Lower melting point binder metals

Abstract

A copper, manganese, nickel, zinc and tin binder metal composition having a melting point of 1500° F. or less that includes zinc and tin at a sum weight of about 26.5% to about 30.5% in which zinc is at least about 12% and Sn is at least about 6.5%. The binder metal having a melting point of 1500° F. or less can be used at an infiltrating temperature of 1800° F. or less in forming drilling tools and tool components.

What is claimed is: 
     
         1 . A binder metal composition having a melting point of 1500° F. or less, the binder metal composition, comprising:
 zinc (Zn) and tin (Sn) having a sum weight % of about 26.5% to about 30.5% in which Zn is at least about 12% and Sn is at least about 6.5%; 
 nickel (Ni) at about 4.5 to about 6.5 weight %; 
 manganese (Mn) at about 11 to about 26 weight %; and 
 copper (Cu) at about 40 to about 55 weight %. 
 
     
     
         2 . The binder metal composition of  claim 1 , wherein Mn is present at about 14 to about 21 weight % and Cu is present at about 40 to about 55 weight %. 
     
     
         3 . The binder metal composition of  claim 1 , wherein Mn is present at about 17 weight % and Cu is present at about 49 weight %. 
     
     
         4 . The binder metal composition of  claim 1 , further comprising an additive selected from the group consisting of boron, silicon, iron cobalt, aluminum, titanium, niobium, molybdenum, tungsten and combinations thereof. 
     
     
         5 . An infiltrated metal-matrix composite comprising:
 hard matrix particles which are infiltrated with the binder metal composition of  claim 1 .   
     
     
         6 . The infiltrated metal-matrix composite of  claim 5 , wherein the infiltrated metal-matrix has a transverse rupture strength (TRS) of 90-140 ksi. 
     
     
         7 . A drill bit body comprising a plurality of blades, the plurality of blades comprising the infiltrated metal-matrix composite of  claim 5 . 
     
     
         8 . An infiltrated metal-matrix composite comprising the binder metal composition of  claim 1 , wherein the infiltrated binder metal has a mixture of a first face-centered cubic (FCC) phase and a second FCC phase, and the first FCC phase has different chemistry and lattice parameters than the second FCC phase. 
     
     
         9 . The infiltrated metal-matrix composite of  claim 8 , wherein the ratio of the first FCC phase to the second FCC phase is about 1 to 1.5:1. 
     
     
         10 . A drill bit body comprising:
 hard matrix particles which are infiltrated with the binder metal composition of  claim 1 .   
     
     
         11 . A binder metal composition having a melting point of 1500° F. or less, the binder metal composition, comprising:
 Sn at about 6.5% to about 16 weight %; 
 Zn at about 12 to about 22.75 weight %; 
 Ni at about 4.5 to about 6.5 weight %; 
 Mn at about 11 to about 26 weight %; and 
 Cu at about 40 to about 55 weight %. 
 
     
     
         12 . The binder metal composition of  claim 11 , wherein Mn is present at about 17 weight % and Cu is present at about 49 weight %. 
     
     
         13 . The binder metal composition of  claim 12 , wherein Sn is present at about 16 weight %; Zn is present at about 12 weight %, and Ni is present at about 6 weight %. 
     
     
         14 . The binder metal composition of  claim 12 , wherein Sn is present at about 10 weight %, Zn is present at about 19 weight %, and Ni is present at about 5 weight %. 
     
     
         15 . The binder metal composition of  claim 12 , wherein Sn is present at about 13 weight %, Zn is present at about 15.5 weight %, and Ni is present at about 5.5 weight %. 
     
     
         16 . The binder metal composition of  claim 12 , wherein Sn is present at about 15 weight %, Zn is present at about 12.5 weight %, and Ni is present at about 6.5 weight %. 
     
     
         17 . The binder metal composition of  claim 12 , wherein Sn is present at about 6.75 weight %, Zn is present at about 22.75 weight %, and Ni is present at about 4.5 weight %. 
     
     
         18 . A method of forming an infiltrated metal-matrix composite, comprising:
 infiltrating tungsten carbide particles using a binder metal, the binder metal comprising:
 zinc (Zn) and tin (Sn) having a sum weight % of about 26.5% to about 30.5% in which Zn is at least about 12% and Sn is at least about 6.5%; 
 nickel (Ni) at about 4.5 to about 6.5 weight %; 
 manganese (Mn) at about 11 to about 26 weight %; and 
 copper (Cu) at about 40 to about 55 weight %. 
   
     
     
         19 . The method of  claim 18 , wherein infiltrating comprises infiltrating at a temperature of about 1800° F. or less. 
     
     
         20 . A binder metal composition having a melting point of 1500° F. or less, the binder metal composition, comprising:
 zinc (Zn) and tin (Sn) having a sum weight % of about 26.5% to about 30.5% in which Zn is at least about 12% and Sn is at least about 6.5%; 
 nickel (Ni) at about 4.5 to about 6.5 weight %; and 
 copper (Cu) at about 51 to about 81 weight %.