Composite structure having a non-planar interface and method of making same

Abstract

A composite structure includes a first portion comprising a first metallic material, a monolayer of particles extending into and bonded with the first portion, and a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles. A method for fabricating a composite structure includes bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion and bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.

1 . A composite structure, comprising: 
 a first portion comprising a first metallic material;    a monolayer of particles extending into and bonded with the first portion; and    a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles.    
   
   
       2 . A composite structure, according to  claim 1 , wherein at least some of the particles and the first portion define recesses exhibiting negative draft angles into which the second portion extends.  
   
   
       3 . A composite structure, according to  claim 1 , wherein the monolayer of particles is co-sintered with the first portion.  
   
   
       4 . A composite structure, according to  claim 1 , wherein the monolayer of particles is bonded to the first portion by metallurgical neck bonds.  
   
   
       5 . A composite structure, according to  claim 1 , wherein the monolayer of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.  
   
   
       6 . A composite structure, according to  claim 1 , wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a diamond composite material, a metal, and a metal alloy.  
   
   
       7 . A composite structure, according to  claim 1 , wherein the monolayer of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.  
   
   
       8 . A composite structure, according to  claim 1 , wherein the first portion is harder than the second portion.  
   
   
       9 . A composite structure, according to  claim 1 , wherein the first portion is softer than the second portion.  
   
   
       10 . A composite structure, according to  claim 1 , further comprising a second monolayer of particles extending into and bonded with the first portion and a third portion comprising a third material, the third portion bonded with the second monolayer of particles and extending into interstices between the particles of the second monolayer of particles.  
   
   
       11 . A composite structure, according to  claim 1 , wherein the second portion comprises a densified powder.  
   
   
       12 . A composite structure, according to  claim 1 , wherein the second portion comprises a solidified metal or metal alloy.  
   
   
       13 . An insert for a rock bit, comprising: 
 a substrate comprising a first metallic material;    a plurality of particles bonded with the substrate; and    a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.    
   
   
       14 . An insert, according to  claim 13 , wherein at least some of the plurality of particles and the substrate define recesses exhibiting negative draft angles into which the densified portion extends.  
   
   
       15 . An insert, according to  claim 13 , wherein the plurality of particles is co-sintered with the substrate.  
   
   
       16 . An insert, according to  claim 13 , wherein the plurality of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.  
   
   
       17 . An insert, according to  claim 13 , wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a diamond composite material, a metal, and a metal alloy.  
   
   
       18 . An insert, according to  claim 13 , wherein the plurality of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.  
   
   
       19 . A composite pick, comprising: 
 a tip comprising a first metallic material;    a plurality of particles bonded with the tip; and    a densified portion comprising a second material, the densified powder bonded with the plurality of particles and extending into interstices between the particles.    
   
   
       20 . A composite pick, according to  claim 19 , wherein the tip defines an undulant surface and the plurality of particles is bonded with the undulant surface.  
   
   
       21 . A composite pick, according to  claim 19 , wherein at least some of the plurality of particles and the tip define recesses exhibiting negative draft angles into which the second portion extends.  
   
   
       22 . A composite pick, according to  claim 19 , wherein the plurality of particles is co-sintered with the substrate.  
   
   
       23 . A composite pick, according to  claim 19 , wherein the plurality of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.  
   
   
       24 . A composite pick, according to  claim 19 , wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a cemented carbide and steel mixture, a metal, and a metal alloy.  
   
   
       25 . A composite pick, according to  claim 20 , wherein the plurality of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.  
   
   
       26 . A method for fabricating a composite structure, comprising: 
 bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion; and    bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.    
   
   
       27 . A method, according to  claim 26 , wherein bonding the monolayer of particles further comprises co-sintering the monolayer of particles with the first portion.  
   
   
       28 . A method, according to  claim 26 , wherein bonding the second portion further comprises: 
 filling the interstices with a powder; and    pressure densifying the powder.    
   
   
       29 . A method, according to  claim 26 , wherein bonding the second portion further comprises: 
 infiltrating the interstices with a liquid metal; and    allowing the liquid metal to solidify.    
   
   
       30 . A method, according to  claim 26 , further comprising extending the second portion into recesses defined by the particles and the first portion.  
   
   
       31 . A method, according to  claim 30 , wherein the recesses exhibit negative draft angles.  
   
   
       32 . A method, according to  claim 26 , further comprising: 
 bonding a second monolayer of particles to a first portion, such that the second monolayer of particles extends into the first portion; and bonding a third portion comprising a third material to the second monolayer of particles, such that the third portion extends into interstices between the particles of the second monolayer of particles.