TECHNICAL FIELD
The present disclosure relates to the joining of a hard powder metallurgical surface in compact or wrought form to a powder/wrought non-carbide metal surface and more particularly relates to joining carbide and non-carbide materials with the help of an interface material and binder material.
BACKGROUND OF DISCLOSURE
In most sintering processes  powdered material is positioned in a mold and heated to a temperature below the melting point of the material  thereby fusing the particles and creating a singular solid piece. Because the sintering temperature is not required to reach the melting point of the material  sintering is often chosen as the shaping process for materials with high melting-points such as tungsten and molybdenum.
Further  sintering is an effective process operable to enhance material properties such as strength  electrical conductivity  translucency and thermal conductivity. However  existing sintering processes have several limitations. For example  sintering of powder materials at high temperatures can alter the properties of the materials  including inducement of undesirable phase transformations in the materials. Further  sintering at lower temperatures often leads to the formation of interfacial porosity. Interfacial porosity is also evident when sintering materials of divergent composition. Interfacial porosity can weaken the mechanical integrity of the sintered product  leading to premature degradation and/or failure of the product.
SUMMARY OF THE DISCLOSURE
In one aspect  processes are described herein operable to mitigate or overcome one or more disadvantages of prior techniques for sintering compositionally divergent materials. Elements  apparatus and methods described herein  however  are not limited to the specific embodiments presented herein. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations will be readily apparent to those of skill in the art without departing from the spirit and scope of the invention.
In one embodiment  a process for joining carbide and non-carbide materials is disclosed  the process comprising sintering the carbide material with an interface material to form a first intermediate component. The non-carbide material is provided  and a binder material is positioned between the first intermediate component and the non-carbide material to provide an assembly. The assembly is heated to join the carbide material and the non-carbide material through the binder material and sintered interface material. In some embodiments  the assembly is heated at a temperature ranging from 1050oC to 1250oC. Further  the joined carbide and non-carbide material can be ground for obtaining the desired dimensions.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the carbide material comprises tungsten carbide (WC). The carbide material  in some embodiments  is cemented carbide. A Cemented carbide  in one embodiment  comprises a cobalt or cobalt alloy binder. A cobalt alloy binder can include alloying elements of nickel  chromium or combinations thereof. Other carbide species of transition metals selected from Groups IVB  VB and VIB of the Periodic Table can be included in the carbide material.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the interface material sintered with the carbide material is selected from the group consisting of a transition metal  a transition metal carbide  a transition metal nitride  a transition metal carbonitride and mixtures thereof. Transition metals can include nickel  chromium  copper  tungsten  cobalt  titanium  tantalum  niobium  zirconium or boron or combinations or mixtures thereof. In an embodiment  the interface material has a thickness ranging from 0.3 mm to 10 mm. Further  in some embodiments  the sintered interface material is mechanically worked prior to formation of the assembly. Mechanical working can include grinding  particle blasting or combinations thereof.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the non-carbide material is steel. Steel  in some embodiments  is selected from the group consisting of tool steel  high speed steel (HSS) and cast iron. The non-carbide material  in some embodiments  comprises a high temperature alloy or super alloy.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the binder material comprises a powder metal or powder alloy composition. In an embodiment  the powder metal or powder alloy composition is selected from the group consisting of Co  Ni  Cr  B  Ag and Cu and alloys thereof. The binder composition can further comprise a carrier for the powder metal or powder alloy composition. In one embodiment  the carrier of the powder metal or powder alloy composition is a sheet of polymeric material. In another embodiment  the carrier of the powder metal or powder alloy composition is a liquid.
In some embodiments of a process for joining carbide and non-carbide materials described herein  hot isostatic pressing (hipping process) is performed after sintering the interface material and carbide material. Suitable temperatures for sintering and hipping can be chosen according to the compositional identities of the carbide material and interface material. For example  in some embodiments  sintering and hipping are administered at a temperature ranging from 1050oC to 1450oC.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the binder material is coupled with the non-carbide material to provide a second intermediate component prior to formation of the assembly. In such embodiments  the second intermediate component is combined with the first intermediate component through the binder material to form the assembly. The assembly is heated to join the carbide and non-carbide material.
In some embodiments of a process for joining carbide and non-carbide materials described herein  the binder material is coupled to the first intermediate component prior to formation of the assembly. In such embodiments  the non-carbide material is positioned adjacent to the binder material to form the assembly. The assembly is heated to join the carbide and non-carbide material.
By incorporating an interface material and a binder material  processes described herein provides a product comprising a carbide material joined to a non-carbide material by a multi-layer bonding structure. The multi-layer bonding structure  in some embodiments  comprises a plurality of interfacial transition regions between the layers  carbide material and/or non-carbide material. Interfacial transition regions of products and processes described herein  in some embodiments  have a structure different from the layers forming the transition regions.
In another aspect  a product comprising a carbide material joined to a non-carbide material is described herein. A product  in some embodiments  comprises a carbide material joined to a non-carbide material by a multi-layer bonding structure comprising a sintered interface material layer and a binder layer. In comprising a multi-layer bonding structure  the product  in some embodiments  demonstrates interfacial transition regions between layers of the bonding structure  carbide material and/or non-carbide material. In one embodiment  for example  the product displays at least three interfacial transition regions between layers of the bonding structure  carbide material and/or non-carbide material.
Products of joined carbide and non-carbide having the foregoing multi-layer bonding structure are produced according to processes described herein. A product described herein  in one embodiment  is produced by a process comprising sintering the carbide material with an interface material to form a first intermediate component. A non-carbide material is provided  and a binder material is positioned between the first intermediate component and the non-carbide material to provide an assembly. The assembly is heated to join the carbide material and the non-carbide material. In some embodiments  the assembly is heated at a temperature ranging from 1050oC to 1250oC. Further  the joined carbide and non-carbide material can be ground for obtaining the desired product dimensions.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects  embodiments  and features described above  further aspects  embodiments  and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself  however  as well as a preferred mode of use  further objectives and advantages thereof  will best be understood by reference to the following detailed description of illustrative embodiments and examples when read in conjunction with the accompanying figures. One or more embodiments are now described  by way of example only  with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
FIG.1 illustrates sintering  hipping and heating processes for joining carbide and non-carbide materials according to one embodiment described herein.
FIG. 2 illustrates sintering  hipping and heating processes for joining carbide and non-carbide materials according to another embodiment described herein.
FIG. 3 is a cross-section metallography illustrating a multi-layer bonding structure of joined carbide and non-carbide materials according to one embodiment described herein.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF DISCLOSURE
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure  both as to its organization and method of operation  together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood  however  that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure  as generally described herein  and illustrated in the figures  can be arranged  substituted  combined  and designed in a wide variety of different configurations  all of which are explicitly contemplated and make part of this disclosure.
Referring now to the drawings wherein the drawings are for the purpose of illustrating exemplary embodiments of the disclosure only  and not for the purpose of limiting the same.
FIG. 1 illustrates sintering  hipping and heating processes for joining of carbide and non-carbide materials according to one embodiment described herein. The carbide material (1)  in some embodiments  comprises cemented WC. In some embodiments  WC is present in the carbide material in an amount of at least 80 weight percent or in an amount of at least 85 weight percent. Cemented WC  in one embodiment  comprises a cobalt or cobalt alloy binder. A cobalt alloy binder can include alloying elements of nickel  chromium or combinations thereof. A cobalt or cobalt alloy binder  in some embodiments  is present in an amount ranging from 3 weight percent to 15 weight percent. The carbide material  in some embodiments  further comprises one or more of the following elements and/or their compounds: titanium  niobium  vanadium  tanatalum  chromium  zirconium and/or hafnium. In some embodiments  titanium  niobium  vanadium  tantalum  chromium  zirconium and/or hafnium form solid solution carbides with the WC in the carbide material. The carbide material  in some embodiments  comprises one or more solid solution carbides in an amount ranging from 0.1 to 5 weight percent. Additionally  the carbide material may contain nitrogen.
An interface material (2) is sintered with the carbide material (1) to provide a first intermediate component (3). The interface material (2) is selected from the group consisting of a transition metal  a transition metal carbide  a transition metal nitride  a transition metal carbonitride and mixtures thereof. Suitable transition metals include Ni  Cr  Cu  W  Co  Ti  Ta  Nb  Zr or B or combinations or mixtures thereof. In some embodiments  the metallic content of the interface material exceeds the metallic content of the carbide material. For example  in one embodiment  the carbide material has 10% cobalt  and the interface material has greater than 10% cobalt. Prior to sintering with the carbide material (1)  the interface material (2)  in some embodiments  is provided as a powder composition. Alternatively  the interface material  in some embodiments  is provided as a thin sheet or foil.
The interface material (2) is layered or pressed onto the carbide material (1). In one embodiment  the interface material (2) is compacted with the carbide material (1) in a layered format. In another embodiment  a compact of the interface material (2) is associated with one or more surfaces of the carbide material (1). The carbide material (1) and the interface material (2) are sintered to provide the first intermediate component (3). The carbide material (1) and the sintered interface material (2) can also be subjected to hot isostatic pressing (hipping) and/or other mechanical processing to achieve the desired densification. The sintered interface material (2) is fully dense or substantially fully dense. Sintering and hipping conditions are selected according to the compositional identities of the carbide material (1) and the interface material (2).
The interface material (2)  in some embodiments  has a thickness ranging from 0.1 mm to 10 mm. In one embodiment  the interface material has a thickness ranging from 0.3 mm to 7 mm or from 1 mm to 6 mm. Further  the sintered interface material (2) is mechanically worked. Mechanical working can include grinding  particle blasting or combinations thereof. Mechanical working can provide the sintered interface material (2) the desired surface roughness prior to receipt of the binder material (5) as described further herein.
A non-carbide material (4) is provided. The non-carbide material (4)  in some embodiments  is steel. In one embodiment  steel is selected from the group consisting of tool steel  HSS and cast iron. The non-carbide material (4)  in some embodiments  is a high temperature alloy or super alloy.
A binder material (5) is positioned between the first intermediate component (3) and the non-carbide material (4) to provide an assembly (7). A binder material  in some embodiments  comprises a powder metal or powder alloy composition. The powder metal or powder alloy composition  in one embodiment  is selected from the group consisting of Co  Ni  Cr  B  Ag  and Cu and alloys thereof. The binder material (5) can further comprise a carrier for the powder metal or powder alloy composition. In some embodiments  the carrier of the powder metal or powder alloy composition is a sheet of polymeric material. In some embodiments  the sheet comprising the powder metal or powder alloy composition is cloth-like in nature. Suitable polymeric materials for use in the sheet  in some embodiments  comprise one or more fluoropolymers including  but not limited to  polytetrafluoroethylene (PTFE).
In some embodiments  the desired powder metal or powder alloy composition of the binder material (5) is selected and combined with a polymeric powder for the formation of the sheet. Any metal or alloy composition recited herein for the binder material (5) can be combined or blended with a polymeric material for the formation of the sheet. The polymeric material and the powder metal or powder alloy composition are mechanically worked or processed to trap the metal or alloy powder in the polymeric material. In one embodiment  for example  the desired powdered metal or powder alloy composition is mixed with 3-10% PTFE in volume and mechanically worked to fibrillate the PTFE and trap the powder metal or powder alloy. Mechanical working can include rolling  ball milling  stretching  elongating  spreading or combinations thereof. In some embodiments  the sheet comprising the powder metal or powder alloy is subjected to cold isostatic pressing. In some embodiments  the resulting sheet comprising the powder metal or powder alloy has a low elastic modulus and high green strength.
Alternatively  the desired powder metal or powder alloy composition of the binder material (5) is combined with a liquid carrier for application to the sintered interface material (2) of the first intermediate component (3) and/or surfaces of the non-carbide material (4). In some embodiments  for example  the powder metal or powder alloy of the binder material (5) is disposed in a liquid carrier to provide a slurry or paint for application. Suitable liquid carriers for powder metal or powder alloy compositions described herein comprise several components including dispersion agents  thickening agents  adhesion agents  surface tension reduction agents and/or foam reduction agents. In some embodiments  suitable liquid carriers are aqueous based.
Powder metal or powder alloy compositions of the binder material (5) disposed in a liquid carrier can be applied to surfaces of the sintered interface material (2) of the first intermediate component (3) and/or surfaces of the non-carbide material (4) by several techniques including  but not limited to  spraying  brushing  flow coating  dipping and/or related techniques. The powder metal or powder alloy composition can be applied in a single application or multiple applications depending on desired thickness of the binder material (5).
Once the binder material (5) is positioned between the first intermediate component (3) and the non-carbide material (4) to provide the assembly (7)  the assembly (7) is heated to join the carbide material (1) and the non-carbide material (4). In some embodiments  the assembly is heated at a temperature ranging from 1050oC to 1250oC. Heating the assembly (7) provides a fully dense or substantially fully dense metal or alloy binder layer adhering the non-carbide material (4) to the first intermediate component (3) comprising the carbide material (1). In some embodiments  heating the assembly (7) melts the powder metal or powder alloy of the binder material (5) to provide the fully dense or substantially fully dense metal or alloy binder layer. In other embodiments  heating the assembly sinters the powder metal or powder alloy of the binder material (5) to provide the fully dense or substantially fully dense metal or alloy binder layer. Heating the assembly (7) additionally decomposes or burns off the carrier of the powder metal or powder alloy of the binder material (5). In some embodiments  the assembly (7) is also subjected to hipping to provide the desired densification of the binder layer.
By incorporating an interface material (2) and a binder material (5)  processes described herein provide a multi-layer bonding structure between (8) between the carbide material (1) and the non-carbide material (4). The multi-layered bonding structure (8)  in some embodiments  can comprise a plurality of interfacial transition regions between the layers of the bonding structure (8)  carbide material (1) and/or non-carbide material (4). For example  in one embodiment  a first interfacial transition region is established between the carbide material (1) and the sintered interface material (2); a second interfacial transition region is established between the sintered interface material (2) and the binder material (5); and a third interfacial transition region is established between the binder material (5) and the non-carbide material (4). In some embodiments  the first  second and third interfacial transition regions each have a structure different from the individual layers forming the transition regions. In some embodiments  the first  second and third interfacial transition regions display structures divergent from one another. Additionally  in some embodiments  each of the interfacial transition regions has a thickness ranging from 1 µm to 200 µm or from 5 µm to 100 µm.
The joined carbide (1) and non-carbide (4) materials  in some embodiments  are subjected to heat treatment in an inert atmosphere for increasing the hardness of the non-carbide material (4). Further  the joined carbide material (1) and non-carbide material (4) can be ground and/or profiled to the desired dimension(s).
FIG. 2 illustrates sintering  hipping and heating processes for joining carbide and non-carbide materials according to another embodiment described herein. The carbide material  interface material  non-carbide material and binder material of FIG. 2 are consistent with those described in FIG. 1 hereinabove.
An interface material (2) is sintered with the carbide material (1) to provide a first intermediate component (3). The interface material (2) is layered or pressed onto the carbide material (1). In one embodiment  the interface material (2) is compacted with the carbide material (1) in a layered format. In another embodiment  a compact of the interface material (2) is associated with one or more surfaces of the carbide material (1). The carbide material (1) and the interface material (2) are sintered to provide the first intermediate component (3). The carbide material (1) and the interface material (2) can also be subjected to hot isostatic pressing (hipping) and/or other mechanical processing to achieve the desired densification. The sintered interface material (2) is fully dense or substantially fully dense. Sintering and hipping conditions are selected according to the compositional identities of the carbide material (1) and the interface material (2). Further  the sintered interface material (2) is mechanically worked. Mechanical working can include grinding  particle blasting or combinations thereof. Mechanical working can provide the sintered interface material (2) the desired surface roughness.
A non-carbide material (4) is provided. A binder material (5) is coupled to the non-carbide material (4) to provide a second intermediate component (6). In one embodiment  the binder material (5) is coupled to the non-carbide material (4) with an adhesive to provide the second intermediate component (6). For example  a binder material (5) comprising a cloth-like polymeric support and a powder metal or powder alloy contained therein is adhered to a non-carbide material (4)  such as steel  to provide the second intermediate component (6).
The first intermediate component (3) and the second intermediate component (6) are placed one over the other  wherein the binder material (5) is in contact with the sintered interface material (2) to provide an assembly (7). In some embodiments  the binder material (5) is in contact with a mechanically worked or ground surface of the sintered interface material (2). The assembly (7) is heated to join the carbide material (1) and the non-carbide material (4). In some embodiments  the assembly is heated at a temperature ranging from 1050oC to 1250oC. As described herein  heating the assembly (7) provides a fully dense or substantially fully dense metal or alloy binder layer adhering the non-carbide material (4) to the first intermediate component (3) comprising the carbide material (1). Heating the assembly (7) additionally decomposes or burns off the carrier of the powder metal or powder alloy of the binder material (5). In some embodiments  the assembly is also subjected to hipping to provide the desired densification of the binder layer formed from the powder metal or powder alloy.
The joined carbide material (1) and non-carbide material (4) can be subjected to heat treatment in an inert atmosphere for increasing the hardness of the non-carbide material (4). Further  the joined carbide material (1) and non-carbide material (4) can be ground and/or profiled to the desired dimension(s).
By incorporating an interface material (2) and a binder material (5)  the process of FIG. 2 provides a multi-layer bonding structure between the carbide material (1) and the non-carbide material (4) consistent with that described in FIG. 1.
Products comprising carbide and non-carbide materials joined according to processes described herein  in some embodiments  demonstrate interfacial shear strength (transverse rupture strength) of at least 200 MPa. In some embodiments  the products demonstrate interfacial shear strength ranging from 200 MPa to 600 MPa. Products produced according to processes described herein  in some embodiments  demonstrate interfacial shear strength ranging from 250 MPa to 550 MPa or from 300 MPa to 500 MPa. Interfacial shear strength is determined according to ISO 3327-2009.
In another aspect  a product comprising a carbide material joined to a non-carbide material is described herein. A product  in some embodiments  comprises a carbide material joined to a non-carbide material by a multi-layer bonding structure comprising a sintered interface material layer and a binder layer. In comprising a multi-layer bonding structure  the product  in some embodiments  demonstrates a plurality of interfacial transition regions between layers of the bonding structure  carbide material and/or non-carbide material.
In one embodiment  for example  the product displays at least three interfacial transition regions between layers of the bonding structure  carbide material and/or non-carbide material. For example  in one embodiment  a first interfacial transition region is established between the carbide material and the sintered interface material; a second interfacial transition region is established between the sintered interface material and the binder material; and a third interfacial transition region is established between the binder material and the non-carbide material. In some embodiments  the first  second and third interfacial transition regions each have a structure different from the individual layers forming the transition regions. In some embodiments  the first  second and third interfacial transition regions display structures divergent from one another. Additionally  in some embodiments  each of the interfacial transition regions has a thickness ranging from 1 µm to 200 µm or from 5 µm to 100 µm.
Products comprising joined carbide and non-carbide materials described herein  in some embodiments  demonstrate interfacial shear strength (transverse rupture strength) of at least 200 MPa. In some embodiments  the products demonstrate interfacial shear strength ranging from 200 MPa to 600 MPa. Products described herein  in some embodiments  demonstrate interfacial shear strength ranging from 250 MPa to 550 MPa or from 300 MPa to 500 MPa. Interfacial shear strength is determined according to ISO 3327-2009. Products comprising joined carbide and non-carbide materials  in some embodiments  are constructed according to processes described herein.
The carbide material  non-carbide material  sintered interface material and binder material of a product described herein have compositions and properties consistent with those of processes described herein.
EXAMPLE 1 – Joining of Carbide and Non-Carbide Materials
A carbide material of cemented WC was provided comprising 15 weight percent Co-Ni-Cr binder. An interface material of WC having 30 weight percent cobalt was brought into contact with the cemented WC and subsequently sintered with the cemented WC at a temperature ranging from 1330oC to 1390oC under vacuum to provide the first intermediate component. A binder material comprising a powder composition of 12-16 weight percent Cr  70-90 weight percent Ni and 1-3 weight percent B in a cloth-like PTFE carrier was coupled to a non-carbide material of ASP2030 steel by adhesive to provide the second intermediate component. The first intermediate component and the second intermediate component were coupled to one another to provide an assembly  wherein the cloth-like PTFE binder material of the second intermediate component contacted the sintered interface material of the first intermediate component. The assembly was heated at a temperature ranging from 1120oC to 1160oC to join the cemented WC and ASP2030 steel through the resulting alloy binder layer and sintered interface material.
FIG. 3 is a cross-section metallography of the resulting joined cemented WC and steel. As illustrated in FIG. 3 the multi-layer bonding structure provided by the fully dense interface and binder materials establish a plurality of interfacial transition regions. A first interfacial transition region is established between the cemented WC and WC-Co interface material  a second interfacial transition region is established between the WC-Co interface material and binder material  and a third interfacial transition region is established between the binder material and ASP2030 steel.

REFERENCE NUMERALS
1 Carbide material
2 Interface material
3 First Intermediate component
4 Non-Carbide material
5 Binder material
6 Second Intermediate component
7 Assembly
8 Multi-layer bonding structure

EQUIVALENTS
With respect to the use of substantially any plural and/or singular terms herein  those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that  in general  terms used herein  and especially in the appended claims (e.g.  bodies of the appended claims) are generally intended as “open” terms (e.g.  the term “including” should be interpreted as “including but not limited to ” the term “having” should be interpreted as “having at least ” the term “includes” should be interpreted as “includes but is not limited to ” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended  such an intent will be explicitly recited in the claim  and in the absence of such recitation no such intent is present. For example  as an aid to understanding  the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However  the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation  even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g.  “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition  even if a specific number of an introduced claim recitation is explicitly recited  those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g.  the bare recitation of “two recitations ” without other modifiers  typically means at least two recitations  or two or more recitations). Furthermore  in those instances where a convention analogous to “at least one of A  B  and C  etc.” is used  in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g.  “a system having at least one of A  B  and C” would include but not be limited to systems that have A alone  B alone  C alone  A and B together  A and C together  B and C together  and/or A  B  and C together  etc.). In those instances where a convention analogous to “at least one of A  B  or C  etc.” is used  in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g.  “a system having at least one of A  B  or C” would include but not be limited to systems that have A alone  B alone  C alone  A and B together  A and C together  B and C together  and/or A  B  and C together  etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms  whether in the description  claims  or drawings  should be understood to contemplate the possibilities of including one of the terms  either of the terms  or both terms. For example  the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

While various aspects and embodiments have been disclosed herein  other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting  with the true scope and spirit being indicated by the following claims.

WE CLAIM:
1. A product comprising:
a carbide material (1) joined to a non-carbide material (4) by a multi-layer bonding structure (8)  the multi-layer bonding structure comprising a layer of binder material (5) and a layer of sintered interfacial material (2).

2. The product of claim 1  wherein the carbide material (1) is tungsten carbide.
3. The product of claim 2  wherein the carbide material (1) is cemented tungsten carbide comprising a metal or alloy binder selected from the group consisting of cobalt  nickel  chromium and alloys thereof.
4. The product of claim 2  wherein the carbide material (1) further comprises one or more elements selected from the group consisting of titanium  niobium  vanadium  tantalum  chromium  zirconium  hafnium and combinations thereof.
5. The product of claim 1  wherein the sintered interface material (2) is selected from the group consisting of a transition metal  a transition metal carbide  a transition metal nitride  a transition metal carbonitride and mixtures thereof.
6. The product of claim 5  wherein the transition metal is selected from the group consisting of nickel  chromium  copper  tungsten  cobalt  titanium  tantalum  niobium or zirconium or mixtures thereof.
7. The product of claim 5  wherein the layer of sintered interface material (2) is substantially fully dense.
8. The product of claim 1  wherein the layer of sintered interface material (2) has a thickness ranging from 0.3 mm to 10 mm.
9. The product of claim 1  wherein the binder material (5) is a metal or alloy.
10. The product of claim 9  wherein the metal or alloy is selected from the group consisting of cobalt  nickel  chromium  silver and copper and alloys thereof.
11. The product of claim 1 further comprising a first interfacial transition region between the carbide material (1) and the layer of sintered interface material (2).
12. The product of claim 11 further comprising a second interfacial transition region between the layer of sintered interface material (2) and the layer of binder material (5).
13. The product of claim 12 further comprising a third interfacial transition region between the layer of binder material (5) and the non-carbide material (4).
14. The product of claim 1  wherein the non-carbide material (4) is steel.
15. The product of claim 14  wherein the steel is selected from the group consisting of tool steel  hollow high speed steel and cast iron.
16. The product of claim 1  wherein the non-carbide material (4) is a high temperature alloy or super alloy.
17. The product of claim 14  wherein the product has interfacial shear strength of at least 200 MPa determined according to ISO 3327-2009.
18. The product of claim 14  wherein the product has interfacial shear strength ranging from 200 MPa to 600 MPa determined according to ISO 3327-2009.
19. A process for joining a carbide material and a non-carbide material comprising:
sintering the carbide material (1) with an interface material (2) to form a first intermediate component (3);
providing a non-carbide material (4);
positioning a binder material (5) between the first intermediate component (3) and the non-carbide material (4) to provide an assembly (7); and
heating the assembly (7) to join the carbide material (1) and the non-carbide material (4) through the binder material (5) and the sintered interface material (2).
20. The process of claim 19  wherein the carbide material (1) is tungsten carbide.
21. The process of claim 20  wherein the carbide material (1) is cemented tungsten carbide comprising a metal or alloy binder selected from the group consisting of cobalt  nickel  chromium and alloys thereof.
22. The process of claim 20  wherein the carbide material (1) further comprises one or more elements selected from the group consisting of titanium  niobium  vanadium  tantalum  chromium  zirconium  hafnium and combinations thereof.
23. The process of claim 19  wherein the interface material (2) is selected from the group consisting of a transition metal  a transition metal carbide  a transition metal nitride  a transition metal carbonitride and mixtures thereof.
24. The process of claim 23  wherein the transition metal is selected from the group consisting of nickel  chromium  copper  tungsten  cobalt  titanium  tantalum  niobium or zirconium or mixtures thereof.
25. The process of claim 19  wherein the interface material (2) has a thickness ranging from 0.3 mm to 10 mm.
26. The process of claim 19  wherein the assembly (7) is heated at a temperature ranging from 1050oC to 1250oC.
27. The process of claim 19  wherein the interface material (2) is mechanically worked after sintering with the carbide material (1).
28. The process of claim 27  wherein mechanical working comprises grinding.
29. The process of claim 19  wherein the binder material (5) comprises a powder metal or powder alloy disposed in a carrier.
30. The process of claim 29  wherein the powder metal or powder alloy is selected from the group consisting of cobalt  nickel  chromium  boron  silver and copper and alloys thereof.
31. The process of claim 29  wherein the carrier is polymeric sheet.
32. The process of claim 29  wherein the carrier is a liquid.
33. The process of claim 19  wherein the non-carbide material (4) is steel.
34. The process of claim 33  wherein the steel is selected from the group consisting of tool steel  high speed steel and cast iron.
35. The process of claim 19  wherein the non-carbide material (4) is a high temperature alloy or super alloy.
36. The process of claim 19  wherein heating the assembly (7) provides a multi-layer bonding structure (8) between the carbide material (1) and non-carbide material (4).
37. The process of claim 36  wherein the multi-layer bonding structure (8) comprises a plurality of interfacial transition regions between layers of the bonding structure (8)  the carbide material (1) and non-carbide material (4).
38. The process of claim 19 further comprising grinding or profiling at least one of the joined carbide (1) and non-carbide (4) materials.