Metal formulations

Abstract

The invention is directed to a formulation containing at least one hard material powder and at least 2 binder metal powders. The formulation is characterized in that the cobalt is completely contained in the first binder metal powder and is prealloyed with one or more elements of groups 3 to 8 of the Periodic Table of the Elements which are elements of the fourth period and at least one further binder metal powder from the group consisting of powders of the elements Fe, Ni, Al, Mn, Cr and alloys of these elements with one another is present and the further binder metal powders do not contain any cobalt in unprealloyed form. The invention further relates to the use of the inventive formulation in a cemented hard material, a porous sintered agglomerate and a thermal spray powder. The invention also relates to a method of controlling the toxic effect of cobalt-containing metal formulation by utilizing the inventive formulation.

1 .- 23 . (canceled) 
   
   
       24 . A formulation comprising at least one hard material powder and at least 2 binder metal powders, and all the cobalt is present in the first binder metal powder and is prealloyed with one or more elements of groups 3 to 8 of the Periodic Table of the Elements which are elements of the fourth period and at least one further binder metal powder from the group consisting of powders of the elements Fe, Ni, Al, Mn, Cr and alloys of these elements with one another is present and the further binder metal powders do not contain any cobalt in unprealloyed form. 
   
   
       25 . A formulation comprising at least one hard material powder and at least 2 binder metal powders, and all the cobalt is present in the first binder metal powder and is prealloyed with one or more elements of groups 3 to 8 of the Periodic Table of the Elements and at least one further binder metal powder from the group consisting of powders of the elements Fe, Ni, Al, Mn, Cr and alloys of these elements with one another is present and the further binder metal powders do not contain any cobalt in unprealloyed form, where the free corrosion potential between the hard material and the first binder metal powder, measured in air-saturated water at atmospheric pressure and room temperature, is less than 0.300 volt, with the hard material having the positive polarity. 
   
   
       26 . A formulation comprising at least one hard material powder and at least 2 binder metal powders, and all the cobalt is present in the first binder metal powder and is prealloyed with one or more elements of groups 3 to 8 of the Periodic Table of the Elements and at least one further binder metal powder selected from the group consisting of iron powders, nickel powders, FeNi alloy powders and prealloyed FeNi alloy powders is used and the further binder metal powders do not contain any cobalt in unprealloyed form. 
   
   
       27 . The formulation according to  claim 25 , wherein the alloying partner of the cobalt in the first binder metal powder is an element of the fourth period. 
   
   
       28 . The formulation according to  claim 24 , wherein the alloying partner of the cobalt in the first binder metal powder is an element selected from the group consisting of Fe, Ni, Cr, Mn, Ti and Al. 
   
   
       29 . The formulation according to  claim 24 , wherein the first binder metal powder contains further elements in alloyed form. 
   
   
       30 . The formulation according to  claim 29 , wherein said further elements are Al and/or Cu. 
   
   
       31 . The formulation according to  claim 24 , wherein one or more further binder metal powders selected from the group consisting of iron powders, nickel powders, FeNi alloy powders and prealloyed FeNi alloy powders are used in addition to the first binder metal powder. 
   
   
       32 . The formulation according to  claim 24 , wherein the free corrosion potential between the hard material and the first binder metal powder, measured in air-saturated water at atmospheric pressure and room temperature, is less than 0.300 volt, with the hard material having the positive polarity. 
   
   
       33 . The formulation according to  claim 24 , wherein the hard material contains titanium carbide, vanadium carbide, molybdenum carbide or tungsten carbide. 
   
   
       34 . The formulation according to  claim 33 , wherein the hard material has a BET surface area of greater than 0.3 m 2 /g. 
   
   
       35 . The formulation according to  claim 33 , wherein the hard material has a BET surface area of greater than 1 m 2 /g. 
   
   
       36 . The formulation according to  claim 24 , wherein the weight ratio of the first binder metal powder to the further binder metal powder or powders is from 1:10 to 10:1. 
   
   
       37 . The formulation according to  claim 24 , which comprises a) at least one prealloyed powder selected from the group consisting of iron/cobalt and iron/nickel/cobalt; b) at least one element powder selected from the group consisting of iron and nickel or a prealloyed powder consisting of iron/nickel which is different from component a); c) hard material powder, where the overall composition of the components a) and b) together contains a maximum of 90% of cobalt and a maximum of 70% by weight of nickel. 
   
   
       38 . The formulation according to  claim 37 , wherein the iron content is at least 10% by weight. 
   
   
       39 . The formulation according to  claim 24 , wherein the overall composition of the binder is max. 90% by weight of Co, max. 70% by weight of Ni and at least 10% by weight of Fe, where the iron content satisfies the inequality 
     
       
         
           
             Fe 
             ≥ 
             
               
                 100 
                  
                 % 
               
               - 
               
                 
                   % 
                    
                   
                       
                   
                    
                   
                     Co 
                     · 
                     90 
                   
                    
                   % 
                 
                 
                   ( 
                   
                     
                       % 
                        
                       
                           
                       
                        
                       Co 
                     
                     + 
                     
                       % 
                        
                       
                           
                       
                        
                       Ni 
                     
                   
                   ) 
                 
               
               - 
               
                 
                   % 
                    
                   
                       
                   
                    
                   
                     Ni 
                     · 
                     70 
                   
                    
                   % 
                 
                 
                   ( 
                   
                     
                       % 
                        
                       
                           
                       
                        
                       Co 
                     
                     + 
                     
                       % 
                        
                       
                           
                       
                        
                       Ni 
                     
                   
                   ) 
                 
               
             
           
         
       
       (where Fe: iron content in % by weight, % Co: cobalt content in % by weight, % Ni: nickel content in % by weight) and at least two binder powders of which one binder powder is lower in iron than the overall composition of the binder and the other binder powder is richer in iron than the overall composition of the binder and at least one binder powder is prealloyed from at least two elements selected from the group consisting of iron, nickel and cobalt are used. 
     
   
   
       40 . A cemented hard material which comprises the formulation according to  claim 24 . 
   
   
       41 . A porous sintered agglomerate which comprises the formulation according to  claim 24 . 
   
   
       42 . A porous agglomerate which can be obtained by sintering without pressing of a formulation according to  claim 24 . 
   
   
       43 . A thermal spray powder containing the porous agglomerate according to  claim 42  and also Al, yttrium and/or rare earths. 
   
   
       44 . A method of controlling the toxic effect of cobalt-containing metal formulations in the production of cemented hard material or porous sintered agglomerate which comprises utilizing the metal formulation according to  claim 24 . 
   
   
       45 . A method of controlling the toxic effect of cobalt-containing metal formulations in the production of shaped bodies or coatings which comprises utilizing the metal formulation according to  claim 24 . 
   
   
       46 . A method of controlling the toxic effect of cobalt-containing metal formulations which comprises prealloying cobalt with one or more elements of groups 3 to 8 of the Periodic Table of the Elements in a metal formulation. 
   
   
       47 . The method according to  claim 44 , wherein the toxicological effect encompasses pulmonary fibrosis and/or the disease of cemented carbide lung.