 2

P32
H1 = 6.75, B1 = 2.88, T32 = 90.37, Wax = 2

P33
H1 = 9.93, B1 = 1.41, T32 = 88.66, Wax = 2

P34
L2 = 14.47, I32 = 69.44, Y31 = 16.09

P35
H1 = 8.77, L2 = 10.27, I32 = 65.73, Y31 = 15.23

P36
H1 = 16.66, L2 = 6.50, I32 = 62.4, Y31 = 14.56

P37
H1 = 23.80, L2 = 3.09, I32 = 59.38, Y31 = 13.76

P38
K1 = 15.51, I32 = 68.60, Y31 = 15.89

P39
K2 = 15.51, I32 = 68.60, Y31 = 15.89

P40
H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T32 = 78.92, Wax = 2

P40A
H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T32 = 78.92, Wax = 2

P41
H1 = 11.1, L2 = 1.45, I32 = 5.20, A31 = 5.11, T32 = 77.14, Wax = 2

P41A
H1 = 11.1, L2 = 1.45, I32 = 5.20, A31 = 5.11, T32 = 77.14, Wax = 2

P42
H1 = 9.32, L2 = 3.64, I32 = 6.55, A31 = 6.44, I21 = 0.40, R31 = 4.25, T32 = 69.40, Wax = 2

P43
H1 = 9.04, L2 = 3.53, I32 = 6.35, A31 = 6.24, I21 = 7.39, R31 = 0.22, T32 = 67.24, Wax = 2

P44
H1 = 8.96, L2 = 3.50, I32 = 14.69, A31 = 6.19, T32 = 66.67, Wax = 2

P45
H1 = 9.37, L2 = 3.66, I32 = 15.37, A31 = 6.47, Y31 = 6.51, T32 = 58.61, Wax = 2

P46
H1 = 11.40, L2 = 4.45, I32 = 5.34, A31 = 5.25, T32 = 73.55, Wax = 2

P46A
H1 = 11.40, L2 = 4.45, I32 = 5.34, A31 = 5.25, T32 = 73.55, Wax = 2

P47
H1 = 11.35, B1 = 4.88, I32 = 5.32, A31 = 5.23, T32 = 73.22, Wax = 2

P47A
H1 = 11.35, B1 = 4.88, I32 = 5.32, A31 = 5.23, T32 = 73.22, Wax = 2

P48
H1 = 3.75, L2 = 2.25, I32 = 5, A31 = 5, T32 = 84, Wax = 2

P49
H1 = 7.55, B1 = 3.25, I32 = 5.31, A31 = 5.21, T32 = 78.68, Wax = 2

P50
H1 = 4.83, L2 = 1.89, I32 = 5.31, A31 = 5.22, T32 = 82.75, Wax = 2

P51
H1 = 7.15, L2 = 0.93, I32 = 5.23, A31 = 5.14, T32 = 81.55, Wax = 2

P52
B1 = 8, D31 = 0.6, T3.8 = 91.4, Wax = 2

P53
B1 = 8, D31 = 0.6, T3.4 = 91.4, Wax = 2

P54
B1 = 8, D31 = 0.6, T3.2 = 91.4, Wax = 2

P55
H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.4 = 90.4, Wax = 2

P56
H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.2 = 90.4, Wax = 2

P56A
H1 = 1.8, B1 = 7.2, D31 = 0.6, T3.2 = 90.4, Wax = 2

P57
H1 = 1.8, B1 = 7.2, T3.2 = 91, Wax = 2

P58
L2 = 7.5, D31 = 0.6, T3.2 = 91.9, Wax = 2

P59
H1 = 0.4, B1 = 3, L2 = 4.5, D31 = 0.6, T3.2 = 91.5, Wax = 2

P62
H1 = 14.48, I32 = 5.09, A31 = 5.00, T3.2 = 75.43, Wax = 2

P62A
H1 = 14.48, I32 = 5.09, A31 = 5.00, T3.2 = 75.43, Wax = 2

P63
H1 = 12.47, L2 = 0.86, I32 = 5.16, A31 = 5.07, T3.2 = 76.45, Wax = 2

P65
H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T3.2 = 78.92, Wax = 2

P65A
H1 = 7.57, L2 = 2.96, I32 = 5.32, A31 = 5.23, T3.2 = 78.92, Wax = 2

P66
H1 = 27.92, I32 = 4.91, A31 = 4.82, T3.2 = 62.35, Wax = 2

P67
H1 = 24.37, L3 = 1.62, I32 = 5.04, A31 = 4.95, T32 = 32.01, T33 = 32.01, Wax = 2

P69
L2 = 7.5, D31 = 0.4, T3.2 = 92.1, Wax = 2

P70
L1 = 7.4, D31 = 0.3, T3.2 = 92.3, Wax = 2

P71
L3 = 7.2, D31 = 0.3, T3.2 = 92.5, Wax = 2

P72
H1 = 1.8, B1 = 7.2, D31 = 0.3, T3.2 = 90.7, Wax = 2

P73
H1 = 1.8, B1 = 4.8, L2 = 2.7, D31 = 0.3, T3.2 = 90.4, Wax = 2

P74
H1 = 1.8, B1 = 3, L2 = 4.5, D31 = 0.3, T3.2 = 90.4, Wax = 2

P75
H1 = 0.8, B1 = 3, L2 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2

P76
H1 = 0.8, B1 = 3, L1 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2

P77
H1 = 0.8, B1 = 3, L3 = 4.5, D31 = 0.3, T3.2 = 91.4, Wax = 2

P78
H1 = 0.8, B1 = 4.5, L1 = 3, D31 = 0.3, T3.2 = 91.4, Wax = 2

P79
H1 = 0.8, B1 = 4.5, L3 = 3.1, D31 = 0.3, T3.2 = 91.3, Wax = 2

Several exemplary categories of hardmetal compositions are described below to illustrate the above general designs of the various hardmetal compositions to include either of Re and Nickel-based superalloy, or both. The exemplary categories of hardmetal compositions are defined based on the compositions of the binder matrices for the resulting hardmetals or cermets. The first category uses a binder matrix having pure Re, the second category uses a binder matrix having a Re—Co alloy, the third category uses a binder matrix having a Ni-based superalloy, and the fourth category uses a binder matrix having an alloy having a Ni-based superalloy in combination with of Re with or without Co.

In general, hard and refractory particles used in hardmetals of interest may include, but are not limited to, carbides, nitrides, carbonitrides, borides, and silicides. Some examples of Carbides include WC, TiC, TaC, HfC, NbC, Mo₂C, Cr₂C₃, VC, ZrC, B₄C, and SiC. Examples of Nitrides include TiN, ZrN, HfN, VN, NbN, TaN, and BN. Examples of Carbonitrides include Ti(C,N), Ta(C,N), Nb(C,N), Hf(C,N), Zr(C,N), and V(C,N). Examples of Borides include TiB₂, ZrB₂, HfB₂, TaB₂, VB₂, MoB₂, WB, and W₂B. In addition, examples of Silicides are TaSi₂, Wsi₂, NbSi₂, and MoSi₂. The above-identified four categories of hardmetals or cermets can also use these and other hard and refractory particles.

In the first category of hardmetals based on the pure Re alloy binder matrix, the Re may be approximately from 5% to 40% by volume of all material compositions used in a hardmetal or cermet. For example, the sample with a lot No. P62 in TABLE 4 has 10% of pure Re, 70% of WC, 15% of TiC, and 5% of TaC by volume. This composition approximately corresponds to 14.48% of Re, 75.43% of WC, 5.09% of TiC and 5.0% of TaC by weight. In fabrication, the Specimen P62-4 was vacuum sintered at 2100° C. for about one hour and 2158° C. for about one hour. The density of this material is about 14.51 g/cc, where the calculated density is 14.50 g/cc. The average hardness Hv is 2627±35 Kg/mm²for 10 measurements taken at the room temperature under a load of 10 Kg. The measured surface fracture toughness K_SCis about 7.4×10⁶Pa·m^1/2estimated by Palmvist crack length at a load of 10 Kg.

Another example under this category is P66 in TABLE 4. This sample has about 20% of Re, 60% of WC, 15% of TiC, and 5% of TaC by volume in composition. In the weight percentage, this sample has about 27.92% of Re, 62.35% of WC, 4.91% of TiC, and 4.82% of TaC. The Specimen P66-4 was first processed with a vacuum sintering process at about 2200° C. for one hour and was then sintered in the solid-phase with a HIP process to remove porosities and voids. The density of the resulting hardmetal is about 14.40 g/cc compared to the calculated density of 15.04 g/cc. The average hardness Hv is about 2402±44 Kg/mm²for 7 different measurements taken at the room temperature under a load of 10 Kg. The surface fracture toughness K_SCis about 8.1×10⁶Pa·m^1/2. The sample P66 and other compositions described here with a high concentration of Re with a weight percentage greater than 25%, as the sole binder material or one of two or more different binder materials in the binder, may be used for various applications at high operating temperatures and may be manufactured by using the two-step process based on solid-phase sintering.

The microstructures and properties of Re bound multiples types of hard refractory particles, such as carbides, nitrides, carbon nitrides, silicides, and borides, may provide advantages over Re-bound WC material. For example, Re bound WC—TiC—TaC may have better crater resistance in steel cutting than Re bound WC material. Another example is materials formed by refractory particles of Mo₂C and TiC bound in a Re binder.

For the second category with a Re—Co alloy as the binder matrix, the Re—Co alloy may be about from 5 to 40 Vol % of all material compositions used in the composition. In some implementations, the Re-to-Co ratio in the binder may vary from 0.01 to 0.99 approximately. Inclusion of Re can improve the mechanical properties of the resulting hardmetals, such as hardness, strength and toughness special at high temperature compared to Co bounded hardmetal. The higher Re content is the better high temperature properties are for most materials using such a binder matrix.

The sample P31 in TABLE 4 is one example within this category with 2.5% of Re, 7.5% of Co, and 90% of WC by volume, and 3.44% of Re, 4.40% of Co and 92.12% of WC by weight. In fabrication, the Specimen P31-1 was vacuum sintered at 1725 C. for about one hour. slight under sintering with some porosities and voids. The density of the resulting hardmetal is about 15.16 g/cc (calculated density at 15.27 g/cc). The average hardness Hv is about 1889±18 Kg/mm²at the room temperature under 10 Kg and the surface facture toughness K_SCis about 7.7×10⁶Pa·m^1/2. In addition, the Specimen P31-1 was treated with a hot isostatic press (HIP) process at about 1600 C. /15 Ksi for about one hour after sintering. The HIP reduces or substantially eliminates the porosities and voids in the compound to increase the material density. After HIP, the measured density is about 15.25 g/cc (calculated density at 15.27 g/cc). The measured hardness Hv is about 1887±12 Kg/mm²at the room temperature under 10 Kg. The surface fracture toughness K_SCis about 7.6×10⁶Pa·m^1/2.

Another example in this category is P32 in TABLE 4 with 5.0% of Re, 5.0% of Co, and 90% of WC in volume (6.75% of Re, 2.88% of Co and 90.38% of WC in weight). The Specimen P32-4 was vacuum sintered at 1800 C. for about one hour. The measured density is about 15.58 g/cc in comparison with the calculated density at 15.57 g/cc. The measured hardness Hv is about 2065 Kg/mm²at the room temperature under 10 Kg. The surface fracture toughness K_scis about 5.9×10⁶Pa·m^1/2. The Specimen P32-4 was also HIP at 1600 C /15 Ksi for about one hour after Sintering. The measured density is about 15.57 g/cc (calculated density at 15.57 g/cc). The average hardness Hv is about 2010±12 Kg/mm2 at the room temperature under 10 Kg. The surface fracture toughness K_SCis about 5.8×10⁶Pa·m^1/2.

The third example is P33 in TABLE 4 which has 7.5% of Re, 2.5% of Co, and 90% of WC by volume and 9.93% of Re, 1.41% of Co and 88.66% of WC by weight. In fabrication, the Specimen P33-7 was vacuum sintered at 1950 C. for about one hour and was under sintering with porosities and voids. The measured density is about 15.38 g/cc (calculated density at 15.87 g/cc). The measured hardness Hv is about 2081 Kg/mm²at the room temperature under a force of 10 Kg. The surface fracture toughness Ksc is about 5.6×10⁶Pa·m^1/2. The Specimen P33-7 was HIP at 1600 C./15 Ksi for about one hour after Sintering. The measured density is about 15.82 g/cc (calculated density=15.87 g/cc). The average hardness Hv is measured at about 2039±18 Kg/mm²at the room temperature under 10 Kg. The surface fracture toughness Ksc is about 6.5×10⁶Pa·m^1/2.

TABLE 5Re—Co alloy bound hardmetalsTempera-Densityture ° C.g/ccHvKscGrainSinterHIPCalculatedMeasuredKg/mm²×10⁶Pa · m^1/2sizeP55-11350130014.7714.7920478.6Ultra-fineP56-51360130014.7714.7221338.6Ultra-fineP56A-41350130014.7714.7121088.5Ultra-fineP57-11350130014.9114.93174712.3Fine

The samples P55, P56, P56A, and P57 in TABLE 4 are also examples for the category with a Re—Co alloy as the binder matrix. These samples have about 1.8% of Re, 7.2% of Co, 0.6% of VC except that P57 has no VC, and finally WC in balance. These different composition are made to study the effects of hardmetal grain size on Hv and Ksc. TABLE 5 lists the results.

TABLE 6Properties of Ni-based superalloys, Ni, Re, and CoTestTemp. C.R-95U-700U720NickelRheniumCobaltDensity (g/c.c.)218.27.98.18.9218.9Melting Point (° C.)125512051210145031801495Elastic Modulus2130.332.432.2207460211(Gpa)Ultimate Tensile211620141015703171069234Strength760117010351455(Mpa)800620870690115012004140.2%211310965119560Yield76011008251050Strength800(Mpa)8706351200Tensile2115171330>15Elongation76015209(%)80058702712002Oxidation ResistanceExcellentExcellentExcellentGoodPoorGood

The third category is based on binder matrices with Ni-based superalloys from 5 to 40% in volume of all materials in the resulting hardmetal. Ni-based superalloys are a family of high temperature alloys with γ′ strengthening. Three different strength alloys, Rene′ 95, Udimet 720, and Udimet 700 are used as examples to demonstrate the effects of the binder strength on mechanical properties of the final hardmetals. The Ni-based superalloys have a high strength specially at elevated temperatures. Also, these alloys have good environmental resistance such as resistance to corrosion and oxidation at elevated temperature. Therefore, Ni-based superalloys can be used to increase the hardness of Ni-based superalloy bound hardmetals when compared to Cobalt bound hardmetals. Notably, the tensile strengths of the Ni-based superalloys are much stronger than the common binder material cobalt as shown by TABLE 6. This further shows that Ni-based superalloys are good binder materials for hardmetals.

One example for this category is P58 in TABLE 4 which has 7.5% of Rene′ 95, 0.6% of VC, and 91.9% of WC in weight and compares to cobalt bound P54 in TABLE 4 (8% of Co, 0.6% of VC, and 91.4% of WC). The hardness of P58 is significant higher than P54 as shown in TABLE 7.

TABLE 7Comparison of P54 and P58KscSinteringHIPHv, Kg/mm²×10⁶Pa · m^1/2P54-11350 C./1 hr1305° C.20948.8P54-21380 C./1 hr15KSI under Ar20717.8P54-31420 C./1 hr1 hour21078.5P58-11350, 1380,23227.01400, 1420,1450, 1475for 1 hour ateachtemperatureP58-31450 C./1 hr22727.4P58-51500 C./1 hr22597.2P58-71550 C./1 hr22467.3

The fourth category is Ni-based superalloy plus Re as binder, e.g., approximately from 5% to 40% by volume of all materials in the resulting hardmetal or cermet. Because addition of Re increases the melting point of binder alloy of Ni-based superalloy plus Re, the processing temperature of hardmetal with Ni-based superalloy plus Re binder increases as the Re content increases. Several hardmetals with different Re concentrations are listed in TABLE 8. TABLE 9 further shows the measured properties of the hardmetals in TABLE 8.

TABLE 8Hardmetal with a binder comprising Ni-based superalloy and ReSinteringComposition, weight %TemperatureReRene95U-700U-720WCTiCTaCRe to Binder Ratio° C.P171.54.58833 25%1600˜1750P1833.08833 50%1600˜1775P253.752.25883362.5%1650˜1825P483.752.25845562.5%1650˜1825P504.831.8982.755.315.2271.9%1675˜1850P407.572.9678.925.325.2371.9%1675˜1850P4611.404.4573.555.345.2471.9%1675˜1850P517.150.9381.555.235.1488.5%1700˜1900P4111.101.4577.145.205.1188.5%1700˜1900P6312.470.8676.455.165.0793.6%1850˜2100P191.54.58833 25%1600˜1750P20338833 50%1600˜1775P6724.371.6264.025.044.9593.6%1950˜2300

TABLE 9

Properties of hardmetals bound by Ni-based superalloy and Re

Tem-

pera-

ture, C.
Density, g/cc
Hv
Ksc

Sinter
HIP
Calculated
Measured
Kg/mm²
×10⁶Pa · m^1/2

P17
1700

14.15
14.18
2120
6.8

P17
1700
1600
14.15
14.21
2092
7.2

P18
1700

14.38
14.47
2168
5.9

P18
1700
1600
14.38
14.42
2142
6.1

P25
1750

14.49
14.41
2271
6.1

P25
1750
1600
14.49
14.48
2193
6.5

P48
1800
1600
13.91
13.99
2208
6.3

P50
1800
1600
13.9
13.78
2321
6.5

P40
1800

13.86
13.82
2343

P40
1800
1600
13.86
13.86
2321
6.3

P46
1800

13.81
13.88
2282
7.1

P46
1800
1725
13.81
13.82
2326
6.7

P51
1800
1600
14.11
13.97
2309
6.6

P41
1800
1600
14.18
14.63
2321
6.5

P63
2000

14.31
14.37
2557
7.9

P19
1700

14.11
14.11
2059
7.6

P19
1700
1600
14.11

2012
8.0

P20
1725

14.35
14.52
2221
6.4

P20
1725
1600
14.35
14.35
2151
7.0

P67
2200

14.65
14.21
2113
8.1

P67
2200
1725
14.65
14.34
2210
7.1

Another example under the fourth category uses a Ni-based superalloy plus Re and Co as binder which is also about 5% to 40% by volume. Exemplary compositions of hardmetals bound by Ni-based superalloy plus Re and Co are list in TABLE 10.

TABLE 10Composition of hardmetals bound by Ni-based superalloy plus Re and CoComposition, weight %ReCoRene95U-720U-700WCVCP731.84.82.790.40.3P741.834.590.40.3P750.834.591.40.3P760.834.591.40.3P770.834.591.40.3P780.84.5391.40.3P790.84.53.191.30.3

Measurements on selected samples have been performed to study properties of the binder matrices with Ni-based superalloys. In general, Ni-based superalloys not only exhibit excellent strengths at elevated temperatures but also possess outstanding resistances to oxidation and corrosion at high temperatures. Ni-based superalloys have complex microstructures and strengthening mechanisms. In general, the strengthening of Ni-based superalloys is primarily due to precipitation strengthening of γ-γ′ and solid-solution strengthening. The measurements the selected samples demonstrate that Ni-based superalloys can be used as a high-performance binder materials for hardmetals.

TABLE 11 lists compositions of selected samples by their weight percentages of the total weight of the hardmetals. The WC particles in the samples are 0.2 μm in size. TABLE 12 lists the conditions for the two-step process performed and measured densities, hardness parameters, and toughness parameters of the samples. The Palmqvist fracture toughness Ksc is calculated from the total crack length of Palmqvist crack which is produced by the Vicker Indentor: Ksc=0.087*(Hv*W)^1/2. See, e.g., Warren and H. Matzke, Proceedings Of the International Conference On the Science of Hard Materials, Jackson, Wyoming, Aug 23-28, 1981. Hardness Hv and Crack Length are measured at a load of 10 Kg for 15 seconds. During each measurement, eight indentations were made on each specimen and the average value was used in computation of the listed data.

TABLE 11Weight %Re inVol %ReCoR-95WCVCBinderBinderP5408091.40.6013.13P58007.591.90.6013.25P561.87.2090.40.62013.20P721.87.2090.70.32013.18P731.84.82.790.40.32014.00P741.834.590.40.32014.24

TABLE 12

Palmqvist

Cal.
Measu.

Toughness

Sample
Sinter
HIP
Density
Density
Hardness, Hv
Ksc,

Code
Condition
Condition
g/c.c.
g/c.c.
Kg/mm²
×10⁶Pa · m^1/2

P54-5
1360° C./1 hr

14.63
14.58
2062 ± 35
8.9 ± 0.2

1360° C./1 hr
1305° C./15KSI/1 hr

14.55
2090 ± 22
8.5 ± 0.2

P58-7
1550° C./1 hr

14.50
14.40
2064 ± 12
7.9 ± 0.2

1550° C./1 hr
1305° C./15KSI/1 hr

14.49
2246 ± 23
7.3 ± 0.1

P56-5
1360° C./1 hr

14.77
14.71
2064 ± 23
8.2 ± 0.1

1360° C./1 hr
1305° C./15KSI/1 hr

14.72
2133 ± 34
8.6 ± 0.2

P72-6
1475° C./1 hr

14.83
14.77
2036 ± 34
8.5 ± 0.6

1475° C./1 hr
1305° C./15KSI/1 hr

14.91
2041 ± 30
9.1 ± 0.4

P73-6
1475° C./1 hr

14.73
14.70
2195 ± 23
7.7 ± 0.1

1475° C./1 hr
1305° C./15KSI/1 hr

14.72
2217 ± 25
8.1 ± 0.2

P74-5
1500° C./1 hr

14.69
14.69
2173 ± 30
7.4 ± 0.3

and 1520° C./1 hr

1500° C./1 hr
1305° C./15KSI/1 hr

14.74
2223 ± 34
7.7 ± 0.1

and 1520° C./1 hr

Among the tested samples, the sample P54 uses the conventional binder consisting of Co. The Ni-superalloy R-95 is used in the sample P58 to replace Co as the binder in the sample P54. As a result, the Hv increases from 2090 of P54 to 2246 of P58. In the sample P56, the mixture of Re and Co is used to replace Co as binder and the corresponding Hv increases from 2090 of P54 to 2133 of P56. The samples P72, P73, P74 have the same Re content but different amounts of Co and R95. The mixtures of Re, Co, and R95 are used in samples P73 and P74 to replace the binder having a mixture of Re and Co as the binder in the sample 72. The hardness Hv increases from 2041(P72) to 2217 (P73) and 2223(P74).

TABLE 13Weight %WCRe inVol. %ReR-95CoTiCTaCWC (2 μm)(0.2 μm)BinderBinderP171.54.5033880258.78P1833033880507.31P253.752.2503388062.56.57P483.752.2505584062.56.3P504.831.8905.315.2282.75071.96.4P517.150.9305.235.1481.55088.56.4P497.5503.255.315.2178.68069.910P40A7.572.9605.325.2378.92071.910P6312.470.8605.165.07076.4593.610P62A14.48005.095.00075.4310010P6627.92004.914.82062.3510020

Measurements on selected samples have also been performed to further study properties of the binder matrices with Re in the binder matrices. TABLE 13 lists the tested samples. The WC particles with two different particle sizes of 2 μm and 0.2 μm were used. TABLE 14 lists the conditions for the two-step process performed and the measured densities, hardness parameters, and toughness parameters of the selected samples.

TABLE 14Cal.Measu.PalmqvistSampleSinterHIPDensityDensityHardness, HvToughness**CodeConditionConditiong/c.c.g/c.c.Kg/mm²Ksc, MPam^0.5P17-51800° C./1 hr1600° C./15KSI/1 hr14.1514.212092 ± 3 7.2 ± 0.1P18-31800° C./1 hr1600° C./15KSI/1 hr14.3814.592028 ± 886.8 ± 0.3P25-31750° C./1 hr1600° C./15KSI/1 hr14.4914.482193 ± 8 6.5 ± 0.1P48-11800° C./1 hr1600° C./15KSI/1 hr13.9113.992208 ± 126.3 ± 0.4P50-41800° C./1 hr1600° C./15KSI/1 hr13.913.82294 ± 206.3 ± 0.1P51-11800° C./1 hr1600° C./15KSI/1 hr14.1113.972309 ± 6 6.6 ± 0.1P40A-11800° C./1 hr1600° C./15KSI/1 hr13.8613.862321 ± 106.3 ± 0.1P49-11800° C./1 hr1600° C./15KSI/1 hr13.9113.922186 ± 296.5 ± 0.2P62A-62200° C./1 hr1725° C./30KSI/1 hr14.514.412688 ± 226.7 ± 0.1P63-52200° C./1 hr1725° C./30KSI/1 hr14.3114.372562 ± 316.7 ± 0.2P66-42200° C./1 hr15.0414.402402 ± 448.2 ± 0.4P66-42200° C./1 hr1725° C./30KSI/1 hr15.0414.52P66-42200° C./1 hr1725° C./30KSI/1 hr + 1950° C./15.0414.532438 ± 476.9 ± 0.230KSI/1 hrP66-52200° C./1 hr15.0414.332092 ± 237.3 ± 0.3P66-52200° C./1 hr1725° C./30KSI/1 hr15.0414.63P66-52200° C./1 hr1725° C./30KSI/1 hr + 1850° C./15.0414.662207 ± 177.1 ± 0.230KSI/1 hr

TABLE 15 further shows measured hardness parameters under various temperatures for the selected samples, where the Knoop hardness H_kwere measured under a load of 1 Kg for 15 seconds on a Nikon QM hot hardness tester and R is a ratio of H_kat an elevated testing temperature over H_kat 25° C. The hot hardness specimens of C2 and C6 carbides were prepared from inserts SNU434 which were purchased from MSC Co. (Melville, N.Y.).

TABLE 15(each measured value at a given temperature is an averaged value of 3different measurements)Testing Temperature, ° C.Lot No.25400500600700800900Hv @25°P17-5Hk, Kg/mm²1880 ± 101720 ± 171653 ± 251553 ± 291527 ± 62092 ± 3R, %10091888381P18-3Hk, Kg/mm²1773 ± 321513 ± 121467 ± 211440 ± 101340 ± 162028 ± 88R, %10085838176P25-3Hk, Kg/mm²1968 ± 451813 ± 121710 ± 01593 ± 52193 ± 8R, %100928781P40A-1Hk, Kg/mm²2000 ± 351700 ± 171663 ± 121583 ± 211540 ± 352321 ± 10R, %10085837977P48-1Hk, Kg/mm²1925 ± 251613 ± 151533 ± 291477 ± 61377 ± 152208 ± 12R, %10084807772P49-1Hk, Kg/mm²2023 ± 321750 ± 01633 ± 61600 ± 172186 ± 29R, %100878179P50-4Hk, Kg/mm²2057 ± 251857 ± 151780 ± 201713 ± 61627 ± 402294 ± 20R, %10090878379P51-1Hk, Kg/mm²2050 ± 261797 ± 61743 ± 351693 ± 151607 ± 152309 ± 6R, %10088858378P62A-6Hk, Kg/mm²2228 ± 292063 ± 251960 ± 761750 ± 02688 ± 22R, %100938879P63-5Hk, Kg/mm²1887 ± 61707 ± 351667 ± 151633 ± 61603 ± 252562 ± 31R, %100C2 CarbideHk, Kg/mm²1503 ± 38988 ± 9711 ± 0584 ± 271685 ± 16R, %100664739C6 CarbideHk, Kg/mm²1423 ± 231127 ± 251090 ± 101033 ± 23928 ± 181576 ± 11R, %10079777365

Inclusion of Re in the binder matrices of the hardmetals increases the melting point of binder alloys that include Co—Re, Ni superalloy-Re, Ni superalloy-Re—Co. For example, the melting point of the sample P63 is much higher than the temperature of 2200° C. used for the solid-phase sintering process. Hot hardness values of such hardmetals with Re in the binders (e.g., P17 to P63) are much higher than conventional Co bound hardmetals (C2 and C6 carbides). In particular, the above measurements reveal that an increase in the concentration of Re in the binder increases the hardness at high temperatures. Among the tested samples, the sample P62A with pure Re as the binder has the highest hardness. The sample P63 with a binder composition of 94% of Re and 6% of the Ni-based superalloy R95 has the second highest hardness. The samples P40A(71.9% Re-29.1% R95), P49(69.9% Re-30.1% R95), P51(88.5% Re-11.5% R95), and P50(71.9% Re-28.1% R95) are the next group in their hardness. The sample P48 with 62.5% of Re and 37.5% of R95 in its binder has the lowest hardness at high temperatures among the tested materials in part because its Re content is the lowest.

In yet another category, a hardmetal or cermet may include TiC and TiN bonded in a binder matrix having Ni and Mo or Mo₂C. The binder Ni of cermet can be fully or partially replaced by Re, by Re plus Co, by Ni-based superalloy, by Re plus Ni-based superalloy, and by Re plus Co and Ni-based superalloy. Samples P38 and P39 are examples of Ni-bound cermets. The sample P34 is an example of Rene95-bound Cermet. The P35, P36, P37, and P45 are Re plus Rene95 bound cermet. Compositions of P34, 35, 36, 37, 38, 39, and 45 are listed in TABLE 16.

TABLE 16Composition of P34 to P39Weight %ReRene95Ni 1Ni 2TiCMo₂CWCTaCP3414.4769.4416.09P358.7710.2765.3715.23P3616.66.5062.4014.46P3723.83.0959.3813.76P3815.5168.6015.89P3915.5168.6015.89P459.373.6615.376.5158.66.47

TABLES 17-29 list additional compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications.

TABLE 17Compositions that use pure Re as a binder for binding a carbidefrom carbides of IVb, Vb, & VIb columns of the Periodic Table or a nitridefrom nitrides of IVb & Vb columnsCompositionCompositionCompositionEstimatedRange 1Range 2Range 3MeltingVolume %Weight %Volume %Weight %Volume %Weight %Point, ° C.ReRe7.25 to25 to 747.25 to25 to 707.25 to25 to 653000 to 3200Bound403530TiCTiC60 to26 to65 to30 to 7570 to35 to 7592.757592.7592.75ReRe3 to 409 to 684 to 3512 to 635 to 3014 to 583000 to 3200BoundZrC60 to 9732 to65 to 9637 to 8870 to42 to 86ZrC9395ReRe16.75 to25 to16.75 to25 to 4716.7525 to 423000 to 3200Bound405235to 30HfCHfC60 to48 to65 to53 to 7570 to58 to 7583.257583.2583.25ReRe3 to 4011 to4 to 3514 to 675 to 3017 to 622700 to 3100Bound72VCVC60 to 9728 to65 to 9633 to 8670 to38 to 838995ReRe3 to 408 to 644 to 3510 to 595 to 3012 to 543000 to 3200BoundNbC60 to 9736 to65 to 9641 to 9070 to46 to 88NbC9295ReRe3 to 404 to 494 to 356 to 445 to 307 to 383000 to 3200BoundTaC60 to 9751 to65 to 9656 to 9470 to62 to 93TaC9695ReRe3 to 409 to 684 to 3512 to 635 to 3014 to 571700 to 1900BoundCr₂C₃60 to 9732 to65 to 9637 to 8870 to43 to 86Cr₂C₃9195ReRe3 to 407 to 614 to 359 to 555 to 3011 to 502300 to 2600BoundMo₂C60 to 9739 to65 to 9645 to 9170 to50 to 89Mo₂C9395ReRe20 to 4025 to20 to 3525 to 4220 to25 to 372700 to 2900Bound4730WCWC60 to 8053 to65 to 8058 to 7570 to63 to 757580ReRe3 to 4011 to4 to 3514 to 685 to 3017 to 622900 to 3100Bound72TiNTiN60 to 9728 to65 to 9632 to 8670 to38 to 838995ReRe3 to 408 to 664 to 3511 to 615 to 3013 to 552900 to 3100BoundZrN60 to 9734 to65 to 9639 to 8970 to45 to 87ZrN9295ReRe3 to 404 to 504 to 356 to 455 to 307 to 393000 to 3200BoundHfN60 to 9750 to65 to 9655 to 9470 to61 to 93HfN9695ReRe3 to 409 to 704 to 3513 to 655 to 3016 to 622100 to 2300BoundVN60 to 9730 to65 to 9635 to 8770 to38 to 84VN9195ReRe3 to 408 to 664 to 3511 to 615 to 3013 to 552300 to 2500BoundNbN60 to 9734 to65 to 9639 to 8970 to45 to 87NbN9295ReRe3 to 404 to 494 to 356 to 445 to 307 to 393000 to 3200BoundTaN60 to 9751 to65 to 9656 to 9470 to61 to 93TaN9695

TABLE 18

Compositions that use Ni-based superalloy(NBSA) in a binder for

binding a nitride from nitrides of IVb &Vb columns of the Periodic Table.

Composition
Composition
Composition

Range 1
Range 2
Range 3

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

NBSA—TiN
NBSA
3 to 40
4 to 50
4 to 35
6 to 44
5 to 30
7 to 39

TiN
60 to 97
50 to 96
65 to 96
56 to 94
70 to 95
61 to 93

NBSA—ZrN
NBSA
3 to 40
3 to 42
4 to 35
4 to 37
5 to 30
5 to 32

ZrN
60 to 97
58 to 97
65 to 96
63 to 96
70 to 95
68 to 95

NBSA—HfN
NBSA
3 to 40
1.8 to 28
4 to 35
2.4 to 24
5 to 30
3 to 19

HfN
60 to 97
72 to 98.2
65 to 96
76 to 97.6
70 to 95
81 to 97

NBSA—VN
NBSA
3 to 40
4 to 47
4 to 35
5 to 42
5 to 30
7 to 36

VN
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
64 to 93

NBSA—NbN
NBSA
3 to 40
3 to 42
4 to 35
4 to 37
5 to 30
5 to 32

NbN
60 to 97
52 to 97
65 to 96
33 to 96
70 to 95
68 to 95

NBSA—TaN
NBSA
3 to 40
1.7 to 27
4 to 35
2.3 to 23
5 to 30
3 to 19

TaN
60 to 97
73 to 98.3
65 to 96
77 to 97.7
70 to 95
81 to 97

TABLE 19

Compositions that use Re and Ni-based superalloy (Re + NBSA) in

a binder for binding a carbide from carbides of IVb, Vb, & VIb or a

nitride from nitrides of IVb & Vb. The range of the binder is from 1% Re + 99%

superalloy to 99% Re + 1% superalloy.

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA)—TiC
Re
0.03 to
0.13 to
0.04 to
0.17 to
0.05 to
0.21 to

39.6
73.6
34.7
69.3
29.7
64.3

NBSA
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to

39.6
51.1
34.7
45.9
29.7
40.4

TiC
60 to 97
26.1 to
65 to 96
30.5 to
70 to 95
35.5 to 92

95.1

93.6

(Re + NBSA)—ZrC
Re
0.03 to
0.09 to
0.04 to
0.13 to
0.05 to
0.16 to

39.6
67.7
34.7
62.9
29.7
57.5

NBSA
0.03 to
0.03 to
0.04 to
0.05 to
0.05 to
0.06 to

39.6
44.1
34.7
39.0
29.7
33.8

ZrC
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
42 to 94

(Re + NBSA)—HfC
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to

39.6
52.1
34.7
46.8
29.7
41.2

NBSA
0.03 to
0.02 to
0.04 to
0.025 to
0.05 to
0.03 to 21

39.6
29.2
34.7
25
29.7

HfC
60 to 97
47.7 to
65 to 96
53 to
70 to 95
58.6 to

98.1

97.4

96.7

(Re + NBSA)—VC
Re
0.03 to
0.11 to
0.04 to
0.15 to
0.05 to
0.19 to

39.6
71.5
34.7
67.0
29.7
61.8

NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

39.6
48.4
34.7
43.3
29.7
37.9

VC
60 to 97
28.3 to
65 to 96
32.8 to
70 to 95
38 to 92.8

95.6

94.2

(Re + NBSA)—NbC
Re
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.13 to

39.6
63.8
34.7
58.7
29.7
53.1

NBSA
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to 30

39.6
39.9
34.7
35
29.7

NbC
60 to 97
36 to 96.9
65 to 96
41 to
70 to 95
46.6 to

95.8

94.8

(Re + NBSA)—TaC
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to 38

39.6
48.8
34.7
43.5
29.7

NBSA
0.03 to
0.016 to
0.04 to
0.02 to
0.05 to
0.03 to

39.6
26.5
34.7
22.6
29.7
18.9

TaC
60 to 97
51 to 98.3
65 to 96
56.3 to
70 to 95
61.8 to

97.7

97.1

(Re + NBSA)—Cr₂C₃
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.16 to

39.6
67.3
34.7
62.5
29.7
57.0

NBSA
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

39.6
43.6
34.7
38.6
29.7
33.4

Cr₂C₃
60 to 97
32.4 to
65 to 96
37.3 to
70 to 95
42.8 to

96.4

95.2

94.0

(Re + NBSA)—Mo₂C
Re
0.03 to
0.07 to
0.04 to
0.1 to 55
0.05 to
0.12 to

39.6
60.2
34.7

29.7
49.3

NBSA
0.03 to
0.025 to
0.04 to
0.03 to
0.05 to
0.04 to

39.6
36.3
34.7
31.6
29.7
26.9

Mo₂C
60 to 97
39.6 to
65 to 96
44.8 to
70 to 95
50.5 to

97.3

96.4

95.5

(Re + NBSA)—WC
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to

39.6
46.9
34.7
41.7
29.7
36.3

NBSA
0.03 to
0.015 to 25
0.04 to
0.02 to
0.05 to
0.025 to

39.6

34.7
21.3
29.7
17.8

WC
0 to 97
52.9 to
65 to 96
58.2 to
70 to 95
63.6 to

98.4

97.9

97.3

(Re + NBSA)—TiN
Re
0.03 to
0.1 to 71.7
0.04 to
0.15 to
0.05 to
0.19 to 62

39.6

34.7
67.2
29.7

NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to 38

39.6
48.7
34.7
43.5
29.7

TiN
60 to 97
28 to 95.6
65 to 96
32.6 to
70 to 95
37.8 to

94.1

92.7

(Re + NBSA)—ZrN
Re
0.03 to
0.09 to
0.04 to
0.1 to
0.05 to
0.14 to

39.6
65.3
34.7
60.3
29.7
54.8

NBSA
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

39.6
41.4
34.7
36.5
29.7
31.4

ZrN
60 to 97
34.5 to
65 to 96
39.4 to
70 to 95
45 to 94.5

96.7

95.6

(Re + NBSA)—HfN
Re
0.03 to
0.05 to 50
0.04 to
0.06 to
0.05 to
0.08 to

39.6

34.7
44.7
29.7
39.2

NBSA
0.03 to
0.017 to
0.04 to
0.02 to
0.05 to
0.03 to

39.6
27.5
34.7
23.5
29.7
19.6

HfN
60 to 97
49.8 to
65 to 96
55.1 to
70 to 95
60.7 to 97

98.2

97.6

(Re + NBSA)—VN
Re
0.03 to
0.1 to 69.6
0.04 to
0.14 to
0.05 to
0.17 to

39.6

34.7
65
29.7
59.6

NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

39.6
46.2
34.7
41.1
29.7
35.8

VN
60 to 97
30 to 96
65 to 96
35 to
70 to 95
40 to 93.3

94.7

(Re + NBSA)—NbN
Re
0.03 to
0.09 to
0.04 to
0.1 to
0.05 to
0.14 to

39.6
65.3
34.7
60.4
29.7
54.9

NBSA
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

39.6
41.5
34.7
36.5
29.7
31.5

NbN
60 to 97
34.4 to
65 to 96
39.4 to
70 to 95
45 to 94.5

96.7

95.6

(Re + NBSA)—TaN
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.08 to

39.6
49.1
34.7
43.8
29.7
38.3

NBSA
0.03 to
0.017 to
0.04 to
0.02 to
0.05 to
0.027 to 19

39.6
26.8
34.7
22.8
29.7

TaN
60 to 97
50.7 to
65 to 96
56 to
70 to 95
61.5 to 97

98.3

97.7

TABLE 20

Compositions that use Re and Co (Re + Co) in a binder for

binding a carbide from carbides of IVb, Vb, & VIb or a nitride from

nitrides of IVb & Vb. The range of Binder is from 1% Re + 99% Co to 99%

Re + 1% Co.

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + Co)—TiC
Re
0.03 to
0.13 to
0.04 to
0.17 to
0.05 to
0.20 to

39.6
73.6
34.7
69.3
29.7
64.3

Co
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to

39.6
54.1
34.7
48.9
29.7
43.3

TiC
60 to
26.1
65 to 96
30.4 to
70 to 95
35.5 to 91

97
to94.6

92.8

(Re + Co)—ZrC
Re
0.03 to
0.09 to
0.04 to
0.13 to
0.05 to
0.16 to

39.6
67.7
34.7
62.9
29.7
57.5

Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

39.6
47.1
34.7
42.0
29.7
36.6

ZrC
60 to
32 to 96
65 to 96
37 to 95
70 to 95
42 to 93

97

(Re + Co)—HfC
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to

39.6
52.1
34.7
46.8
29.7
41.2

Co
0.03 to
0.02 to
0.04 to
0.028 to
0.05 to
0.035 to 23

39.6
31.8
34.7
27
29.7

HfC
60 to
47.6 to
65 to 96
53 to
70 to 95
58.6 to

97
97.8

97.1

96.3

(Re + Co)—VC
Re
0.03 to
0.11 to
0.04 to
0.15 to
0.05 to
0.19 to

39.6
71.4
34.7
67.0
29.7
61.8

Co
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.07 to

39.6
51.5
34.7
46.3
29.7
40.8

VC
60 to
28.3 to
65 to 96
32.8 to
70 to 95
38 to 92

97
95.1

93.5

(Re + Co)—NbC
Re
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.13 to

39.6
63.8
34.7
58.7
29.7
53.1

Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

39.6
42.8
34.7
37.8
29.7
32.6

NbC
60 to
36 to
65 to 96
41 to
70 to 95
46.6 to

97
96.5

95.4

94.2

(Re + Co)—TaC
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to 38

39.6
48.8
34.7
43.5
29.7

Co
0.03 to
0.018 to
0.04 to
0.02 to
0.05 to
0.03 to

39.6
28.9
34.7
24.8
29.7
20.8

TaC
60 to
51 to 98
65 to 96
56.3 to
70 to 95
61.8 to

97

97.4

96.8

(Re + Co)—Cr₂C₃
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to

39.6
67.3
34.7
62.5
29.7
57.0

Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

39.6
46.6
34.7
41.5
29.7
36.1

Cr₂C₃
60 to
32.4 to
65 to 96
37.3 to
70 to 95
42.7 to

97
96

94.6

93.3

(Re + Co)—Mo₂C
Re
0.03 to
0.07 to
0.04 to
0.1 to 55
0.05 to
0.12 to

39.6
60.2
34.7

29.7
49.3

Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

39.6
39.2
34.7
34.3
29.7
29.4

Mo₂C
60 to
39.6 to
65 to 96
44.8 to
70 to 95
50.5 to 95

97
97

96

(Re + Co)—WC
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to

39.6
46.9
34.7
41.7
29.7
36.3

Co
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to
0.028 to

39.6
27.4
34.7
23.4
29.7
19.6

WC
60 to
52.9
65 to 96
58.2 to
70 to 95
63.6 to 97

97
to98.2

97

(Re + Co)—TiN
Re
0.03 to
0.1 to
0.04 to
0.15 to
0.05 to
0.19 to 62

39.6
71.6
34.7
67.1
29.7

Co
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.07 to 41

39.6
51.7
34.7
46.5
29.7

TiN
60 to
28 to 95
65 to 96
32.6 to
70 to 95
37.8 to 92

97

93.4

(Re + Co)—ZrN
Re
0.03 to
0.09 to
0.04 to
0.11 to
0.05 to
0.14 to

39.6
65.3
34.7
60.3
29.7
54.8

Co
0.03 to
0.035 to
0.04 to
0.046 to
0.05 to
0.056 to 34

39.6
44.4
34.7
39.3
29.7

ZrN
60 to
34.5 to
65 to 96
39.4 to
70 to 95
45 to 93.8

97
96.3

95

(Re + Co)—HfN
Re
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.08 to

39.6
50
34.7
44.7
29.7
39.2

Co
0.03 to
0.02 to
0.04 to
0.026 to
0.05 to
0.03 to

39.6
30
34.7
25.7
29.7
21.6

HfN
60 to
49.8 to
65 to 96
55.1 to
70 to 95
60.7 to

97
98

97.3

96.6

(Re + Co)—VN
Re
0.03 to
0.1 to
0.04 to
0.14 to
0.05 to
0.17 to

39.6
69.6
34.7
65
29.7
59.6

Co
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.067 to

39.6
49.3
34.7
44
29.7
38.6

VN
60 to
30 to
65 to 96
35 to 94
70 to 95
40 to 92.6

97
95.5

(Re + Co)—NbN
Re
0.03 to
0.09 to
0.04 to
0.11 to
0.05 to
0.14 to

39.6
65.3
34.7
60.4
29.7
54.8

Co
0.03 to
0.035 to
0.04 to
0.046 to
0.05 to
0.057 to

39.6
44.5
34.7
39.4
29.7
34.1

NbN
60 to
34.4 to
65 to 96
39.4 to
70 to 95
45 to 93.8

97
96.3

95

(Re + Co)—TaN
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.075 to

39.6
49.1
34.7
43.8
29.7
38.3

Co
0.03 to
0.019 to
0.04 to
0.025 to
0.05 to
0.03 to 21

39.6
29.2
34.7
25
29.7

TaN
60 to
50.7 to
65 to 96
56 to
70 to 95
61.5 to

97
98

97.4

96.7

TABLE 21

Compositions that use Ni-based superalloy (NBSA) and Co in a

binder for binding a carbide from carbides of IVb, Vb, & VIb or a

nitride from nitrides of IVb & Vb. The range of Binder is from 1% NBSA + 99%

Co to 99% NBSA + 1% Co.

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(NBSA + Co)—TiC
NBSA
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to 29.7
0.08 to

39.6
51.5
34.7
46.2

40.6

Co
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to 29.7
0.09 to

39.6
54.5
34.7
49.2

43.6

TiC
60 to 97
45 to 95
65 to 96
50 to 93.6
70 to 95
56 to 92

(NBSA + Co)—ZrC
NBSA
0.03 to
0.04to
0.04 to
0.05 to
0.05 to 29.7
0.06 to

39.6
44.4
34.7
39.2

57.5

Co
0.03 to
0.04 to
0.04 to
0.05 to 42
0.05 to 29.7
0.07 to

39.6
47.4
34.7

34

ZrC
60 to 97
52 to 96
65 to 96
57 to 95
70 to 95
63 to 94

(NBSA + Co)—HfC
NBSA
0.03 to
0.02 to
0.04 to
0.026 to
0.05 to 29.7
0.03 to

39.6
29
34.7
25

21

Co
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to 29.7
0.036 to

39.6
32
34.7
27.5

23

HfC
60 to 97
68 to 98
65 to 96
72 to 97.4
70 to 95
77 to

96.8

(NBSA + Co)—VC
NBSA
0.03 to
0.04 to
0.04 to
0.06 to 44
0.05 to 29.7
0.07 to

39.6
49
34.7

38

Co
0.03 to
0.05 to
0.04 to
0.06 to 47
0.05 to 29.7
0.08 to

39.6
52
34.7

41

VC
60 to 97
48 to 96
65 to 96
53 to 93.5
70 to 95
59 to 93

(NBSA + Co)—NbC
NBSA
0.03 to
0.03 to
0.04 to
0.04 to 35
0.05 to 29.7
0.05 to

39.6
40
34.7

30

Co
0.03 to
0.035 to
0.04 to
0.046 to
0.05 to 29.7
0.06 to

39.6
43
34.7
38

33

NbC
60 to 97
57 to 97
65 to 96
62 to 96
70 to 95
67 to 95

(NBSA + Co)—TaC
NBSA
0.03 to
0.017 to
0.04 to
0.022 to
0.05 to 29.7
0.03 to

39.6
27
34.7
23

19

Co
0.03 to
0.02 to
0.04 to
0.025 to
0.05 to 29.7
0.03 to

39.6
29
34.7
25

21

TaC
60 to 97
71 to 98
65 to 96
75 to 97.8
70 to 95
79 to 97

(NBSA + Co)—Cr₂C₃
NBSA
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to 29.7
0.15 to

39.6
67.3
34.7
62.5

57.0

Co
0.03 to
0.04 to
0.04 to
0.05 to 39
0.05 to 29.7
0.06 to

39.6
44
34.7

34

Cr₂C₃
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
63 to 94

(NBSA + Co)—Mo₂C
NBSA
0.03 to
0.026 to
0.04 to
0.035 to
0.05 to 29.7
0.044 to

39.6
36.5
34.7
32

27

Co
0.03 to
0.03 to
0.04 to
0.04 to 34
0.05 to 29.7
0.05 to

39.6
39
34.7

30

Mo₂C
60 to 97
60 to 97
65 to 96
65 to 96
70 to 95
70 to

95.6

(NBSA + Co)—WC
NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to 29.7
0.07 to

39.6
46.9
34.7
41.7

36.3

Co
0.03 to
0.018 to
0.04 to
0.024 to
0.05 to 29.7
0.03 to

39.6
27.5
34.7
23.5

19.7

WC
60 to 97
72 to98
65 to 96
76 to 98
70 to 95
80 to 97

(NBSA + Co)—TiN
NBSA
0.03 to
0.4 to 49
0.04 to
0.06 to 44
0.05 to 29.7
0.07 to

39.6

34.7

38

Co
0.03 to
0.05 to
0.04 to
0.065 to
0.05 to 29.7
0.08 to

39.6
52
34.7
47

41

TiN
60 to 97
47 to 96
65 to 96
53 to 94
70 to 95
58 to 93

(NBSA + Co)—ZrN
NBSA
0.03 to
0.03 to
0.04 to
0.04 to 37
0.05 to 29.7
0.05 to

39.6
42
34.7

32

Co
0.03 to
0.04 to
0.04 to
0.05 to 40
0.05 to 29.7
0.06 to

39.6
45
34.7

34

ZrN
60 to 97
55 to 97
65 to 96
60 to 96
70 to 95
65 to 95

(NBSA + Co)—HfN
NBSA
0.03 to
0.02 to
0.04 to
0.027 to
0.05 to 29.7
0.03 to

39.6
31
34.7
27

22

Co
0.03 to
0.02 to
0.04 to
0.024 to
0.05 to 29.7
0.03 to

39.6
27
34.7
23

20

HfN
60 to 97
70 to 98
65 to 96
74 to 97.6
70 to 95
78 to 97

(NBSA + Co)—VN
NBSA
0.03 to
0.045 to
0.04 to
0.06 to 47
0.05 to 29.7
0.07 to

39.6
53
34.7

41

Co
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to 29.7
0.066 to

39.6
44
34.7
40

34

VN
60 to 97
50 to 96
65 to 96
55 to 95
70 to 95
61 to 93

(NBSA + Co)—NbN
NBSA
0.03 to
0.04 to
0.04 to
0.05 to 41
0.05 to 29.7
0.06 to

39.6
47
34.7

36

Co
0.03 to
0.03 to
0.04 to
0.04 to 35
0.05 to 29.7
0.05 to

39.6
40
34.7

30

NbN
60 to 97
55 to 97
65 to 96
60 to 96
70 to 95
65 to 95

(Re + Co)—TaN
NBSA
0.03 to
0.02 to
0.04 to
0.026 to
0.05 to 29.7
0.032 to

39.6
30
34.7
26

22

Co
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to 29.7
0.03 to

39.6
26
34.7
23

19

TaN
60 to 97
70 to 98
65 to 96
75 to 97.7
70 to 95
79 to 97

TABLE 22

Compositions that use Re, Ni-based superalloy (NBSA), and Co

in a binder for binding a carbide from carbides of IVb, Vb, & VIb or a

nitride from nitrides of IVb & Vb. The range of Binder is from 0.5% Re + 0.5%

Co + 99% superalloy to 99% Re + 0.5% Co + 0.5% Superalloy to 0.5% Re + 99%

Co + 0.5% Superalloy

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume
Weight %

(Re + Co + NBSA)—TiC
Re
0.015 to
0.06 to
0.02 to
0.08 to
0.025 to
0.1 to 64.3

39.6
73.6
34.65
69.3
29.7

NBSA
0.015 to
0.02 to
0.02 to
0.03 to
0.025 to
0.035 to

39.6
51.3
34.65
46.0
29.7
40.5

Co
0.015 to
0.03 to
0.02 to
0.036 to
0.025 to
0.045 to

39.6
54.3
34.65
49.0
29.7
43.5

TiC
60 to 97
26 to 95
65 to 96
30 to 94
70 to 95
35 to 92

(Re + Co + NBSA)—ZrC
Re
0.015 to
0.05 to
0.02 to
0.06 to
0.025 to
0.08 to

39.6
67.7
34.65
62.9
29.7
57.5

NBSA
0.015 to
0.017 to
0.02 to
0.022 to
0.025 to
0.028 to

39.6
44.2
34.65
39.1
29.7
33.9

Co
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.034 to

39.6
47.2
34.65
42.0
29.7
36.7

ZrC
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
43 to 94

(Re + Co + NBSA)—HfC
Re
0.015 to
0.025 to
0.02 to
0.034 to
0.025 to
0.042 to

39.6
52.1
34.65
46.8
29.7
41.2

NBSA
0.015 to
0.009 to
0.02 to
0.012 to
0.025 to
0.015 to 21

39.6
29.3
34.65
25.1
29.7

Co
0.015 to
0.01 to
0.02 to
0.014 to
0.025 to
0.018 to

39.6
31.8
34.65
27.4
29.7
23.1

HfC
60 to 97
48 to 98
65 to 96
53 to
70 to 95
59 to 96.8

97.4

(Re + Co + NBSA)—VC
Re
0.015 to
0.06 to
0.02 to
0.08 to
0.025 to
0.09 to

39.6
71.5
34.65
67
29.7
61.8

NBSA
0.015 to
0.02 to
0.02 to
0.026 to
0.025 to
0.032 to 38

39.6
48.6
34.65
43.4
29.7

Co
0.015 to
0.024 to
0.02 to
0.032 to
0.025 to
0.04 to

39.6
51.7
34.65
46.4
29.7
40.9

VC
60 to 97
28 to 96
65 to 96
33 to 94
70 to 95
38 to 93

(Re + Co + NBSA)—NbC
Re
0.015 to
0.04 to
0.02 to
0.05 to
0.025 to
0.07 to

39.6
63.8
34.65
58.7
29.7
53.1

NBSA
0.015 to
0.015 to
0.02 to
0.02 to
0.025 to
0.024 to 30

39.6
40
34.65
35
29.7

Co
0.015 to
0.017 to
0.02 to
0.023 to
0.025 to
0.03 to

39.6
43
34.65
37.9
29.7
32.7

NbC
60 to 97
36 to 97
65 to 96
41 to 96
70 to 95
47 to 95

(Re + Co + NBSA)—TaC
Re
0.015 to
0.02 to
0.02 to
0.03 to
0.025 to
0.04 to 38

39.6
48.8
34.65
43.5
29.7

NBSA
0.015 to
0.008 to
0.02 to
0.011 to
0.025 to
0.013 to

39.6
26.6
34.65
22.6
29.7
18.9

Co
0.015 to
0.01 to
0.02 to
0.013 to
0.025 to
0.016 to

39.6
29
34.65
24.8
29.7
20.8

TaC
60 to 97
51 to
65 to 96
56 to
70 to 95
61.8 to

98.3

97.7

97.2

(Re + Co + NBSA)—Cr₂C₃
Re
0.015 to
0.05 to
0.02 to
0.06 to
0.025 to
0.08 to 57

39.6
67.3
34.65
62.5
29.7

NBSA
0.015 to
0.017 to
0.02 to
0.022 to
0.025 to
0.027 to

39.6
43.8
34.65
38.7
29.7
33.5

Co
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.033 to

39.6
46.8
34.65
41.6
29.7
36.2

Cr₂C₃
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
43 to94

(Re + Co + NBSA)—Mo₂C
Re
0.015 to
0.03 to
0.02 to
0.05 to
0.025 to
0.06 to 49

39.6
60.2
34.65
55
29.7

NBSA
0.015 to
0.013 to
0.02 to
0.017 to
0.025 to
0.02 to 27

39.6
36.4
34.65
31.7
29.7

Co
0.015 to
0.015 to
0.02 to
0.02 to
0.025 to
0.025 to 29

39.6
39.3
34.65
34
29.7

Mo₂C
60 to 97
39 to 97
65 to 96
45 to 96
70 to 95
50 to 95.6

(Re + Co + NBSA)—WC
Re
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.034 to

39.6
46.9
34.65
41.7
29.7
36.3

NBSA
0.015 to
0.008 to
0.02 to
0.01 to
0.025 to
0.013 to

39.6
25.1
34.65
21.3
29.7
17.8

Co
0.015 to
0.009 to
0.02 to
0.012 to
0.025 to
0.015 to

39.6
27.5
34.65
23.5
29.7
19.6

WC
60 to 97
53 to 98
65 to 96
58 to
70 to 95
64 to 97.4

97.8

(Re + Co + NBSA)—TiN
Re
0.015 to
0.06 to
0.02 to
0.08 to
0.025 to
0.1 to 62

39.6
71.6
34.65
67.2
29.7

NBSA
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.032 to

39.6

34.65
43.6
29.7
38.2

Co
0.015 to
0.025 to
0.02 to
0.03 to
0.025 to
0.04 to

39.6
51.9
34.65
46.6
29.7
41

TiN
60 to 97
28 to 96
65 to 96
33 to 94
70 to 95
38 to 93

(Re + Co + NBSA)—ZrN
Re
0.015 to
0.04 to
0.02 to
0.06 to
0.025 to
0.07 to

39.6
65.3
34.65
60.3
29.7
54.8

NBSA
0.015 to
0.016 to
0.02 to
0.02 to
0.025 to
0.025 to

39.6
41.6
34.65
36.6
29.7
31.5

Co
0.015 to
0.02 to
0.02 to
0.025 to
0.025 to
0.03 to

39.6
44.6
34.65
40
29.7
34

ZrN
60 to 97
34 to 97
65 to 96
39 to 96
70 to 95
45 to 95

Re + Co + NBSA—HfN
Re
0.015 to
0.02 to
0.02 to
0.03to 45
0.025 to
0.04 to

39.6
50
34.65

29.7
39

NBSA
0.015 to
0.009 to
0.02 to
0.011 to
0.025 to
0.014 to

39.6
27.5
34.65
23.5
29.7
20

Co
0.015 to
0.01 to
0.02 to
0.013 to
0.025 to
0.017 to

39.6
30
34.65
25.8
29.7
22

HfN
60 to 97
50 to 98
65 to 96
55 to 97.6
70 to 95
61 to 97

Re + Co + NBSA—VN
Re
0.015 to
0.05 to
0.02 to
0.07 to 65
0.025 to
0.09 to

39.6
60
34.65

29.7
60

NBSA
0.015 to
0.02 to
0.02 to
0.024to
0.025 to
0.03 to

39.6
46.4
34.65
41.2
29.7
36

Co
0.015 to
0.02 to
0.02 to
0.03 to 44
0.025 to
0.04 to

39.6
49
34.65

29.7
39

VN
60 to 97
30 to 96
65 to 96
35 to 95
70 to 95
40 to 93

Re + Co + NBSA—NbN
Re
0.015 to
0.04 to
0.02 to
0.06 to 60
0.025 to
0.07 to

39.6
65
34.65

29.7
55

NBSA
0.015 to
0.016to
0.02 to
0.02 to 37
0.025 to
0.025 to

39.6
42
34.65

29.7
32

Co
0.015 to
0.02 to
0.02 to
0.025 to
0.025 to
0.03 to

39.6
45
34.65
39.5
29.7
34

NbN
60 to 97
34to 97
65 to 96
39 to 96
70 to 95
45 to 95

Re + Co + NBSA—TaN
Re
0.015 to
0.02 to
0.02 to
0.03 to 44
0.025 to
0.04 to

39.6
49
34.65

29.7
38

NBSA
0.015 to
0.008 to
0.02 to
0.011 to
0.025 to
0.014 to

39.6
27
34.65
23
29.7
19

Co
0.015 to
0.01 to
0.02 to
0.013 to
0.025 to
0.016 to

39.6
29
34.65
25
29.7
21

TaN
60 to 97
51 to
65 to 96
56 to 97.7
70 to 95
61.5 to

98.3

97.1

TABLE 23

Compositions that use Re for binding WC + TiC or WC + TaC or

WC + TiC + TaC

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

Re -
Re
3 to 40
4 to 54
4 to 35
5 to 49
5 to 30
7 to 43

WC + TiC
WC
40 to 96
40 to 96
43 to 94.5
44 to 94
45 to 93
48 to 93

TiC
1 to 48
0.3 to 21
1.5 to 43
0.5 to 19
2 to 45
0.6 to 18

Re -
Re
3 to 40
4 to 48
4 to 35
5 to 42
5 to 30
7 to 37

WC + TaC
WC
50 to 96.5
44 to 96
55 to 95
49 to 94
60 to 93.5
55 to 92

TaC
0.5 to 24
0.5 to 21
1 to 22
1 to 19
1.5 to 18
1.5 to18

Re -
Re
3 to 40
4 to 48
4 to 35
5 to 43
5 to 30
7 to 38

WC + TiC + TaC
WC
40 to 95.5
36 to 95
45 to 93
41 to 93
50 to 90
48 to 90

TiC
1 to 48
0.3 to 22
2 to 45
0.6 to 20
3 to 42
0.9 to 18

TaC
0.5 to 20
0.5 to 25
1 to 18
0.8 to 22
2 to 15
2 to 17

TABLE 24

Compositions that use Ni-based superalloy (NBSA) for binding

WC + TiC or WC + TaC or WC + TiC + TaC

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

NBSA -
NBSA
3 to 40
1.5 to 31
4 to 35
2 to 26
5 to 30
3 to 23

WC + TiC
WC
40 to 96
60 to 98
43 to 94.5
63 to 97
45 to 93
66 to 96.5

TiC
1 to 48
0.3 to 25
1.5 to 43
0.5 to 22
2 to 45
0.6 to 20

NBSA -
NBSA
3 to 40
1.5 to 26
4 to 35
2 to 22
5 to 30
3 to 18

WC + TaC
WC
50 to 96.5
63 to 98
55 to 95
67 to 97
60 to 93.5
71 to 96

TaC
0.5 to 24
0.5 to 26
1 to 22
1 to 23
1.5 to 18
1.5 to 21

NBSA -
NBSA
3 to 40
1.5 to 26
4 to 35
2 to 22
5 to 30
3 to 19

WC + TiC + TaC
WC
40 to 95.5
51 to 98
45 to 93
56 to 96
50 to 90
61 to 94

TiC
1 to 48
0.4 to 23
2 to 45
0.8 to 21
3 to 42
1 to 19

TaC
0.5 to 20
0.6 to 26
1 to 18
1 to 23
2 to 15
2 to 18

TABLE 25

Compositions that use Re and Ni-based superalloy (NBSA) in a

binder for binding WC + TiC or WC + TaC or WC + TiC + TaC

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA) -
Re
0.03 to
0.04 to
0.04 to
0.06 to 48
0.05 to
0.07 to

WC + TiC

39.6
52
34.65

29.7
45

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 26
0.05 to
0.026 to

39.6
29
34.65

29.7
23

WC
40 to 96
40 to 98
43 to
44 to 97
45 to 93
48 to

94.5

96.6

TiC
1 to 48
0.3 to 24
1.5 to 45
0.5 to 22
2 to 42
0.6 to 21

(Re + NBSA) -
Re
0.03 to
0.04 to
0.04 to
0.055 to 42
0.05 to
0.07 to

WC + TaC

39.6
47
34.65

29.7
37

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 22
0.05 to
0.025 to

39.6
25
34.65

29.7
18

WC
50 to
44 to 98
55 to 95
50 to 97
60 to 93
55 to

96.5

95.5

TaC
0.5 to 22
0.5 to 24
1 to 20
1 to 21.5
2 to 18
2 to 19

(Re + NBSA) -
Re
0.03 to
0.04 to
0.04 to
0.06 to 47
0.05 to
0.07 to

WC + TiC + TaC

39.6
53
34.65

29.7
41

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 25
0.05 to
0.026 to

39.6
30
34.65

29.7
21

WC
40 to
40 to 98
45 to 93
46 to 96
50 to 90
51 to 94

95.5

TiC
1 to 48
0.3 to 23
2 to 45
0.6 to 21
3 to 42
0.9 to 19

TaC
0.5 to 20
0.4 to 26
1 to 18
0.8 to 23
2 to 15
2 to 18

TABLE 26

Compositions that use Re and Co in a binder for binding WC + TiC

or WC + TaC or WC + TiC + TaC

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + Co) -
Re
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.07 to

WC + TiC

39.6
53
34.65
48
29.7
43

Co
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to
0.03 to

39.6
31
34.65
28
29.7
26

WC
40 to 96
40 to 98
43 to 94.5
44 to 97
45 to 93
48 to 96

TiC
1 to 48
0.3 to 23
1.5 to 45
0.5 to 22
2 to 42
0.6 to 21

(Re + Co) -
Re
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.07 to

WC + TaC

39.6
47
34.65
42
29.7
37

CO
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to
0.03 to

39.6
28
34.65
24
29.7
20

WC
50 to
44 to 98
55 to 95
50 to 97
60 to 93
55 to 95

96.5

TaC
0.5 to
0.5 to 24
1 to 20
1 to 21
2 to 18
2 to 19

22

(Re + Co) -
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to

WC + TiC + TaC

39.6
53
34.65
47
29.7
41

Co
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to
0.03 to

39.6
33
34.65
28
29.7
23

WC
40 to
40 to 98
45 to 93
46 to 96
50 to 90
51 to 94

95.5

TiC
1 to 48
0.3 to 23
2 to 45
0.6 to 21
3 to 42
0.9 to 19

TaC
0.5 to
0.4 to 26
1 to 18
0.8 to 23
2 to 15
2 to 18

20

TABLE 27

Compositions that use Co and Ni-based superalloy (NBSA) in a

binder for binding WC + TiC or WC + TaC or WC + TiC + TaC

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Co + NBSA) -
Co
0.03 to
0.018 to
0.04 to
0.024 to 29
0.05 to
0.03 to

WC + TiC

39.6
33
34.65

29.7
25

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 26
0.05 to
0.03 to

39.6
29
34.65

29.7
23

WC
40 to 96
58 to 98
43 to
61 to 97
45 to 93
64 to

94.5

96.7

TiC
1 to 48
0.3 to 24
1.5 to 45
0.5 to 22
2 to 42
0.7 to 21

(Co + NBSA) -
Co
0.03 to
0.018 to
0.04 to
0.024 to 24
0.05 to
0.03 to

WC + TaC

39.6
28
34.65

29.7
20

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 22
0.05 to
0.025 to

39.6
25
34.65

29.7
18

WC
50 to
61 to 98
55 to 95
65 to 97
60 to 93
69 to 95

96.5

TaC
0.5 to
0.5 to 24
1 to 20
1 to 21.5
2 to 18
2 to 19

22

(Co + NBSA) -
Co
0.03 to
0.018 to
0.04 to
0.024 to 28
0.05 to
0.03 to

WC + TiC + TaC

39.6
33
34.65

29.7
23

NBSA
0.03 to
0.015 to
0.04 to
0.02 to 25
0.05 to
0.026 to

39.6
30
34.65

29.7
21

WC
40 to
57 to 98
45 to 93
62 to 96
50 to 90
67 to 94

95.5

TiC
1 to 48
0.4 to 23
2 to 45
0.7 to 21
3 to 42
1 to 19

TaC
0.5 to
0.6 to 26
1 to 18
1 to 23
2 to 15
2 to 18

20

TABLE 28

Compositions that use Re, Ni-based superalloy (NBSA), and Co

in a binder for binding WC + TiC or WC + TaC or WC + TiC + TaC. The range of

Binder is from 0.5% Re + 99.5% superalloy to 99.5% Re + 0.5% Superalloy

to 0.5% Re + 0.5% Superalloy + 99% Co.

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + Co
Re
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.035 to

NBSA) -

39.8
54
34.8
48
29.9
43

WC + TiC
NBSA
0.015 to
0.008 to
0.02 to
0.01 to
0.025 to
0.13 to

39.8
29
34.8
26
29.9
24

Co
0 to
0 to 32
0 to 34.7
0 to 29
0 to 29.8
0 to 26

39.6

WC
40 to 96
40 to 98
43 to
44 to 97
45 to 93
48 to 96

94.5

TiC
1 to 48
0.3 to 24
1.5 to 45
0.5 to 22
2 to 42
0.6 to 21

(Re + Co + NBSA) -
Re
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.034 to

WC + TaC

39.8
47
34.8
42
29.9
37

NBSA
0.015 to
0.008 to
0.02 to
0.01 to
0.025 to
0.13 to

39.8
26
34.8
22
29.9
18

Co
0 to
0 to 28
0 to 34.7
0 to 24
0 to 29.8
0 to 20

39.6

WC
50 to
45 to 98
55 to 95
50 to 97
60 to 93
55 to 95

96.5

TaC
0.5 to
0.5 to 24
1 to 20
0.9 to 21
2 to 18
1.8 to19

22

(Re + NBSA + Co) -
Re
0.015 to
0.02 to
0.02 to
0.027 to
0.025 to
0.034 to

WC + TiC + TaC

39.8
65
34.8
58
29.9
51

NBSA
0.015 to
0.008
0.02 to
0.01 to
0.025 to
0.13 to

39.8
to41
34.8
34
29.9
28

Co
0 to
0 to 44
0 to 34.7
0 to 37
0 to 29.8
0 to 31

39.6

WC
35 to 85
35 to 93
40 to 80
41 to 88
40 to 75
47 to83

TiC
1 to 50
0.3 to 25
2 to 45
0.6 to 22
3 to 40
0.9 to 18

TaC
0.5 to
0.4 to 26
1 to 22
0.8 to 24
2 to 20
1.6 to 21

25

TABLE 29

Additional Material Samples and Their Compositions

Lot No.
Re
R95
Co
U700
U720
Ni
WC
TiC
TaC
VC
Mo₂C
TiN

Composition in Weight %

P80
0
0
14.28

74.15
5.835
5.733

P81
0.736
0
13.904

73.84
5.811
5.709

P82
0.707
6.026
7.3694

74.31
5.847
5.744

P83
0.679
12.82
0

74.83
5.889
5.785

P84
1.45
5.903
7.1237

73.98
5.822
5.719

P85
3.06
5.532
6.7027

73.27
5.766
5.665

P86
1.45
5.903
7.1237

36.99
5.822
5.719

P87
1.063
4.126
5.4174

78.14
5.676
5.576

P88
1.861
7.57
9.1372

69.59
5.974
5.869

P89
1.368
5.572
6.7242

80.31
3.004
3.023

P99
0
0

5.5
15
29
10

9.5
20

P100
4.8

4.65
14.5
28.1
9.7

9.5
19.4

P101
4.8
4.65

14.5
28.1
9.7

9.5
19.4

P102
4.8
10

14.5
28.1
9.7

9.5
19.4

P103
9.6
20

11.25
21.65
7.5

7.1
14.9

P104
7.2
15

12.8
25
8.6

8.1
17.3

P105
15
7.5

13.6
26.35
9.05

8.9
18.1

P106
14.49
0
0

74.415
5.092
6.003

P107
15.101
0
0

66.875
7.076
10.95

P108
11.796
0.7485
0.437

75.727
5.182
6.109

P109
12.303
0.7807
0.456

68.105
7.206
11.15

P110
9.5724
1.4017
0.761

76.812
5.256
6.196

P111
9.9896
1.4628
0.794

69.124
7.314
11.32

P112
6.9929
2.1369
1.16

78.07
5.342
6.298

P113
14.131
4.3182
2.343

67.447
5.398
6.363

P114
21.418
6.545
3.552

56.602
5.454
6.43

P115
3.8745
3.0258
1.642

79.591
5.446
6.421

P116
7.988
6.2383
3.385

70.155
5.614
6.619

P117
12.363
9.6552
5.24

60.119
5.793
6.829

P118
1.8824
3.5833
1.961

80.561
5.513
6.499

P119
2.8849
5.4917
3.006

76.345
5.632
6.64

P120
5.0264
9.5681
5.237

67.339
5.888
6.941

P121
13.157
0.5708
0

75.078
5.138
6.057

P122
5.294
2.0672
0

81.057
5.316
6.266

Weight %

P123
19.908
5.9798
1.976

60.41
5.382
6.344

P124
20.68
9.9386
2.736

54.464
5.59
6.59

P125
1.5492
3.0246
0.833

82.731
5.444
6.418

P126
8.4621
13.217
3.639

61.723
5.948
7.011

P127
12.191
13.964
3.844

61.702
3.808
4.49

P128
11.906
0.5166
0

86.99

0.604

P129
1.6752
2.0169
1.9524

93.77

0.599

P130
11.97
8.0334
8.085

71.33

0.6

P131
1.4372
3.8162
3.7765

90.39

0.596

P132
6.6223
1.3705
1.3191

90.1

0.605

P133
5.505
1.7196
1.6331

90.55

0.609

P134
11.43
5.0212
4.8443

78.11

0.613

P135
1.644
2.3344
2.571

79.98
3.151
10.32

P136
3.6545
5.1371
5.657

73.439
0
12.11

P137
4.4642
6.3916
7.039

69.776
0
12.33

P138
4.899
6.5757
7.241

69.279
1.435
10.57

P139
6.5381
7.902
8.702

64.651
1.459
10.75

P140
3.0601
5.5324
6.703

73.274
5.766
5.665

P141
2.9261
5.2902
6.409

71.233
3.308
10.83

P142
5.0649
6.1371
7.419

67.113
3.337
10.93

A
13.853
0.2847
0.314

74.887
5.125
5.538

B
2.7327
5.0305
0

81.358
5.488
5.391

C
3.0601
5.5324
6.703

73.274
5.766
5.665

D
1.8803
3.5793
1.988

81.637
5.507
5.41

E
7.7737
9.4819
0

71.578
5.633
5.534

P144
0.6786
12.821
0

74.827
5.889
5.785

P145
0.6437
5.663
0

80.041
3.194
10.46

P146
1.8837
5.3941
0

81.786
5.517
5.42

P147
2.3479
5.1953
0

81.552
5.501
5.404

P148
1.5479
8.462
0

76.038
3.264
10.69

P149
1.6376
15.347
0

68.255
3.453
11.11

J
25.75

2.5

14.5
24.1
8.5

8
16.65

K
11.671
0.4143
0.3935
0
0

86.92

0.605

L
2.6826
5.5683
0
0
0

91.32

0.43

M
3.5669
0
14.235
0
0

81.75

0.452

N
0
7.5039
0
0
0

92.06

0.44

O
12.515
0
0
0
0.2541

86.63

0.601

P
1.7969

0
0
6.9309

90.68

0.597

Q
0

0
0
7.4214

91.98

0.602

S
8.371

0
0
5.3814

85.67

0.579

T
1.6967

0
4.681
0

92.98

0.645

U
3.9002

0
0
3.8684

91.6

0.636

P150
0

0

14.847

84.68

0.469

P151
0

3.2554

11.851

84.38

0.51

P152
1.5219

3.225

11.153

83.59

0.505

P153
12.451

1.2899

4.6957

81.09

0.478

P154
2.6486

2.9933

7.6052

54.464

0.509

P155
0

0

11.55

82.731

0.414

P156
1.1019

3.5804

6.2338

61.723

0.671

P157
0

3.761

6.5607

86.24

0.675

P158
0

0

9.9898

88.04

0.512

P159
0.9437

3.0766

5.5161

88.41

0.502

P160
0

3.0946

5.9144

89

0.505

P161
0

0

8.7552

89.5

0.506

P162
2.967

5.6892
0.6379
0.654

89.817

0.2346

P163
0.581

8.1942
0.9297
0.8972

89.156

0.2413

P164
2.16

7.569
0.8669
0.8333

88.331

0.2391

P165
2.801

6.7279
1.976
2.026

86.226

0.2422

P166
2.797

8.3834
1.2603
1.2361

86.082

0.2418

P167
2.789

11.13
0
0

85.84

0.2411

The following TABLES 30-41 list exemplary cermet compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications.

TABLE 30Compositions that use Re as a binder for binding TiC + Mo₂C, orTiN + Mo₂C, or TiC + TiN + Mo₂C, or TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃CompositionCompositionCompositionRange 1Range 2Range 3MaterialVolume %Weight %Volume %Weight %Volume %Weight %Re -Re3 to 309.5 to 654 to 2713 to 605 to 2515 to 58TiC + Mo₂CTiC43 to 9719 to 8848 to 9223 to 7951 to 9025 to 75Mo₂C0 to 270 to 380 to 260 to 360 to 240 to 33Re -Re3 to 309 to 634 to 2712 to 585 to 2515 to 56TiN + Mo₂CTiN43 to 9721 to 8948 to 9225 to 8151 to 9027 to 76Mo₂C0 to 270 to 360 to 260 to 340 to 240 to 31Re -Re3 to 309 to 644 to 2712 to 605 to 2515 to 58TiC + TiN + Mo₂CTiC0.3 to0.2 to 840.4 to0.3 to 790.5 to0.35 to93.791.689.574TiN0.3 to0.3 to 850.4 to0.4 to 800.5 to0.5 to 7693.791.689.5Mo₂C0 to 270 to 360 to 260 to 340 to 240 to 31Re -Re3 to 306 to 654 to 279 to 615 to 2511 to 65TiC + TiN + Mo₂C +TiC0.3 to0.1 to 830.4 to0.2 to 780.5 to0.3 to 74WC + TaC + VC +93.591.389.1Cr₂C₃TiN0.3 to0.15 to0.4 to0.2 to 800.5 to0.3 to 7693.58591.389.1Mo₂C0 to 280 to 250 to 260 to 250 to 240 to 24WC0.1 to0.15 to0.15 to0.25 to0.2 to0.35 to203915321228TaC0.1 to0.15 to0.15 to0.25 to0.2 to0.3 to 221530122510VC0 to 150 to 110 to 120 to 100 to 100 to 9Cr₂C₃0 to 150 to 160 to 120 to 140 to 100 to12

TABLE 31

Compositions that use Ni-based superalloy (NBSA) as a binder for

binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

NBSA -
NBSA
3 to 30
4 to 41
4 to 27
5 to 37
5 to 25
6 to 34

TiC + Mo₂C
TiC
43 to 94
30 to 90
48 to 92
35 to 87
51 to 90
37 to 84

Mo₂C
3 to 27
4 to 40
4 to 26
6 to 39
5 to 24
8 to 36

NBSA —
NBSA
3 to 30
4 to 38
4 to 27
5 to 34
5 to 25
6 to 32

TiN + Mo₂C
TiN
43 to 94
32 to 91
48 to 92
37 to 88
51 to 90
40 to 85

Mo₂C
3 to 27
4 to 38
4 to 26
6 to 37
5 to 24
7 to 34

NBSA -
NBSA
3 to 30
4 to 40
4 to 27
5 to 36
5 to 25
6 to 34

TiC + TiN + Mo₂C
TiC
0.3 to
0.2 to 90
0.4 to
0.3 to 86
0.5 to
0.4 to 83

93.7

91.6

89.5

TiN
0.3 to
0.3 to 91
0.4 to
0.4 to 88
0.5 to
0.5 to 85

93.7

91.6

89.5

Mo₂C
3 to 27
4 to 38
4 to 26
6 to 37
5 to 24
8 to 34

NBSA -
NBSA
3 to 30
2 to 40
4 to 27
4 to 36
5 to 25
5 to 34

TiC + TiN + Mo₂C +
TiC
0.3 to
0.15 to
0.4 to
0.2 to 86
0.5 to
0.3 to 83

WC + TaC +

93.3
90
91.3

89.3

VC + Cr₂C₃
TiN
0.3 to
0.25 to
0.4 to
0.35 to
0.5 to
0.45 to

93.3
90
91.3
87
89.3
84

Mo₂C
3 to 27
4 to 25
4 to 26
6 to 26
5 to 24
8 to 25.5

WC
0.1 to 20
0.25 to
0.15 to
0.4 to 34
0.2 to 12
0.5 to 29

42
15

TaC
0.1 to 15
0.25 to
0.15 to
0.4 to 30
0.2 to 10
0.5 to 26

36
12

VC
0 to 15
0 to 14
0 to 12
0 to 12
0 to 10
0 to 10

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to13

TABLE 32

Compositions that use Re and Ni-based superalloy (NBSA) in a

binder for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA) -
Re
0.03 to
0.1 to 64
0.04 to
0.13 to
0.05 to
0.16 to

TiC + TiN + Mo₂C

29.7

26.73
60
24.75
57

NBSA
0.03 to
0.03 to
0.04 to
0.05 to
0.05 to
0.06 to

29.7
40
26.73
36
24.75
34

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + NBSA) -
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.12 to

TiC + TiN + Mo₂C +

29.7
64
26.73

24.75
57

WC + TaC + VC +
NBSA
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.04 to

Cr₂C₃

29.7
40
26.73
36
24.75
34

TiC
0.3 to
0.15 to
.40 to
0.2 to 86
0.5 to
0.3 to 83

93.5
89
91.3

89.1

TiN
0.3 to
0.15 to
.40 to
0.2 to 87
0.5 to
0.3 to 84

93.5
90
91.3

89.1

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to 25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to
0.35 to

20
42
15
35
12
29

TaC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to
0.3 to 24

15
33
12
28
10

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 33

Compositions that use Re and Ni in a binder for binding TiC + Mo₂C,

or TiN + Mo₂C, or TiC + TiN + Mo₂C, or TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + Ni) −
Re
0.03 to
0.1 to 64
0.04 to
0.13 to 60
0.05 to
0.16 to

TiC + TiN +

29.7

26.73

24.75
57

Mo₂C
Ni
0.03 to
0.04 to
0.04 to
0.05 to 38
0.05 to
0.06 to

29.7
42
26.73

24.75
36

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 83

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + Ni) −
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.12 to

TiC + TiN +

29.7
64
26.73

24.75
57

Mo₂C +
Ni
0.03 to
0.03 to
0.04 to
0.04 to 39
0.05 to
0.05 to

WC + TaC +

29.7
42
26.73

24.75
36

VC + Cr₂C₃
TiC
0.3 to
0.15 to
.40 to
0.2 to 85
0.5 to 89.1
0.3 to

93.5
89
91.3

82

TiN
0.3 to
0.15 to
.40 to
0.2 to 87
0.5 to 89.1
0.3 to

93.5
90
91.3

83

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to

25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to 35
0.2 to 12
0.35 to

20
42
15

29

TaC
0.1 to
0.15 to
0.15 to
0.25 to 28
0.2 to 10
0.3 to

15
33
12

24

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 34

Compositions that use Re and Co in a binder for binding TiC + Mo₂C, or TiN + Mo₂C,

or TiC + TiN + Mo₂C, or TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

Re + Co −
Re
0.03 to
0.1 to 64
0.04 to
0.13 to
0.05 to
0.16 to

TiC + TiN +

29.7

26.73
60
24.75
57

Mo₂C
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

29.7
43
26.73
39
24.75
36

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 83

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

Re + Co −
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.12 to

TiC + TiN +

29.7
64
26.73

24.75
57

Mo₂C +
Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

WC + TaC +

29.7
43
26.73
39
24.75
36

VC + Cr₂C₃
TiC
0.3 to
0.15 to
.40 to
0.2 to 85
0.5 to
0.3 to 82

93.5
89
91.3

89.1

TiN
0.3 to
0.15 to
.40 to
0.2 to 87
0.5 to
0.3 to 83

93.5
90
91.3

89.1

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to 25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to 12
0.35 to

20
42
15
34

29

TaC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to 10
0.3 to 24

15
32
12
27

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 35

Compositions that use Ni-based superalloy (NBSA) and Co in a binder

for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(NBSA + Co) −
NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

TiC + TiN +

29.7
40
26.73
37
24.75
34

Mo₂C
Co
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to

29.7
43
26.73
39
24.75
37

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 86

Mo₂C
3 to 27
4 to 38
4 to 26
6 to 37
5 to 24
7 to 34

(NBSA + Co) −
NBSA
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.05 to

TiC + TiN +

29.7
40
26.73
36
24.75
34

Mo₂C +
Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

WC + TaC +

29.7
43
26.73
39
24.75
36

VC + Cr₂C₃
TiC
0.3 to
0.15 to
.40 to
0.2 to
0.5 to
0.3 to

93.5
89
91.3
86
89.1
83

TiN
0.3 to
0.25 to
.40 to
0.35 to
0.5 to
0.45 to

93.5
90
91.3
87
89.1
84

Mo₂C
3 to 28
4 to 26
4 to 26
6 to 26
5 to 24
7 to

25.5

WC
0.1 to 20
0.25 to
0.15 to
0.38 to
0.2 to 12
0.5 to

42
15
35

29

TaC
0.1 to 15
0.23 to
0.15 to
0.35 to
0.2 to 10
0.47 to

33
12
28

24

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 36

Compositions that use Ni-based superalloy (NBSA) and Ni in a

binder for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(NBSA + Ni) −
NBSA
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

TiC + TiN +

29.7
40
26.73
37
24.75
34

Mo₂C
Ni
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.07 to

29.7
43
26.73
39
24.75
36

TiC
0 to 94
0 to 90
0 to 92
0 to 88
0 to 90
0 to 85

TiN
0 to 94
0 to 91
0 to 92
0 to 89
0 to 90
0 to 86

Mo₂C
3 to 27
4 to 38
4 to 26
6 to 37
5 to 24
7 to 34

(NBSA + Ni) −
NBSA
0.03 to
0.02 to
0.04 to
0.035 to
0.05 to
0.05 to

TiC + TiN +

29.7
40
26.73
36
24.75
34

Mo₂C +
Ni
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

WC + TaC +

29.7
43
26.73
39
24.75
36

VC + Cr₂C₃
TiC
0.3 to
0.15 to
.40 to
0.2 to 86
0.5 to
0.3 to 83

93.5
89
91.3

89.1

TiN
0.3 to
0.25 to
.40 to
0.35 to
0.5 to
0.45 to

93.5
90
91.3
87
89.1
84

Mo₂C
3 to 28
4 to 26
4 to 26
6 to 26
5 to 24
7 to 25.5

WC
0.1 to 20
0.25 to
0.15 to
0.38 to
0.2 to 12
0.5 to 29

42
15
35

TaC
0.1 to 15
0.23 to
0.15 to
0.35 to
0.2 to 10
0.47 to

33
12
28

24

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to13

TABLE 37

Compositions that use Re, Co, and Ni-based superalloy (NBSA) in a

binder for binding TiC and Mo₂C, or TiN and Mo₂C, or TiC, TiN,

and Mo₂C, or TiC, TiN, Mo₂C, WC, TaC, VC, and Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA + Co) −
Re
0.03 to
0.1 to 64
0.04 to
0.13 to 60
0.05 to
0.16 to 57

TiC + TiN + Mo₂C

29.4

26.46

24.5

NBSA
0.03 to
0.035 to
0.04 to
0.045 to 36
0.05 to
0.055 to

29.4
40
26.46

24.5
34

Co
0.03 to
0.04 to
0.04 to
0.05 to 39
0.05 to
0.06 to 36

29.4
42
26.46

24.5

TiC
0 to 94
0 to 90
0 to 92
0 to 88
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + NBSA + Co) −
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.13 to 57

TiC + TiN + Mo₂C +

29.4
63
26.46

24.5

WC + TaC + VC +
NBSA
0.03 to
0.02 to
0.0 to
0.03 to 36
0.05 to
0.04 to 33

Cr₂C₃

29.4
39
26.46

24.5

Co
0.03 to
0.03 to
0.04 to
0.04 to 39
0.05 to
0.05 to 36

29.4
42
26.46

24.5

TiC
0.3 to
0.15 to
0.4 to
0.2 to 86
0.5 to
0.3 to 83

93.5
89
91.3

89.1

TiN
0.3 to
0.15 to
0.4 to
0.2 to 87
0.5 to
0.3 to 84

93.5
90
91.3

89.1

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to 25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to 35
0.2 to 12
0.35 to 29

20
42
15

TaC
0.1 to
0.15 to
0.15 to
0.25 to 28
0.2 to 10
0.3 to 24

15
33
12

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 38

Compositions that use Re, Ni, and Ni-based superalloy (NBSA) in a

binder for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA + Ni) −
Re
0.03 to
0.1 to 63
0.04 to
0.13 to
0.05 to
0.16 to

TiC + TiN + Mo₂C

29.4

26.46
60
24.5
57

NBSA
0.03 to
0.035 to
0.04 to
0.045 to
0.05 to
0.055 to

29.4
40
26.46
36
24.5
33

Ni
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

29.4
42
26.46
38
24.5
36

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + NBSA + Ni) −
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.13 to

TiC + TiN + Mo₂C +

29.4
63
26.46

24.5
57

WC + TaC + VC + Cr₂C₃
NBSA
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.04 to

29.4
39
26.46
36
24.5
33

Ni
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

29.4
42
26.46
38
24.5
36

TiC
0.3 to
0.15 to
0.4 to
0.2 to 86
0.5 to
0.3 to 83

93.5
89
91.3

89.1

TiN
0.3 to
0.15 to
0.4 to
0.2 to 87
0.5 to
0.3 to 84

93.5
90
91.3

89.1

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to 25.5

WC
0.1 to 20
0.15 to
0.15 to
0.25 to
0.2 to
0.35 to

42
15
35
12
29

TaC
0.1 to 15
0.15 to
0.15 to
0.25 to
0.2 to
0.3 to 24

33
12
28
10

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 39

Compositions that use Re, Ni, and Co in a binder for binding TiC + Mo₂C,

or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + Ni + Co) −
Re
0.03 to
0.1 to 63
0.04 to
0.13 to
0.05 to
0.16 to

TiC + TiN + Mo₂C

29.4

26.46
60
24.5
57

Ni
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

29.4
42
26.46
38
24.5
36

Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

29.4
42
26.46
39
24.5
36

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 83

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + Ni + Co) −
Re
0.03 to
0.06 to
0.04 to
0.1 to 60
0.05 to
0.13 to

TiC + TiN + Mo₂C +

29.4
63
26.46

24.5
57

WC + TaC + VC + Cr₂C₃
Ni
0.03 to
0.025 to
0.04 to
0.04 to
0.05 to
0.05 to

29.4
42
26.46
38
24.5
36

Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to

29.4
42
26.46
39
24.5
36

TiC
0.3 to
0.15 to
0.4 to
0.2 to 85
0.5 to
0.3 to 82

93.5
89
91.3

89.1

TiN
0.3 to
0.15 to
0.4 to
0.2 to 87
0.5 to
0.3 to 83

93.5
90
91.3

89.1

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to 25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to 12
0.35 to

20
42
15
35

29

TaC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to 10
0.3 to 24

15
33
12
28

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 40

Compositions that use Co, Ni, and Ni-based superalloy (NBSA) in a

binder for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(NBSA + Ni + Co) −
NBSA
0.03 to
0.04 to
0.04 to
0.5 to 36
0.05 to
0.06 to 34

TiC + TiN + Mo₂C

29.4
40
26.46

24.5

Ni
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.07 to 37

29.4
42
26.46
39
24.5

Co
0.03 to
0.04 to
0.04 to
0.055 to
0.05 to
0.07 to 36

29.4
43
26.46
39
24.5

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
4 to 38
4 to 26
5 to 37
5 to 24
7 to 34

(NBSA + Ni + Co) −
NBSA
0.03 to
0.025 to
0.04 to
0.035 to
0.05 to
0.05 to 33

TiC + TiN + Mo₂C +

29.4
40
26.46
36
24.5

WC + TaC + VC + Cr₂C₃
Ni
0.03 to
0.025 to
0.04 to
0.04 to 38
0.05 to
0.05 to 36

29.4
42
26.46

24.5

Co
0.03 to
0.03 to
0.04 to
0.04 to 39
0.05 to
0.05 to 36

29.4
42
26.46

24.5

TiC
0.3 to
0.15 to
0.4 to
0.2 to 86
0.5 to
0.3 to 83

93.5
89
91.3

89.1

TiN
0.3 to
0.25 to
0.4 to
0.35 to 87
0.5 to
0.45 to 84

93.5
90
91.3

89.1

Mo₂C
3 to 28
4 to 26
4 to 26
6 to 26
5 to 24
7 to 25.5

WC
0.1 to
0.25 to
0.15 to
0.35 to 35
0.2 to 12
0.5 to 29

20
42
15

TaC
0.1 to
0.25 to
0.15 to
0.35 to 28
0.2 to 10
0.45 to 24

15
33
12

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

TABLE 41

Compositions that use Re, Ni, Co, and Ni-based superalloy (NBSA) in a

binder for binding TiC + Mo₂C, or TiN + Mo₂C, or TiC + TiN + Mo₂C, or

TiC + TiN + Mo₂C + WC + TaC + VC + Cr₂C₃

Composition
Composition
Composition

Range 1
Range 2
Range 3

Material
Volume %
Weight %
Volume %
Weight %
Volume %
Weight %

(Re + NBSA + Ni + Co) −
Re
0.03 to
0.1 to
0.04 to
0.13 to
0.05 to
0.16 to

TiC + TiN + Mo₂C

29.1
63
26.19
59
24.25
57

NBSA
0.03 to
0.035 to
0.04 to
0.45 to
0.05 to
0.055 to

29.1
39
26.19
36
24.25
33

Ni
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to

29.1
42
26.19
38
24.25
36

Co
0.03 to
0.04 to
0.04 to
0.5 to
0.05 to
0.06 to

29.1
42
26.19
38
24.25
36

TiC
0 to 94
0 to 90
0 to 92
0 to 87
0 to 90
0 to 84

TiN
0 to 94
0 to 91
0 to 92
0 to 88
0 to 90
0 to 85

Mo₂C
3 to 27
3 to 38
4 to 26
4 to 37
5 to 24
5 to 34

(Re + NBSA + Ni + Co) −
Re
0.03 to
0.06 to
0.04 to
0.1 to
0.05 to
0.12 to

TiC + TiN + Mo₂C +

29.1
63
26.19
59
24.25
56

WC + TaC + VC + Cr₂C₃
NBSA
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.04 to

29.1
39
26.19
35
24.25
33

Ni
0.03 to
0.025 to
0.04 to
0.035 to
0.05 to
0.05 to

29.1
42
26.19
38
24.25
35

Co
0.03 to
0.025 to
0.04 to
0.03 to
0.05 to
0.05 to

29.1
42
26.19
38
24.25
36

TiC
0.3 to
0.15 to
0.4 to
0.2 to
0.5 to
0.3 to

93.5
89
91.3
86
89.1
83

TiN
0.3 to
0.15 to
0.4 to
0.2 to
0.5 to
0.3 to

93.5
90
91.3
87
89.1
84

Mo₂C
3 to 28
3 to 26
4 to 26
4 to 26
5 to 24
5 to

25.5

WC
0.1 to
0.15 to
0.15 to
0.25 to
0.2 to 12
0.3 to

20
42
15
35

29

TaC
0.1 to
0.15 to
0.15 to
0.2 to
0.2 to 10
0.3 to

15
33
12
28

24

VC
0 to 15
0 to 16
0 to 12
0 to 13
0 to 10
0 to 11

Cr₂C₃
0 to 15
0 to 18
0 to 12
0 to 15
0 to 10
0 to 13

The following TABLES 42-51 list additional examples of various compositions with 3 exemplary composition ranges 1, 2, and 3 which may be used for different applications. Similar to some compositions described above, some compositions in TABLES 42-51 may be particularly useful for applications at high temperatures as indicated in the last row under “estimated melting points.”

As described above, binder matrix materials with rhenium, a nickel-based superalloy or a combination of both can enhance material performance at high temperatures. Tungsten is typically used as a constituent element in various hard particles such as carbides, nitrides, carbonitrides, borides, and silicides. When used as a binder matrix material, either alone or in combination with other metals, tungsten can significantly raise the melting point of the final hardmetal materials to the range of about 2500 to about 3500° C. Hence, hardmetals using W-based binder matrix materials can be used in applications at high temperatures that may not be possible with other materials. Notably, certain compositions that use a binder matrix based on tungsten (W) shown in TABLES 43-48 show expected high melting points around 3500° C.

For the compositions made of nitrides bound by rhenium and cobalt in TABLE 47, each nitride may be substituted by a combination of a nitride and carbide as the hard particle material. A material under this design includes hard particles comprising at least one nitride from nitrides of IVB and VB columns in the periodic table and one carbide from carbides of IVB, VB and VIB columns in the periodic table, and a binder matrix that binds the hard particles and comprises rhenium and cobalt.

TABLE 42Re bound a Boride from Borides of IVb, Vb, & VIb or a Silicidefrom Silicides of IVb, Vb & VIbCompositionCompositionCompositionEstimatedRange 1Range 2Range 3MeltingVolume %Weight %Volume %Weight %Volume %Weight %Point, ° C.ReRe3 to 4012.5 to4 to 3516 to 715 to 3020 to 672700 toBound763000TiB₂TiB₂60 to 9724 to65 to 9629 to 8470 to 9533 to 8087.5ReRe3 to 409.5 to4 to 3512.5 to5 to 3015 to 602800 toBound70653000ZrB₂ZrB₂60 to 9730 to65 to 9635 to70 to 9540 to 8590.587.5ReRe3 to 405.5 to4 to 357 to 505 to 309 to3000 toBound55.544.53200HfB₂HfB₂60 to 9744.5 to65 to 9650 to 9370 to 9555.5 to94.591ReRe3 to 4011 to 734 to 3514.5 to5 to 3018 to 642000 toBound692500VB₂VB₂60 to 9727 to 8965 to 9631 to70 to 9536 to 8285.5ReRe3 to 408 to 664 to 3511 to 615 to 3013 to2800 toBound55.53100NbB₂NbB₂60 to 9734 to 9265 to 9639 to 8970 to 9544.5 to87ReRe3 to 405 to 534 to 356.5 to5 to 308 to 423000 toBound473200TaB₂TaB₂60 to 9747 to 9565 to 9653 to70 to 9558 to 9293.5ReRe3 to 409.5 to4 to 3512.5 to5 to 3015 to 601800 toBound69.5652200Cr₃B₂Cr₃B₂60 to 9730.5 to65 to 9635 to70 to 9540 to 8590.587.5ReRe3 to 407.5 to4 to 3510 to 595 to 3012.5 to2000 toBound64542400MoB₂MoB₂60 to 9736 to65 to 9641 to 9070 to 9546 to92.587.5ReRe3 to 404 to 474 to 355 to 415 to 306.5 to2700 toBound363000WBWB60 to 9753 to 9665 to 9659 to 9570 to 9564 to93.5ReRe3 to 404 to 474 to 355 to 415 to 306.5 to2600 toBound362900W₂BW₂B60 to 9753 to 9665 to 9659 to 9570 to 9564 to93.5ReRe3 to 4013 to 774 to 3517 to 725 to 3020 to 682000 toBoundTi₅Si₃60 to 9723 to 8765 to 9628 to 8370 to 9532 to 802400Ti₅Si₃ReRe3 to 4010 to 724 to 3514 to 675 to 3017 to 622100 toBoundZr₆Si₅60 to 9728 to 9065 to 9633 to 8670 to 9538 to 832500Zr₆Si₅ReRe3 to 409 to 694 to 3512 to 645 to 3015 to 591800 toBoundNbSi₂60 to 9731 to 9165 to 9636 to 8870 to 9541 to 852200NbSi₂ReRe3 to 407 to 624 to 359 to 575 to 3012 to 512200 toBoundTaSi₂60 to 9738 to 9365 to 9643 to 9170 to 9549 to 882600TaSi₂ReRe3 to 409 to 694 to 3512 to 645 to 3015 to 591800 toBoundMoSi₂60 to 9731 to 9165 to 9636 to 8870 to 9541 to 852200MoSi₂ReRe3 to 406 to 604 to 359 to 555 to 3011 to 491800 toBoundWSi₂60 to 9740 to 9465 to 9645 to 9170 to 9551 to 892200WSi₂

TABLE 43

W bound a carbide from carbides of IVb, Vb, & VIb or a nitride

from nitrides of IVb & Vb.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

W
W
3 to 40
11 to 72
4 to 35
25.02 to
5 to 30
25.02 to
3000 to

Bound

70

65
3300

TiC
TiC
60 to 97
28 to 89
65 to 96
30 to
70 to 95
35 to

74.98

74.98

W
W
3 to 40
8 to 66
4 to 35
11 to 61
5 to 30
13 to 56
3200 to

Bound
ZrC
60 to 97
34 to 92
65 to 96
39 to 89
70 to 95
44 to 87
3500

ZrC

W
W
3 to 40
4 to 50
4 to 35
6 to 45
5 to 30
7 to 40
3300 to

Bound
HfC
60 to 97
50 to 96
65 to 96
55 to 64
70 to 95
60 to 93
3500

HfC

W
W
3 to 40
10 to 70
4 to 35
13 to 65
5 to 30
16 to 60
2700 to

Bound
VC
60 to 97
30 to 90
65 to 96
35 to 87
70 to 95
40 to 84
3300

VC

W
W
3 to 40
7 to 62
4 to 35
9 to 57
5 to 30
11 to 51
3000 to

Bound
NbC
60 to 97
38 to 93
65 to 96
43 to 91
70 to 95
49 to 89
3500

NbC

W
W
3 to 40
4 to 47
4 to 35
5 to 42
5 to 30
7 to 36
3300 to

Bound
TaC
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
64 to 93
3500

TaC

W
W
3 to 40
8 to 66
4 to 35
11 to 61
5 to 30
13 to 55
1700 to

Bound
Cr₂C₃
60 to 97
34 to 92
65 to 96
39 to 89
70 to 95
45 to 87
2100

Cr₂C₃

W
W
3 to 40
6 to 59
4 to 35
8 to 53
5 to 30
10 to 48
2400 to

Bound
Mo₂C
60 to 97
41 to 94
65 to 96
47 to 93
70 to 95
52 to 90
2600

Mo₂C

W
W
3 to 40
4 to 45
4 to 35
5 to 40
5 to 30
6 to 35
2800 to

Bound
WC
60 to 97
55 to 96
65 to 96
60 to 95
70 to 95
65 to 94
3000

WC

W
W
3 to 40
11 to 72
4 to 35
14 to 68
5 to 30
16 to 60
2800 to

Bound
TiN
60 to 97
28 to 89
65 to 96
32 to 86
70 to 95
40 to 84
3300

TiN

W
W
3 to 40
8 to 64
4 to 35
10 to 59
5 to 30
12 to 53
2900 to

Bound
ZrN
60 to 97
36 to 92
65 to 96
41 to 90
70 to 95
47 to 88
3300

ZrN

W
W
3 to 40
4 to 48
4 to 35
6 to 43
5 to 30
7 to 37
3200 to

Bound
HfN
60 to 97
52 to 96
65 to 96
57 to 94
70 to 95
63 to 93
3500

HfN

W
W
3 to 40
9 to 68
4 to 35
12 to 63
5 to 30
15 to 58
2000 to

Bound
VN
60 to 97
32 to 91
65 to 96
37 to 88
70 to 95
42 to 85
2400

VN

W
W
3 to 40
8 to 64
4 to 35
10 to 59
5 to 30
12 to 53
2200 to

Bound
NbN
60 to 97
36 to 92
65 to 96
41 to 90
70 to 95
47 to 88
2600

NbN

W
W
3 to 40
4 to 47
4 to 35
5 to 42
5 to 30
7 to 37
3000 to

Bound
TaN
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
63 to 93
3500

TaN

TABLE 44

W bound a Boride from Borides of IVb, Vb, & VIb or a Silicide

from Silicides of IVb, Vb & Vib

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

W
W
3 to 40
12 to 74
4 to 35
15 to 70
5 to 30
18 to 65
2700 to

Bound
TiB₂
60 to 97
26 to 88
65 to 96
30 to 85
70 to 95
35 to 82
3000

TiB₂

W
W
3 to 40
9 to 68
4 to 35
12 to 63
5 to 30
14 to 58
2800 to

Bound
ZrB₂
60 to 97
32 to 91
65 to 96
37 to 88
70 to 95
42 to 86
3000

ZrB₂

W
W
3 to 40
5 to 54
4 to 35
7 to 48
5 to 30
8 to 42
3000 to

Bound
HfB₂
60 to 97
46 to 95
65 to 96
52 to 93
70 to 95
58 to 92
3400

HfB₂

W
W
3 to 40
10 to 72
4 to 35
14 to 67
5 to 30
17 to 62
2000 to

Bound
VB₂
60 to 97
28 to 90
65 to 96
33 to 86
70 to 95
38 to 83
2500

VB₂

W
W
3 to 40
8 to 64
4 to 35
10 to 59
5 to 30
12 to 53
2900 to

Bound
NbB₂
60 to 97
36 to 92
65 to 96
41 to 90
70 to 95
47 to 88
3400

NbB₂

W
W
3 to 40
5 to 51
4 to 35
6 to 45
5 to 30
7 to 40
3100 to

Bound
TaB₂
60 to 97
49 to 95
65 to 96
55 to 94
70 to 95
60 to 93
3400

TaB₂

W
W
3 to 40
9 to 68
4 to 35
12 to 63
5 to 30
14 to 58
1800 to

Bound
Cr₃B₂
60 to 97
32 to 91
65 to 96
37 to 88
70 to 95
42 to 86
2200

Cr₃B₂

W
W
3 to 40
7 to 62
4 to 35
9 to 57
5 to 30
12 to 52
2000 to

Bound
MoB₂
60 to 97
38 to 93
65 to 96
43 to 91
70 to 95
48 to 88
2400

MoB₂

W
W
3 to 40
4 to 45
4 to 35
5 to 39
5 to 30
6 to 34
2700 to

Bound
WB
60 to 97
55 to 96
65 to 96
61 to 95
70 to 95
66 to 94
3000

WB

W
W
3 to 40
3 to 44
4 to 35
5 to 38
5 to 30
6 to 33
2600 to

Bound
W₂B
60 to 97
56 to 97
65 to 96
62 to 95
70 to 95
67 to 94
2900

W₂B

W
W
3 to 40
12 to 75
4 to 35
16 to 71
5 to 30
19 to 66
2000 to

Bound
Ti₅Si₃
60 to 97
25 to 88
65 to 96
29 to 84
70 to 95
34 to 81
2400

Ti₅Si₃

W
W
3 to 40
10 to 70
4 to 35
13 to 65
5 to 30
16 to 60
2100 to

Bound
Zr₆Si₅
60 to 97
30 to 90
65 to 96
35 to 87
70 to 95
40 to 84
2500

Zr₆Si₅

W
W
3 to 40
9 to 67
4 to 35
11 to 62
5 to 30
14 to 57
1800 to

Bound
NbSi₂
60 to 97
33 to 91
65 to 96
38 to 89
70 to 95
43 to 86
2200

NbSi₂

W
W
3 to 40
7 to 60
4 to 35
9 to 55
5 to 30
11 to 49
2200 to

Bound
TaSi₂
60 to 97
40 to 93
65 to 96
45 to 91
70 to 95
51 to 89
2600

TaSi₂

W
W
3 to 40
9 to 67
4 to 35
11 to 62
5 to 30
14 to 57
1800 to

Bound
MoSi₂
60 to 97
31 to 91
65 to 96
38 to 89
70 to 95
43 to 86
2200

MoSi₂

W
W
3 to 40
6 to 58
4 to 35
8 to 53
5 to 30
10 to 47
1800 to

Bound
WSi₂
60 to 97
42 to 94
65 to 96
47 to 92
70 to 95
43 to 90
2200

WSi₂

TABLE 45

Re and W (Re + W) bound a carbide from carbides of IVb, Vb, &

VIb or a nitride from nitrides of IVb & Vb. The range of Binder is

from 1% Re + 99% W to 99% Re + 1% W.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + W
Re
0.03 to
0.12 to
0.04 to
0.15 to
0.05 to
0.19 to
2900

Bound

39.6
73
34.7
69
29.7
64
to

TiC
W
0.03 to
0.1 to 72
0.04 to
0.14 to
0.05 to
0.17 to
3300

39.6

34.7
67
29.7
62

TiC
60 to 97
26 to 89
65 to 96
30 to 86
70 to 95
35 to 83

Re + W
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to
3000

Bound

39.6
67
34.7
63
29.7
57
to

ZrC
W
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.13 to
3400

39.6
66
34.7
61
29.7
55

ZrC
60 to 97
32 to 92
65 to 96
37 to 89
70 to 95
42 to 87

Re + W
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
3100

Bound

39.6
52
34.7
47
29.7
41
to

HfC
W
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.07 to
3500

39.6
50
34.7
45
29.7
39

HfC
60 to 97
48 to 95
65 to 96
53 to 94
70 to 95
58 to 93

Re + W
Re
0.03 to
0.11 to
0.14 to
0.15 to
0.17 to
0.19 to
2700

Bound

39.6
71
67
67.0
62
61.8
to

VC
W
0.03 to
0.1 to 69
0.13 to
0.06 to
0.15 to
0.07 to
3000

39.6

65
46.3
60
40.8

VC
60 to 97
28 to 90
33 to 87
32.8 to
70 to 95
38 to 84

93.5

Re + W
Re
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.13 to
3200

Bound

39.6
64
34.7
59
29.7
53
to

NbC
W
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
3500

39.6
56
34.7
56
29.7
51

NbC
60 to 97
36 to 93
65 to 96
41 to 91
70 to 95
47 to 88

Re + W
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
3100

Bound

39.6
49
34.7
43
29.7
38
to

TaC
W
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
3500

39.6
47
34.7
41
29.7
36

TaC
60 to 97
51 to 96
65 to 96
56 to 95
70 to 95
62 to 93

Re + W
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.14 to
1700

Bound

39.6
67
34.7
62
29.7
57
to

Cr₂C₃
W
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.13 to
1900

39.6
65
34.7
60
29.7
55

Cr₂C₃
60 to 97
32 to 92
65 to 96
37 to 89
70 to 95
43 to 87

Re + W
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
2400

Bound

39.6
60
34.7
55
29.7
49
to

Mo₂C
W
0.03 to
0.06 to
0.04 to
0.08 to
0.05 to
0.1 to 47
2600

39.6
58
34.7
53
29.7

Mo₂C
60 to 97
39 to 94
65 to 96
45 to 92
70 to 95
50 to 90

Re + W
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
2700

Bound

39.6
47
34.7
42
29.7
36
to

WC
W
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
2900

39.6
45
34.7
40
29.7
34

WC
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
63 to 94

Re + W
Re
0.03 to
0.1 to 71
0.04 to
0.14 to
0.05 to
0.17 to
2900

Bound

39.6

34.7
67
29.7
62
to

TiN
W
0.03 to
0.1 to 70
0.04 to
0.13 to
0.05 to
0.16 to
3200

39.6

34.7
65
29.7
60

TiN
60 to 97
28 to 90
65 to 96
32 to 87
70 to 95
38 to 84

Re + W
Re
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.13 to
2900

Bound

39.6
65
34.7
60
29.7
55
to

ZrN
W
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.12 to
3200

39.6
63
34.7
58
29.7
53

ZrN
60 to 97
34 to 92
65 to 96
39 to 90
70 to 95
45 to 88

Re + W
Re
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.08 to
3100

Bound

39.6
50
34.7
45
29.7
39
to

HfN
W
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
3400

39.6
48
34.7
43
29.7
37

HfN
60 to 97
50 to 96
65 to 96
55 to 95
70 to 95
61 to 93

Re + W
Re
0.03 to
0.1 to 69
0.04 to
0.13 to
0.05 to
0.16 to
2100

Bound

39.6

34.7
65
29.7
59
to

VN
W
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.14 to
2300

39.6
67
34.7
63
29.7
57

VN
60 to 97
30 to 91
65 to 96
35 to 88
70 to 95
40 to 86

Re + W
Re
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.13 to
2300

Bound

39.6
65
34.7
60
29.7
55
to

NbN
W
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.12 to
2500

39.6
63
34.7
58
29.7
53

NbN
60 to 97
35 to 92
65 to 96
39 to 90
70 to 95
45 to 88

Re + W
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
2900

Bound

39.6
49
34.7
44
29.7
38
to

TaN
W
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
3400

39.6
47
34.7
42
29.7
36

TaN
60 to 97
51 to 96
65 to 96
56 to 95
70 to 95
61 to 93

TABLE 46

Re and W (Re + W) bound a boride from borides of IVb, Vb, & VIb

or a silicide from silicides of IVb & Vb. The range of Binder is from

1% Re + 99% W to 99% Re + 1% W

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + W
Re
0.03 to
0.13 to
0.04 to
0.16 to
0.05 to
0.2 to
2900

Bound

39.6
75
34.7
71
29.7
66
to

TiB₂
W
0.03 to
0.12 to
0.04 to
0.15 to
0.05 to
0.18 to
3100

39.6
73
34.7
69
29.7
64

TiB₂
60 to 97
24 to 88
65 to 96
29 to 85
70 to 95
33 to 82

Re + W
Re
0.03 to
0.1 to 69
0.04 to
0.13 to
0.05 to
0.16 to
2900

Bound

39.6

34.7
64
29.7
59
to

ZrB₂
W
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.14 to
3100

39.6
67
34.7
63
29.7
57

ZrB₂
60 to 97
30 to 91
65 to 96
35 to 88
70 to 95
40 to 86

Re + W
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.09 to
3100

Bound

39.6
54
34.7
50
29.7
44
to

HfB₂
W
0.03 to
0.05 to
0.04 to
0.07to
0.05 to
0.08to
3300

39.6
53
34.7
48
29.7
42

HfB₂
60 to 97
44 to 95
65 to 96
50 o 93
70 to 95
55 to 92

Re + W
Re
0.03 to
0.11 to
0.14 to
0.15 to
0.17 to
0.18 to
2000

Bound

39.6
73
67
68
62
63
to

VB₂
W
0.03 to
0.1 to 71
0.13 to
0.13 to
0.15 to
0.16 to
2200

39.6

65
66
60
61

VB₂
60 to 97
27 to 90
33 to 87
31 to
70 to 95
36 to

86

84

Re + W
Re
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.13 to
2900

Bound

39.6
65
34.7
61
29.7
55
to

NbB₂
W
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.12 to
3100

39.6
63
34.7
58
29.7
53

NbB₂
60 to 97
34 to 92
65 to 96
39 to 90
70 to 95
44 to 88

Re + W
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
3100

Bound

39.6
52
34.7
47
29.7
41
to

TaB₂
W
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.07 to
3300

39.6
50
34.7
39
29.7
39

TaB₂
60 to 97
47 to 96
65 to 96
53 to 94
70 to 95
58 to 93

Re + W
Re
0.03 to
0.1 to 69
0.04 to
0.13 to
0.05 to
0.16 to
1900

Bound

39.6

34.7
64
29.7
59
to

Cr₃B₂
W
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.14 to
2100

39.6
67
34.7
62
29.7
57

Cr₃B₂
60 to 97
32 to 91
65 to 96
35 to 88
70 to 95
40 to 86

Re + W
Re
0.03 to
0.08 to
0.04 to
0.1 to
0.05 to
0.13 to
2000

Bound

39.6
64
34.7
59
29.7
53
to

MoB₂
W
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
2200

39.6
62
34.7
57
29.7
51

MoB₂
60 to 97
36 to 93
65 to 96
41 to 91
70 to 95
46 to 88

Re + W
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
2800

Bound

39.6
46
34.7
41
29.7
36
to

WB
W
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
2900

39.6
44
34.7
39
29.7
34

WB
60 to 97
53 to 96
65 to 96
57 to 95
70 to 95
64 to 94

Re + W
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
2700

Bound

39.6
45
34.7
40
29.7
35
to

W₂B
W
0.03 to
0.03 to
0.04 to
0.05 to
0.05 to
0.06 to
2900

39.6
43
34.7
38
29.7
33

W₂B
60 to 97
54 to 97
65 to 96
60 to 95
70 to 95
65 to 94

Re + W
Re
0.03 to
0.13 to
0.04 to
0.17 to
0.05 to
0.21 to
2000

Bound

39.6
76
34.7
72
29.7
67
to

Ti₅Si₃
W
0.03 to
0.12 to
0.04 to
0.16 to
0.05 to
0.19 to
2200

39.6
74
34.7
70
29.7
65

Ti₅Si₃
60 to 97
24 to 88
65 to 96
28 to 84
70 to 95
32 to 81

Re + W
Re
0.03 to
0.11 to
0.04 to
0.14 to
0.05 to
0.17 to
2100

Bound

39.6
71
34.7
67
29.7
61
to

Zr₆Si₅
W
0.03 to
0.1 to 69
0.04 to
0.13 to
0.05 to
0.15 to
2400

39.6

34.7
65
29.7
59

Zr₆Si₅
60 to 97
28 to 90
65 to 96
33 to 87
70 to 95
38 to 84

Re + W
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to
1900

Bound

39.6
68
34.7
64
29.7
58
to

NbSi₂
W
0.03 to
0.09 to
0.04 to
0.11 to
0.05 to
0.14 to
2100

39.6
66
34.7
62
29.7
56

NbSi₂
60 to 97
31 to 91
65 to 96
36 to 89
70 to 95
41 to 86

Re + W
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.12 to
2300

Bound

39.6
62
34.7
57
29.7
51
to

TaSi₂
W
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
2500

39.6
60
34.7
54
29.7
49

TaSi₂
60 to 97
38 to 93
65 to 96
43 to 91
70 to 95
49 to 89

Re + W
Re
0.03 to
0.1 to 69
0.04 to
0.12 to
0.05 to
0.15 to
1900

Bound

39.6

34.7
64
29.7
58
to

MoSi₂
W
0.03 to
0.09 to
0.04 to
0.11 to
0.05 to
0.14 to
2100

39.6
67
34.7
62
29.7
56

MoSi₂
60 to 97
31 to 91
65 to 96
36 to 89
70 to 95
41 to 86

Re + W
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
1900

Bound

39.6
60
34.7
54
29.7
49
to

WSi₂
W
0.03 to
0.06 to
0.04 to
0.08 to
0.05 to
0.1 to
2100

39.6
58
34.7
52
29.7
47

WSi₂
60 to 97
40 to 94
65 to 96
45 to 92
70 to 95
51 to 90

TABLE 47

Re and Co (Re + Co) bound a carbide from carbides of IVb, Vb, &

VIb or a nitride from nitrides of IVb & Vb. The range of Binder is

from 1% Re + 99% Co to 99% Re + 1% Co.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + Co
Re
0.03 to
0.12 to
0.04 to
0.17 to
0.05 to
0.2 to 64
1400

Bound

39.6
74
34.7
69
29.7

to

TiC
Co
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
3200

39.6
54
34.7
49
29.7
43

TiC
60 to 97
26 to 95
65 to 96
30 to 93
70 to 95
35 to 91

Re + Co
Re
0.03 to
0.09 to
0.04 to
0.13 to
0.05 to
0.16 to
1400

Bound

39.6
68
34.7
63
29.7
57
to

ZrC
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
3200

39.6
47
34.7
42
29.7
37

ZrC
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
42 to 93

Re + Co
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
1400

Bound

39.6
52
34.7
47
29.7
41
to

HfC
Co
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.04 to
3200

39.6
32
34.7
27
29.7
23

HfC
60 to 97
48 to 98
65 to 96
53 to 97
70 to 95
59 to 96

Re + Co
Re
0.03 to
0.11 to
0.14 to
0.15 to
0.17 to
0.19 to
1400

Bound

39.6
71
67
67.0
62
62
to

VC
Co
0.03 to
0.05 to
0.13 to
0.06 to
0.15 to
0.07 to
2900

39.6
51
65
46
60
41

VC
60 to 97
28 to 95
33 to 87
33 to 94
70 to 95
38 to 92

Re + Co
Re
0.03 to
0.08 to
0.04 to
0.1 to 59
0.05 to
0.13 to
1400

Bound

39.6
64
34.7

29.7
53
to

NbC
Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
3200

39.6
43
34.7
38
29.7
33

NbC
60 to 97
36 to 97
65 to 96
41 to 95
70 to 95
47 to 94

Re + Co
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1400

Bound

39.6
49
34.7
43
29.7
38
to

TaC
Co
0.03 to
0.02 to
0.04 to
0.024 to
0.05 to
0.03 to
3200

39.6
29
34.7
25
29.7
21

TaC
60 to 97
51 to 98
65 to 96
56 to 97
70 to 95
62 to 97

Re + Co
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to
1400

Bound

39.6
67
34.7
62
29.7
57
to

Cr₂C₃
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
1900

39.6
47
34.7
41
29.7
36

Cr₂C₃
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
43 to 93

Re + Co
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
1400

Bound

39.6
60
34.7
55
29.7
49
to

Mo₂C
Co
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
2600

39.6
39
34.7
34
29.7
29

Mo₂C
60 to 97
40 to 97
65 to 96
45 to 96
70 to 95
50 to 95

Re + Co
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
1400

Bound

39.6
47
34.7
42
29.7
36
to

WC
Co
0.03 to
0.017 to
0.04 to
0.023 to
0.05 to
0.028 to
2900

39.6
27
34.7
23
29.7
20

WC
60 to 97
53 to 96
65 to 96
58 to 95
70 to 95
63 to 94

Re + Co
Re
0.03 to
0.11 to
0.04 to
0.15 to
0.05 to
0.19 to
1400

Bound

39.6
71
34.7
67
29.7
62
to

TiN
Co
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.07 to
3200

39.6
52
34.7
46
29.7
41

TiN
60 to 97
28 to 95
65 to 96
33 to 93
70 to 95
38 to 92

Re + Co
Re
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.14 to
1400

Bound

39.6
65
34.7
60
29.7
55
to

ZrN
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
3200

39.6
44
34.7
39
29.7
34

ZrN
60 to 97
34 to 96
65 to 96
39 to 95
70 to 95
45 to 94

Re + Co
Re
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.08 to
1400

Bound

39.6
50
34.7
45
29.7
39
to

HfN
Co
0.03 to
0.019 to
0.04 to
0.026 to
0.05 to
0.032 to
3200

39.6
30
34.7
26
29.7
22

HfN
60 to 97
50 to 98
65 to 96
55 to 97
70 to 95
61 to 97

Re + Co
Re
0.03 to
0.1 to 70
0.04 to
0.14 to
0.05 to
0.17 to
1400

Bound

39.6

34.7
65
29.7
60
to

VN
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
2300

39.6
49
34.7
44
29.7
39

VN
60 to 97
30 to 96
65 to 96
35 to 94
70 to 95
40 to 93

Re + Co
Re
0.03 to
0.08 to
0.04 to
0.11 to
0.05 to
0.14 to
1400

Bound

39.6
65
34.7
60
29.7
55
to

NbN
Co
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
2500

39.6
45
34.7
39
29.7
34

NbN
60 to 97
34 to 96
65 to 96
39 to 95
70 to 95
45 to 94

Re + Co
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1400

Bound

39.6
49
34.7
44
29.7
38
to

TaN
Co
0.03 to
0.02 to
0.04 to
0.025 to
0.05 to
0.03 to
3200

39.6
29
34.7
25
29.7
21

TaN
60 to 97
51 to 98
65 to 96
56 to 97
70 to 95
62 to 98

TABLE 48

Re and Co (Re + Co) bound a boride from borides of IVb, Vb, &

VIb or a silicide from silicides of IVb & Vb. The range of Binder is

from 1% Re + 99% Co to 99% Re + 1% Co.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + Co
Re
0.03 to
0.13 to
0.04 to
0.18 to 71
0.05 to
0.22 to
1400

Bound

39.6
75
34.7

29.7
66
to

TiB₂
Co
0.03 to
0.05 to
0.04 to
0.07 to 51
0.05 to
0.08 to
3100

39.6
56
34.7

29.7
45

TiB₂
60 to 97
24 to 34
65 to 96
29 to 92
70 to 95
34 to 90

Re + Co
Re
0.03 to
0.1 to 69
0.04 to
0.13 to 64
0.05 to
0.17 to
1400

Bound

39.6

34.7

29.7
59
to

ZrB₂
Co
0.03 to
0.04 to
0.05 to
0.05 to 44
0.05 to
0.07 to
3100

39.6
49
34.7

29.7
38

ZrB₂
60 to 97
30 to 96
65 to 96
35 to 94
70 to 95
40 to 93

Re + Co
Re
0.03 to
0.06 to
0.04 to
0.08 to 50
0.05 to
0.09 to
1400

Bound

39.6
55
34.7

29.7
44
to

HfB₂
Co
0.03 to
0.2 to 34
0.04 to
0.03 to 30
0.05 to
0.04 to
3200

39.6

34.7

29.7
25

HfB₂
60 to 97
45 to 98
65 to 96
50 o 97
70 to 95
56 to 96

Re + Co
Re
0.03 to
0.12 to
0.14 to
0.16 to 69
0.17 to
0.2 to 63
1400

Bound

39.6
73
67

62

to

VB₂
Co
0.03 to
0.05 to
0.13 to
0.06 to 48
0.15 to
0.08 to
2200

39.6
53
65

60
42

VB₂
60 to 97
27 to 95
33 to 87
31 to 93
70 to 95
36 to 91

Re + Co
Re
0.03 to
0.09 to
0.04 to
0.12 to 61
0.05 to
0.14 to
1400

Bound

39.6
66
34.7

29.7
55
to

NbB₂
Co
0.03 to
0.04 to
0.04 to
0.05 to 40
0.05 to
0.06 to
3100

39.6
45
34.7

29.7
34

NbB₂
60 to 97
34 to 96
65 to 96
39 to 95
70 to 95
45 to 94

Re + Co
Re
0.03 to
0.05 to
0.04 to
0.07 to 47
0.05 to
0.08 to
1400

Bound

39.6
52
34.7

29.7
41
to

TaB₂
Co
0.03 to
0.02 to
0.04 to
0.03 to 27
0.05 to
0.035 to
3300

39.6
32
34.7

29.7
23

TaB₂
60 to 97
48 to 98
65 to 96
53 to 97
70 to 95
58 to 96

Re + Co
Re
0.03 to
0.1 to 69
0.04 to
0.13 to 65
0.05 to
0.17 to
1400

Bound

39.6

34.7

29.7
59
to

Cr₃B₂
Co
0.03 to
0.04 to
0.04 to
0.05 to 44
0.05 to
0.07 to
2100

39.6
49
34.7

29.7
38

Cr₃B₂
60 to 97
30 to 96
65 to 96
35 to 93
70 to 95
41 to 93

Re + Co
Re
0.03 to
0.08 to
0.04 to
0.1 to 59
0.05 to
0.13 to
1400

Bound

39.6
64
34.7

29.7
53
to

MoB₂
Co
0.03 to
0.03 to
0.04 to
0.04 to 38
0.05 to
0.05 to
2200

39.6
43
34.7

29.7
33

MoB₂
60 to 97
36 to 97
65 to 96
41 to 95
70 to 95
46 to 94

Re + Co
Re
0.03 to
0.04 to
0.04 to
0.05 to 41
0.05 to
0.07 to
1400

Bound

39.6
46
34.7

29.7
36
to

WB
Co
0.03 to
0.017 to
0.04 to
0.022 to 23
0.05 to
0.028 to
2900

39.6
27
34.7

29.7
19

WB
60 to 97
53 to 98
65 to 96
59 to 98
70 to 95
64 to 97

Re + Co
Re
0.03 to
0.04 to
0.04 to
0.05 to 40
0.05 to
0.06 to
1400

Bound

39.6
45
34.7

29.7
35
to

W₂B
Co
0.03 to
0.016 to
0.04 to
0.021 to 22
0.05 to
0.027 to
2900

39.6
26
34.7

29.7
19

W₂B
60 to 97
55 to 98
65 to 96
60 to 98
70 to 95
65 to 97

Re + Co
Re
0.03 to
0.14 to
0.04 to
0.18 to 72
0.05 to
0.23 to
1400

Bound

39.6
76
34.7

29.7
67
to

Ti₅Si₃
Co
0.03 to
0.06 to
0.04 to
0.07 to 52
0.05 to
0.09 to
2200

39.6
57
34.7

29.7
47

Ti₅Si₃
60 to 97
24 to 94
65 to 96
28 to 92
70 to 95
32 to 90

Re + Co
Re
0.03 to
0.11 to
0.04 to
0.15 to 67
0.05 to
0.19 to
1400

Bound

39.6
71
34.7

29.7
62
to

Zr₆Si₅
Co
0.03 to
0.05 to
0.04 to
0.06 to 46
0.05 to
0.07 to
2400

39.6
51
34.7

29.7
41

ZrN
60 to 97
28 to 95
65 to 96
33 to 94
70 to 95
38 to 92

Re + Co
Re
0.03 to
0.1 to 69
0.04 to
0.13 to 64
0.05 to
0.16 to
1400

Bound

39.6

34.7

29.7
58
to

NbSi₂
Co
0.03 to
0.04 to
0.04 to
0.05 to 43
0.05 to
0.06 to
2100

39.6
48
34.7

29.7
37

NbSi₂
60 to 97
31 to 96
65 to 96
36 to 94
70 to 95
41 to 93

Re + Co
Re
0.03 to
0.07 to
0.04 to
0.1 to 57
0.05 to
0.12 to
1400

Bound

39.6
62
34.7

29.7
51
to

TaSi₂
Co
0.03 to
0.03 to
0.04 to
0.04 to 36
0.05 to
0.05 to
2500

39.6
41
34.7

29.7
31

TaSi₂
60 to 97
38 to 97
65 to 96
43 to 96
70 to 95
49 to 95

Re + Co
Re
0.03 to
0.1 to 69
0.04 to
0.13 to 64
0.05 to
0.16 to
1400

Bound

39.6

34.7

29.7
59
to

MoSi₂
Co
0.03 to
0.04 to
0.04 to
0.05 to 43
0.05 to
0.07 to
2100

39.6
48
34.7

29.7
38

MoSi₂
60 to 97
31 to 96
65 to 96
36 to 94
70 to 95
41 to 93

Re + Co
Re
0.03 to
0.07 to
0.04 to
0.09 to 55
0.05 to
0.11 to
1400

Bound

39.6
60
34.7

29.7
49
to

WSi₂
Co
0.03 to
0.03 to
0.04 to
0.04 to 34
0.05 to
0.046 to
2100

39.6
39
34.7

29.7
29

WSi₂
60 to 97
40 to 97
65 to 96
45 to 96
70 to 95
51 to 95

TABLE 49

Re and Mo (Re + Mo) bound a carbide from carbides of IVb, Vb, &

VIb. The range of Binder is from 1% Re + 99% Mo to 99% Re + 1% Mo.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + Mo
Re
0.03 to
0.12 to
0.04 to
0.16 to
0.05 to
0.2 to
2600

Bound

39.6
74
34.7
69
29.7
64
to

TiC
Mo
0.03 to
0.06 to
0.04 to
0.07 to
0.05 to
0.09 to
3200

39.6
57
34.7
52
29.7
46

TiC
60 to 97
26 to 94
65 to 96
30 to 92
70 to 95
35 to 90

Re + Mo
Re
0.03 to
0.09 to
0.04 to
0.13 to
0.05 to
0.16 to
2600

Bound

39.6
68
34.7
63
29.7
57
to

ZrC
Mo
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
3200

39.6
50
34.7
45
29.7
39

ZrC
60 to 97
32 to 95
65 to 96
37 to 94
70 to 95
42 to 92

Re + Mo
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
2600

Bound

39.6
52
34.7
47
29.7
41
to

HfC
Mo
0.03 to
0.02 to
0.04 to
0.03 to
0.05 to
0.04 to
3200

39.6
34
34.7
30
29.7
25

HfC
60 to 97
48 to 98
65 to 96
53 to 97
70 to 95
59 to 96

Re + Mo
Re
0.03 to
0.11 to
0.14 to 67
0.15 to
0.17 to
0.18 to
2600

Bound

39.6
71

67.0
62
62
to

VC
Mo
0.03 to
0.05 to
0.13 to 65
0.07 to
0.15 to
0.08 to
2900

39.6
55

49
60
44

VC
60 to 97
28 to 95
33 to 87
33 to 93
70 to 95
38 to 91

Re + Mo
Re
0.03 to
0.08 to
0.04 to
0.1 to 59
0.05 to
0.13 to
2600

Bound

39.6
64
34.7

29.7
53
to

NbC
Mo
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
3200

39.6
46
34.7
41
29.7
35

NbC
60 to 97
36 to 96
65 to 96
41 to 95
70 to 95
47 to 94

Re + Mo
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
2600

Bound

39.6
49
34.7
43
29.7
38
to

TaC
Mo
0.03 to
0.02 to
0.04 to
0.028 to
0.05 to
0.03 to
3200

39.6
31
34.7
27
29.7
22

TaC
60 to 97
51 to 98
65 to 96
56 to 97
70 to 95
62 to 96

Re + Mo
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to
1700

Bound

39.6
67
34.7
62
29.7
57
to

Cr₂C₃
Mo
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1900

39.6
50
34.7
45
29.7
39

Cr₂C₃
60 to 97
32 to 95
65 to 96
37 to 94
70 to 95
43 to 92

Re + Mo
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
2500

Bound

39.6
60
34.7
55
29.7
49
to

Mo₂C
Mo
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
2600

39.6
42
34.7
37
29.7
32

Mo₂C
60 to 97
40 to 97
65 to 96
45 to 96
70 to 95
50 to 95

Re + Mo
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
2600

Bound

39.6
47
34.7
42
29.7
36
to

WC
Mo
0.03 to
0.019 to
0.04 to
0.026 to
0.05 to
0.032 to
2900

39.6
30
34.7
26
29.7
22

WC
60 to 97
53 to 98
65 to 96
58 to 97
70 to 95
64 to 97

TABLE 50

Re and Ni (Re + Ni) bound a carbide from carbides of IVb, Vb, &

VIb. The range of Binder is from 1% Re + 99% Ni to 99% Re + 1% Ni.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + Ni
Re
0.03 to
0.12 to
0.04 to
0.17 to
0.05 to
0.2 to 64
1400

Bound

39.6
74
34.7
69
29.7

to

TiC
Ni
0.03 to
0.05 to
0.04 to
0.06 to
0.05 to
0.08 to
3200

39.6
54
34.7
49
29.7
43

TiC
60 to 97
26 to 95
65 to 96
30 to 93
70 to 95
35 to 91

Re + Ni
Re
0.03 to
0.09 to
0.04 to
0.13 to
0.05 to
0.16 to
1400

Bound

39.6
68
34.7
63
29.7
57
to

ZrC
Ni
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
3200

39.6
47
34.7
42
29.7
36

ZrC
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
42 to 93

Re + Ni
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.08 to
1400

Bound

39.6
52
34.7
47
29.7
41
to

HfC
Co
0.03 to
0.02 to
0.04 to
0.027 to
0.05 to
0.034 to
3200

39.6
31
34.7
27
29.7
23

HfC
60 to 97
48 to 98
65 to 96
53 to 97
70 to 95
59 to 96

Re + Ni
Re
0.03 to
0.11 to
0.14 to
0.15 to
0.17 to
0.19 to
1400

Bound

39.6
71
67
67.0
62
62
to

VC
Ni
0.03 to
0.04 to
0.13 to
0.06 to
0.15 to
0.07 to
2900

39.6
51
65
46
60
40

VC
60 to 97
28 to 95
33 to 87
33 to 94
70 to 95
38 to 92

Re + Ni
Re
0.03 to
0.08 to
0.04 to
0.1 to 59
0.05 to
0.13 to
1400

Bound

39.6
64
34.7

29.7
53
to

NbC
Ni
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
3200

39.6
43
34.7
37
29.7
32

NbC
60 to 97
36 to 97
65 to 96
41 to 95
70 to 95
47 to 94

Re + Ni
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1400

Bound

39.6
49
34.7
43
29.7
38
to

TaC
Ni
0.03 to
0.018 to
0.04 to
0.024 to
0.05 to
0.03 to
3200

39.6
29
34.7
25
29.7
21

TaC
60 to 97
51 to 98
65 to 96
56 to 97
70 to 95
62 to 97

Re + Ni
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.15 to
1400

Bound

39.6
67
34.7
62
29.7
57
to

Cr₂C₃
Ni
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
1900

39.6
46
34.7
41
29.7
36

Cr₂C₃
60 to 97
32 to 96
65 to 96
37 to 95
70 to 95
43 to 93

Re + Ni
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
1400

Bound

39.6
60
34.7
55
29.7
49
to

Mo₂C
Ni
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
2600

39.6
39
34.7
34
29.7
29

Mo₂C
60 to 97
40 to 97
65 to 96
45 to 96
70 to 95
50 to 95

Re + Ni
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1400

Bound

39.6
47
34.7
42
29.7
36
to

WC
Ni
0.03 to
0.017 to
0.04 to
0.022 to
0.05 to
0.028 to
2900

39.6
27
34.7
23
29.7
19

WC
60 to 97
53 to 98
65 to 96
58 to 98
70 to 95
64 to 97

TABLE 51

Re and Cr (Re + Cr) bound a carbide from carbides of IVb, Vb, &

VIb. The range of Binder is from 1% Re + 99% Cr to 99% Re + 1% Cr.

Estimated

Composition Range 1
Composition Range 2
Composition Range 3
Melting

Volume %
Weight %
Volume %
Weight %
Volume %
Weight %
Point, ° C.

Re + Cr
Re
0.03 to
0.13 to
0.04 to
0.17 to
0.05 to
0.2 to 64
1800

Bound

39.6
74
34.7
69
29.7

to

TiC
Cr
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.06 to
3200

39.6
48
34.7
43
29.7
39

TiC
60 to 97
26 to 96
65 to 96
30 to 94
70 to 95
36 to 93

Re + Cr
Re
0.03 to
0.1 to 68
0.04 to
0.13 to
0.05 to
0.16 to
1800

Bound

39.6

34.7
63
29.7
57
to

ZrC
Cr
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
3200

39.6
41
34.7
36
29.7
32

ZrC
60 to 97
32 to 97
65 to 96
37 to 95
70 to 95
42 to 94

Re + Cr
Re
0.03 to
0.05 to
0.04 to
0.07 to
0.05 to
0.09 to
1800

Bound

39.6
52
34.7
47
29.7
41
to

HfC
Cr
0.03 to
0.017 to
0.04 to
0.022 to
0.05 to
0.027 to
3200

39.6
27
34.7
23
29.7
19

HfC
60 to 97
48 to 98
65 to 96
53 to 98
70 to 95
59 to 97

Re + Cr
Re
0.03 to
0.11 to
0.14 to
0.15 to
0.17 to
0.19 to
1800

Bound

39.6
71
67
67.0
62
62
to

VC
Cr
0.03 to
0.04 to
0.13 to
0.05 to
0.15 to
0.06 to
2900

39.6
46
65
41
60
35

VC
60 to 97
28 to 96
33 to 87
33 to 95
70 to 95
38 to 93

Re + Cr
Re
0.03 to
0.08 to
0.04 to
0.1 to 59
0.05 to
0.13 to
1800

Bound

39.6
64
34.7

29.7
53
to

NbC
Cr
0.03 to
0.026 to
0.04 to
0.034 to
0.05 to
0.04 to
3200

39.6
37
34.7
33
29.7
28

NbC
60 to 97
36 to 97
65 to 96
41 to 96
70 to 95
47 to 95

Re + Cr
Re
0.03 to
0.04 to
0.04 to
0.06 to
0.05 to
0.07 to
1800

Bound

39.6
49
34.7
43
29.7
38
to

TaC
Cr
0.03 to
0.015 to
0.04 to
0.019 to
0.05 to
0.024 to
3200

39.6
25
34.7
21
29.7
17

TaC
60 to 97
51 to 98
65 to 96
56 to 98
70 to 95
62 to 97

Re + Cr
Re
0.03 to
0.09 to
0.04 to
0.12 to
0.05 to
0.16 to
1800

Bound

39.6
67
34.7
62
29.7
57
to

Cr₂C₃
Cr
0.03 to
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
1900

39.6
41
34.7
36
29.7
31

Cr₂C₃
60 to 97
32 to 97
65 to 96
37 to 96
70 to 95
43 to 95

Re + Cr
Re
0.03 to
0.07 to
0.04 to
0.09 to
0.05 to
0.11 to
1800

Bound

39.6
60
34.7
55
29.7
49
to

Mo₂C
Cr
0.03 to
0.023 to
0.04 to
0.03 to
0.05 to
0.037 to
2600

39.6
34
34.7
29
29.7
25

Mo₂C
60 to 97
40 to 98
65 to 96
45 to 97
70 to 95
50 to 96

Re + Cr
Re
0.03 to
0.04 to
0.04 to
0.05 to
0.05 to
0.07 to
1800

Bound

39.6
47
34.7
42
29.7
36
to

WC
Cr
0.03 to
0.014 to
0.04 to
0.018 to
0.05 to
0.023 to
2900

39.6
23
34.7
20
29.7
16

WC
60 to 97
53 to
65 to 96
58 to 98
70 to 95
64 to

98.6

97.6

The above compositions for hardmetals or cermets may be used for a variety of applications. For example, a material as described above may be used to form a wear part in a tool that cuts, grinds, or drills a target object by using the wear part to remove the material of the target object. Such a tool may include a support part made of a different material, such as a steel. The wear part is then engaged to the support part as an insert. The tool may be designed to include multiple inserts engaged to the support part. For example, some mining drills may include multiple button bits made of a hardmetal material. Examples of such a tool includes a drill, a cutter such as a knife, a saw, a grinder, and a drill. Alternatively, hardmetals descried here may be used to form the entire head of a tool as the wear part for cutting, drilling or other machining operations. The hardmetal particles may also be used to form abrasive grits for polishing or grinding various materials. In addition, such hardmetals may also be used to construct housing and exterior surfaces or layers for various devices to meet specific needs of the operations of the devices or the environmental conditions under which the devices operate.

More specifically, the hardmetals described here may be used to manufacture cutting tools for machining metals, alloys, composite materials, plastic materials, wooden materials, and others. The cutting tools may include indexable inserts for turning, milling, boring and drilling, drills, end mills, reamers, taps, hobs and milling cutters. Since the temperature of the cutting edge of such tools may be higher than 500° C. during machining, the hardmetal compositions for high-temperature operating conditions described above may have special advantages when used in such cutting tools, e.g., extended tool life and improved productivity by such tools by increasing the cutting speed.

The hardmetals described here may be used to manufacture tools for wire drawing, extrusion, forging and cold heading. Also as mold and Punch for powder process. In addition, such hardmetals may be used as wear-resistant material for rock drilling and mining.

The hardmetal materials described in this application may be fabricated in bulk forms or as coatings on metal surfaces. Coatings with such new hardmetal materials may be advantageously used to form a hard layer on a metal surface to achieve desired hardness that would otherwise be difficult to achieve with the underlying metal material. Bulk hardmetal materials based on the compositions in this application may be expensive and hence the use of coatings on less expensive metals with lower hardness may be used to reduce the costs of various components or parts with high hardness.

A number of powder processes for producing commercial hardmetals may be used to manufacture the hardmetals of this application. As an example, a binder alloy with Re higher than 85% in weight may be fabricated by the process of solid phase sintering to eliminate open porosities then HIP replaces liquid phase sintering.

FIG. 9 shows a flowchart for several fabrication methods for materials or structures from the above hardmetal compositions. As illustrated, alloy powders for the binders and the hard particle powders may be mixed with a milling liquid in a wet mixing process with or without a lubricant (e.g., wax). The fabrication flows on the left hand side of FIG. 9 are for fabricating hardmetals with lubricated wet mixing. The mixture is first dried by vacuum drying or spray drying process to produce lubricated grade powder. Next, the lubricated grade power is shaped into a bulky material via pill pressing, extruding, or cold isostatic press (CIP) and shaping. The CIP is a process to consolidate powder by isostatic pressure. The bulky material is then heated to remove the lubricant and is sintered in a presintering process. Next, the material may be processed via several different processes. For example, the material may be processed via a liquid phase sintering in vacuum or hydrogen and then further processed by a HIP process to form the final hardmetal parts. Alternatively, the material after the presintering may go through a solid phase sintering to eliminate open porosity and then a HIP process to form the final hardmetal parts.

When alloy powders for the binders and the hard particle powders are mixed without the lubricant, the unlubricated grade power after the drying process may be processed in two different ways to form the final hardmetal parts. The first way as illustrated simply uses hot pressing to complete the fabrication. The second way uses a thermal spray forming process to form the grade powder on a metal substrate in vacuum. Next, the metal substrate is removed to leave the structure by the thermal spray forming as a free-standing material as the final hardmetal part. In addition, the free-standing material may be further processed by a HIP process to reduce the porosities if needed.

In forming a hardmetal coating on a metal surface, a thermal spray process may be used under a vacuum condition to produce large parts coated with hardmetal materials. For example, surfaces of steel parts and tools may be coated to improve their hardness and thus performance. FIG. 10 shows an exemplary flow chart of a thermal spray process.

Various thermal spray processes are known for coating metal surfaces. For example, the ASM Handbook Vol. 7 (P408, 1998) describes the thermal spray as a family of particulate/droplet consolidation processes capable of forming metals, ceramics, intermetallics, composites, and polymers into coatings or freestanding structures. During the process, powder, wire, or rods can be injected into combustion or arc-heated jets, where they are heated, melted or softened, accelerated, and directed toward the surface, or substrate, being coated. On impact at the substrate, the particles or droplets rapidly solidify, cool, contract, and incrementally build up to form a deposit on a target surface. The thin “splats” may undergo high cooling rates, e.g., in excess of 10⁶K/s for metals.

A thermal spray process may use chemical (combustion) or electrical (plasma or arc) energy to heat feed materials injected into hot-gas jets to create a stream of molten droplets that are accelerated and directed toward the substrates being coated. Various thermal spray processes are shown in FIG. 3 and 4 in ASM Handbook Vol. 7, pages 409-410.

Various details of thermal spray processes are described in “Spray Forming” by Lawley et al. and “Thermal Spray Forming of Materials” by Knight et al., which are published in ASM Handbook, Volume 7, Powder Metal Technologies and Application (1998), from pages 396 to 407, and pages 408 to 419, respectively.

In various applications, selected hardmetal compositions described here can be used to maintain high material strength and hardness at high temperatures at or above 1500° C. For example, certain high-power engines operate at such high temperatures such as various jet and rocket engines used in various flying devices and vehicles. More specifically, jet and rocket nozzles, including non-erosive nozzle throats and low-erosive nozzle throats, in these and other engines may be partially or entirely made of the selected hardmetal materials described in this application.

For example, hardmetals based on one or more of (1) one or more carbides, (2) one or more nitrides, (3) one or more borides and (4) a combination of two or more of (1), (2) and (3) with a binder material which is either pure Re or a composite binder material with Re as one component. The melting points of various carbides, nitrides, and borides in this application are above 2400° C. Examples of suitable carbides for the present high-temperature hardmetal materials include TaC, HfC, NbC, ZrC, TiC, WC, VC, Al₄C₃, ThC₂, Mo₂C, SiC and B₄C. Examples of suitable nitrides for the present high-temperature hardmetal materials include HfN, TaN, BN, ZrN, and TiN. Examples of suitable borides for the present high-temperature hardmetal materials include HfB₂, ZrB₂, TaB₂, TiB₂, NbB₂, and WB. Two examples of the composite binder material with Re as one component are (1) W and Re and (2) Ta and Re.

In the binder material compositions described in this application, Rhenium can be used in a binder material to achieve cetain properties. For example, addition of Re into W in a binder material can improve the mechanical properities, such as the ductility, of the W—Re alloy binder material over W without Re. As another example, addition of Re into Mo in a binder material can improvethe mechanical properities (e.g., ductility) of the Mo—Re alloy binder material over Mo without Re. As yet another example, addition of Re into Cr in a binder material can improve the mechanical properities (e.g., ductility) of the Cr—Re alloy binder material over Cr without Re.

Molybdenum can also be added in a binder material to improve the properties of the binder material. Adding Mo into a Ni-bound TiC material forms a Ni—Mo-bound TiC material and can improve the ductility and toughness of the Ni—Mo-bound TiC material over the Ni-bound TiC material. In hardmetals using Ni-based superalloy binder materials, Mo can be added to the Ni-based superalloy binder material. For example, Mo can be added to the Ni-based superalloy-bound TiC to improve the ductility and toughness of Ni-based superalloy-Mo-bound TiC over Ni-based superalloy-bound TiC.

While this specification contains many specifics, these should not be construed as limitations on the scope of an invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or a variation of a subcombination.

Only a few implementations and examples are disclosed. However, it is understood that variations and enhancements may be made.

	Number	Date	Country
	60764003	Jan 2006	US
	60710016	Aug 2005	US

	Number	Date	Country
Parent	11507928	Aug 2006	US
Child	11669791	Jan 2007	US
Parent	11081928	Mar 2005	US
Child	11669791	Jan 2007	US
Parent	PCT/US06/32654	Aug 2006	US
Child	11669791	Jan 2007	US

High-Performance Friction Stir Welding Tools

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