Tungsten rhenium compounds and composites and methods for forming the same

Abstract

The present invention relates to tungsten rhenium compounds and composites and to methods of forming the same. Tungsten and rhenium powders are mixed together and sintered at high temperature and high pressure to form a unique compound. An ultra hard material may also be added. The tungsten, rhenium, and ultra hard material are mixed together and then sintered at high temperature and high pressure.

What is claimed is: 
     
         1 . A polycrystalline composite material comprising:
 a binder comprising,
 tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and 
 at least one of a molybdenum and lanthanum, wherein the at least one of a molybdenum and lanthanum is within the range of approximately 1% to approximately 50% of the volume of the binder; and 
   a polycrystalline ultra hard material.   
     
     
         2 . The material of  claim 1 , wherein said tungsten, said at least one of a molybdenum and lanthanum, and ultra hard material define a polycrystalline ultra hard material layer and wherein the composite material further comprises a substrate bonded to said polycrystalline ultra hard material layer forming a compact. 
     
     
         3 . A drill bit comprising a body comprising the compact as recited in  claim 2  mounted thereon. 
     
     
         4 . A method of forming a polycrystalline composite material, comprising:
 providing a binder comprising,
 tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and 
 molybdenum, wherein the molybdenum is within the range of approximately 1% to approximately 50% of the volume of the binder; 
   providing an ultra hard material; and   sintering the ultra hard material with the binder at a high temperature and high pressure to form a polycrystalline composite material.   
     
     
         5 . The method of  claim 4 , wherein sintering comprises sintering the ultra-hard material and the binder at a temperature not less than approximately 1000° C. and a pressure not less than approximately 20 kilobars. 
     
     
         6 . The method of  claim 4 , wherein sintering comprises sintering the ultra-hard material and the binder at a temperature in the range of approximately 1000° C. to approximately 2300° C., and a pressure in the range of approximately 20 kilobars to approximately 65 kilobars. 
     
     
         7 . The method of  claim 6 , wherein the ultra hard material is selected from the group consisting of cubic boron nitride, diamond, and diamond-like carbon. 
     
     
         8 . The method of  claim 6 , wherein the ultra hard material is approximately 50% or greater of the volume of the material, and the molybdenum and tungsten are approximately 50% or lower of the volume of the material. 
     
     
         9 . The method of  claim 6 , wherein the sintering the mixture comprises forming a chemical bond between the ultra hard material and at least one of the tungsten or molybdenum. 
     
     
         10 . The method of  claim 6 , further comprising providing a substrate, wherein sintering comprises sintering the tungsten, molybdenum and the substrate. 
     
     
         11 . A method of forming a polycrystalline composite material, comprising:
 providing a binder comprising,
 tungsten, wherein the tungsten is within the range of approximately 50% to approximately 99% of the volume of the binder, and 
 lanthanum, wherein the lanthanum is within the range of approximately 1% to approximately 50% of the volume of the binder, 
   providing an ultra hard material; and   sintering the ultra hard material with the binder at a high temperature and high pressure to form a polycrystalline composite material.   
     
     
         12 . The method of  claim 11 , wherein sintering comprises sintering the ultra-hard material and the binder at a temperature not less than approximately 1000° C. and a pressure not less than approximately 20 kilobars. 
     
     
         13 . The method of  claim 12 , wherein sintering comprises sintering the ultra-hard material and the binder at a temperature in the range of approximately 1000° C. to approximately 2300° C., and a pressure in the range of approximately 20 kilobars to approximately 65 kilobars. 
     
     
         14 . The method of  claim 13 , wherein the ultra hard material is selected from the group consisting of cubic boron nitride, diamond, and diamond-like carbon. 
     
     
         15 . The method of  claim 13 , wherein the ultra hard material is approximately 50% or greater of the volume of the material, and the lanthanum and tungsten are approximately 50% or lower of the volume of the material. 
     
     
         16 . The method of  claim 13 , wherein the sintering the mixture comprises forming a chemical bond between the ultra hard material and at least one of the tungsten or lanthanum. 
     
     
         17 . The method of  claim 13 , further comprising providing a substrate, wherein sintering comprises sintering the tungsten, lanthanum and the substrate.