CEMENTED CARBIDE TOOL

Abstract: A tool or wear part comprises a cast iron or cast steel body (3) carrying one or more cast-in inserts (1). Each insert (1) com­ prises a cemented carbide cutting or wearing element par­ tially embedded in the body (3), and an enclosure (2) completely surrounding the embedded portion of the element. The enclo­ sure (2) is cast-in with respect to the body (3) and has a higher melting point than the body (3). The enclosure (2) is connected by a metallurgical bond to the body (3) and by a shrink-fit to the element.

Description: The present invention relates to cemented carbide tools and, in particular, to tools for drilling of rock and other minerals comprising a cast iron or steel body carrying one or more cast-in inserts but it is also applicable to other cemented carbide cutting tools and wear parts. US 4,584,020 discloses a wear part having a carbide wear layer. This wear layer comprises a cast-in layer which is metallurgically bonded to the body and to a steel layer which is disposed along one or two sides of the carbide. The rear side is uncovered to permit the molten material of the body to flow among the carbide particles during the fabrication process. The carbide particles are directly cast-in relative to the body. In US 2,743,495 a tool comprises a metal body, a plurality of cemented carbide elements embedded within and projecting from the body and jackets surrounding the embedded portions of the elements. The jackets are connected to the cemented carbide elements by a metallurgical (fused) connection. When casting-in cemented carbide parts in iron alloys such as steel and cast iron the cemented carbide parts are exposed to complex residual stresses due to the essentially lower thermal expansion of the cemented carbide than that of the iron base material. This has no negative influence on the performance of the product as long as the cemented carbide part is completely embedded in the matrix such as disclosed in U.S. Pat. No. 4,119,459 assigned to the same assignee as the present application. However, when the cemented carbide body has a certain protrusion from the matrix the complex tensions in the transition matrix - free cemented carbide part lead to an unacceptable decrease of strength. Another great disadvantage from a strength point of view is that, in addition, a brittle transition zone is formed due to dissolution of iron in the surface zone of the cemented carbide. Thus, the above-mentioned two factors result in great limi­ tations on the casting technique, in particular, for prod­ ucts requiring a certain protrusion of the cemented carbide such as buttons or inserts in rock drill bits. For such products today, conventional methods of fastening have to be used (brazing, pressing etc.). These methods result in high costs due to the necessity of precision manufacturing (boring - grinding). It is an object of the present invention to avoid or allevi­ ate the problems of the prior art. The disadvantages described above can be avoided by protect­ ing the cemented carbide part during the casting operation according to the following: The cemented carbide part is provided with an enclosure of steel or similar suitable alloy. The cemented carbide part with the enclosure is placed in the mould. At the subse­ quent casting a good metallurgical bond is obtained between the enclosure and the cast alloy and simultaneously a good shrink fit between the enclosure and the cemented carbide part is obtained. The cemented carbide part never comes in contact with the melt and, thus, the above-mentioned brit­ tle transition zone is never formed. In a preferred embodiment of the invention the cemented carbide part protrudes above the surface of the cast iron. Said protrusion shall be at least 10% and preferably at least 20 % of the height of the cemented carbide part. Fig 1 shows a crossectional view through a tool according to the present invention. In the figure 1 is the cemented carbide insert, 2 is the enclosure and 3 is cast iron or steel. The material of the enclosure is chosen in such a way that its melting point is higher, at least 50 °C preferably 200 - 400 °C above the melting point of the cast alloy of the tool body. When an essentially graphitic cast iron is used for the tool body a low carbon steel has turned out to be a suitable enclosure material. Generally the carbon con­ tent of the steel enclosure is 0.2% at most. The wall of the enclosure should be so thick that it pro­ tects the cemented carbide part during the casting. Howev­ er, it must also be thin enough to allow a certain deformation during the cooling in order to further fasten the cemented carbide body in the cast iron body. A wall thickness of 0.5 - 10 mm preferably 1 - 5 mm is suitable in most cases. In a preferred embodiment the enclosure protrudes somewhat above the surface of the cast iron in order to protect the 'corner' cemented carbide - cast iron where the notch effect is particularly severe. A protrusion of >1 mm is generally sufficient. The steel enclosure is generally in the form of a cylindri­ cal cup but other shapes are also possible. To further decrease the residual stresses the enclosure can be cham­ fered towards the inside. The joint can be compared with conventional shrink joints as regards strength and residual stresses. It is strong enough to withstand the impacts occurring in heavy wear applications. As mentioned, the invention is particularly applicable to rock drill applications. For oil well drill bit cutting, elements of diamond and/or cubic boron nitride are often used. In tools or wear parts according to the invention, the cast iron part exposed to wear is advantageously provided with a surface layer in which cemented carbide particles are dispersed e.g. according to U.S. Pat. No. 4,119,459. The thickness of said layer should be less than 10 mm prefera­ bly 5 - 7 mm. The following examples illustrate the invention in rock drilling applications. Example 1 In order to lower the cost when producing button bits, attempts were made with the casting technique. The buttons were cast in the drill according to the invention, i.e., with a low carbon steel enclosure (0.05% C) and without enclosure in the conventional way. Drill bit: ⊘ 178 mm DTH (= Down-The-Hole-bit) low alloyed steel with 0.6% C Cemented carbide button 6% Co, 94% WC ⊘ 16 mm, height 30 mm, protrusion 8 mm. Machine Ingersoll Rand Rock Granite Variant 1 Standard bit with bored shrink fitted buttons Variant 2 Bit according to the invention (cast-in carbide) Variant 3 Bit with buttons without enclosure (cast-­ in carbide) Example 2 In order to improve the erosion resistance of oil well drill bits of PDC-type such bits were manufactured of nodular iron with cemented carbide particles in the surface layer (US 4,119,459) and studs according to the invention. Drill bit: ⊘ 216 mm, Fish Tail bit PDC-stud ⊘ 17.5 mm, height 33 mm, protrusion 15 mm The test was performed in a laboratory rig in order to test the strength of the cemented carbide stud. The drilling was performed in granite in order to enhance the strain. Variant 1 PDC drill bit of standard type with shrink fitted cemented carbide studs Variant 2 PDC bit according to the invention Variant 3 PDC bit with cast in cemented carbide studs without enclosure. Data: Load 10, 20, 30, 40 tons Penetration rate 1 mm/ rev Number of revolutions 70 rpm Cemented carbide grade 15 % Co, 85 % WC Result Variants 1 and 2 withstood the load of 10 - 40 tons Variant 3 was damaged already at 10 tons.

Claims: 1. Cemented carbide tool or wear part comprising a cast iron or cast steel body carrying one or more cast-in inserts characterized in that each said insert comprises a cutting or wearing element of cemented carbide including an embedded portion extending into said body and a projecting portion extending beyond said body and an enclosure cast-in with respect to said body and completely surrounding said embedded portion, said enclosure compris­ ing a material having a higher melting point than said body and connected by a metallurgical bond to said body and by a shrink fit to said element. 2. Cemented carbide tool or wear part according to claim 1 characterized in that the wall thickness of the enclosure is 0.5 - 10 mm and the melting point of the enclo­ sure is more than 50°C above the melting point of the body. 3. Cemented carbide tool or wear part according to claim 1 characterized in that a surface of the body exposed to wear has thereon a layer with a thickness of less than 10 mm in which cemented carbide particles are dispersed. 4. Cemented carbide tool or wear part according to claim 1 characterized in that said tool or wear part comprises a rotary drill bit, said cutting or wearing ele­ ment comprising a cutting button with a diamond and/or cubic boron nitride layer.

Inventors: FISCHER, UDO, HARTZELL, TORBJOERN, WALDENSTROEM, MATS, Hartzell, Torbjörn, Waldenström, Mats
Applicants: SANDVIK AKTIEBOLAG
Application year: 1988
Main classification: B28D1
IPC codes: E21B10, B22D19