Composite materials comprising a hard ceramic phase and a Cu-Ni-Mn infiltration alloy

Abstract

Composite materials comprising a hard ceramic phase and an infiltration alloy are disclosed. The hard ceramic phase may comprise a carbide such as tungsten carbide and/or cast carbide. The infiltration alloy is a heat treatable Cu-based alloy comprising Ni and Mn. The infiltration alloy may be substantially free of Sn and Zn. The composite material is heat treated in order to improve its mechanical properties. For example, the composition of the Cu—Ni—Mn infiltration alloy may be selected such that its hardness, wear resistance, toughness and/or transverse rupture strength are improved after the composite material is solutionized, cooled and thermally aged.

1 . A composite material comprising:
 a ceramic phase; and   a metal phase comprising a heat treated Cu-based infiltration alloy comprising Ni and Mn, wherein the ceramic phase comprises from about 60 to about 80 weight percent of the composite material, the infiltration alloy comprises from about 20 to about 40 weight percent of the composite material, and the heat treated Cu-based infiltration alloy is substantially free of Zn.   
   
   
       2 . The composite material of  claim 1 , wherein the heat treated Cu-based infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       3 . The composite material of  claim 1 , wherein the heat treated Cu-based infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       4 . The composite material of  claim 1 , wherein the heat treated Cu-based infiltration alloy is substantially free of Sn. 
   
   
       5 - 7 . (canceled) 
   
   
       8 . The composite material of  claim 1 , wherein the ceramic phase comprises at least one carbide selected from tungsten carbide, titanium carbide, tantalum carbide, niobium carbide, molybdenum carbide, chromium carbide, vanadium carbide, zirconium carbide and hafnium carbide. 
   
   
       9 . The composite material of  claim 8 , wherein the carbide comprises WC. 
   
   
       10 . The composite material of  claim 1 , further comprising at least one additional phase. 
   
   
       11 . The composite material of  claim 10 , wherein the at least one additional phase comprises iron, 4600 steel, tungsten, cobalt, nickel, manganese, silicon, molybdenum, copper, zinc, chromium, boron, carbon, nitrides and/or carbonitrides. 
   
   
       12 . The composite material of  claim 1 , further comprising Co. 
   
   
       13 . The composite material of  claim 1 , wherein the composite material has been subjected to thermal aging at a temperature of from about 100 to about 450° C. for a time of from about 0.5 to about 72 hours. 
   
   
       14 . A method of making a composite material comprising
 infiltrating an alloy into ceramic particles, wherein the infiltration alloy consists essentially of Cu, Ni and Mn and is substantially free of Zn, the ceramic particles comprise from about 60 to about 80 weight percent of the composite material, and the infiltration alloy comprises from about 20 to about 40 weight percent of the composite material; and   heat treating the composite material.   
   
   
       15 . The method of  claim 14 , wherein the infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       16 . The method of  claim 14 , wherein the infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       17 . The method of  claim 14 , wherein the infiltration alloy is substantially free of Sn. 
   
   
       18 . (canceled) 
   
   
       19 . The method of  claim 14 , wherein the ceramic particles comprise WC. 
   
   
       20 . (canceled) 
   
   
       21 . The method of  claim 14 , wherein the heat treating includes thermal aging at a temperature of from about 100 to about 450° C. for a time of from about 0.5 to about 72 hours. 
   
   
       22 . A method of heat treating a composite material comprising:
 providing a composite material including a ceramic phase and an infiltration alloy comprising Cu, Ni and Mn, wherein the ceramic phase comprises from about 60 to about 80 weight percent of the composite material, the infiltration alloy comprises from about 20 to about 40 weight percent of the composite material, and the infiltration alloy is substantially free of Zn; and   heat treating the composite.   
   
   
       23 . The method of  claim 22 , wherein the heat treating includes thermal aging at a temperature of from about 100 to about 450° C. for a time of from about 0.5 to about 72 hours. 
   
   
       24 . The method of  claim 23 , wherein the heat treating comprises solutionizing the infiltration alloy at an elevated temperature and cooling the solutionized infiltration alloy prior to the step of thermally aging the composite. 
   
   
       25 . The method of  claim 24 , wherein the solutionizing step is performed at a temperature of from about 500 to about 1,000° C. for a time of from about 0.5 to about 3 hours. 
   
   
       26 . The method of  claim 24 , wherein the solutionized infiltration alloy is cooled to room temperature prior to the step of thermally aging the composite. 
   
   
       27 . The method of  claim 22 , wherein the heat treated Cu-based infiltration alloy comprises from about 15 to about 35 weight percent Ni, from about 15 to about 35 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       28 . The method of  claim 22 , wherein the heat treated Cu-based infiltration alloy comprises from about 18 to about 22 weight percent Ni, from about 18 to about 22 weight percent Mn, and the balance Cu and incidental impurities. 
   
   
       29 . The method of  claim 28 , wherein the infiltration alloy is substantially free of Sn.