Synthesis of aluminum infiltrated boron suboxide drag cutters and drill bits

Abstract

Synthesis of boron suboxide (B6O) was made by reactive sintering of crystalline boron and zinc oxide powders at 1450 °C, in argon, for 12 h. After sintering, Vickers microhardness testing was performed on the material synthesized and an average hardness value of 34 GPa was obtained. Sintered suboxide (in crushed and ground powder form) was then analyzed through optical and scanning electron microscopies and X-ray diffraction. Following the completion of the analyses, consolidation of the powder was performed. Two different routes were carried out: (1) “explosive consolidation” which was performed in double tube (with a density value of 2.22 g/cm3) and single tube (with a density value of 2.12 g/cm3) canister design arrangements and (2) “hot pressing” which was performed in a graphite die assembly, at 1600 °C, in vacuum, for 2 and 4 h (with density values of 2.15 and 2.18 g/cm3 respectively). Consolidated samples of both routes showed different levels of mechanical attachment, agglomeration, porosity, fracture toughness and fracture strength values, whereas microhardness values and X-ray diffraction plots (as shown in Table I and Figs 6 and 8 respectively) were determined to be similar. Following characterizations, compacts of both routes were then given a high temperature sintering treatment (pressureless sintering) at 1800 °C, in vacuum, for full densification. Both in the “as consolidated” and “densification sintered” stages test results revealed the most desirable and well-established properties for the “explosively consolidated double tube design” compacts (with densification sintered density, microhardness and fracture toughness values of 2.46 g/cm3, 38 GPa and 7.05 MPa m1/2 respectively). Consolidation and desification sintering steps were then followed by a pressureless infiltration step. Aluminum was infiltrated into densification sintered “double tube design consolidated” and “4 h of pressed” samples (better-compacted and better-sintered compacts) in the temperature range 1100–1250 °C, in argon, for 10 h. During infiltrations, the optimum temperature of the infiltration process was determined to be 1200 °C. Characterization results revealed the most uniform and well established properties once more for the double tube design explosively consolidated compact (with aluminum infiltrated density, microhardness and fracture toughness values of 2.55 g/cm3, 41 GPa and 8.70 MPa m1/2 respectively).