Tungsten Powder and Bronze Composite Material

Lead has been used in a variety of industrial applications for many thousands of years. In the last hundred years, the toxic effects of lead have become apparent. In an effort to reduce reliance on lead, there has recently been extensive research into materials that could be used to replace lead.
 
In this regard, much effort has been focussed on producing metal composites that mimic the properties of lead. Since the density of lead is the most obvious characteristic to mimic, most efforts have concentrated on finding composites that have the same or similar density as lead. However, other important properties of lead have been largely ignored and, as a result, no completely satisfactory lead replacement has yet been found.
 
In addition to being non-toxic and to having a similar density to lead, a successful composite should have reasonable softness coupled with structural rigidity. Ideally the composite is substantially homogeneous and relatively cheap to manufacture in large quantities.
 
tungsten powdertungsten powder
 
There still remains a need for a composite materials having a suitably high density, suitable processing characteristics and suitable properties for a variety of applications.
 
There is provided a composite comprising tungsten and bronze.
There is also provided a composite consisting essentially of tungsten, bronze, and iron.
There is also provided a process for producing a composite, the process comprising: blending powdered tungsten, powdered bronze, and an organic binder, thereby forming a homogeneous mixture; compounding the mixture at elevated temperature; and, cooling the mixture to form a composite having consistent characteristics throughout the composite.
 
There is also provided a process for producing an article comprising: providing a mold having an open ended cavity; placing a quantity of a homogeneous mixture of powders comprising tungsten and bronze in the cavity; placing a quantity of a powdered infiltrant on the mixture of powders in the cavity; sintering the mixture of tungsten and bronze powders at a first temperature followed by melting the infiltrant at a second temperature; and, cooling the mold and the articles formed therein.
 
Tungsten is generally used in the form of tungsten powder of polygonal shape and may be milled to the desired shape and mean particle size. The mean particle size is preferably about 0.5–50 μm, more preferably about 1–20 μm.
Bronze is typically an alloy of copper and tin. The ratio of copper to tin may vary depending on the particular alloy and the desired proportions of copper to tin in the composite. Most industrially useful compositions have a tin content of under 25% by weight. Many other additions at various levels are commonly used to alter the properties of bronzes. These may include but are not limited to metals and non-metals such as zinc, iron, manganese, magnesium, aluminium, phosphorus, silicon, lithium compounds, etc. Preferably, bronze having a Cu:Sn ratio of about 9:1 is used, this includes bronze having a Cu:Sn ratio of 89:11. Bronze is preferably used in the form of a powder and may be milled to the desired shape and mean particle size. The mean particle size is preferably under 100 μm, more preferably under 50 μm.
Generally, the density of the composite can be adjusted at will by varying the ratio of tungsten (density=19.3 g/cc) and bronze (density=8.9 g/cc for a 90:10 alloy of Cu:Sn). 
 
It was found that a composite comprising 40–85% tungsten by weight of the composite, the balance being bronze comprising 80–95% copper and 5–20% tin by weight of the bronze, was effective at producing a composite suitable for use as a lead replacement. Preferably, the composite comprises 50 to 55% tungsten, even more preferably 52% tungsten by weight of the composite and the bronze comprises copper and tin in a ratio of about 9:1 by weight of the bronze.
 
Tungsten particles offer resistance to densification during compaction as well as sintering. These issues may place an upper limit on the useful fraction of tungsten. The latter issue can also be partially offset by using finer tungsten grains.
The use of bronze in the formation of tungsten composites offers significant advantages over composite materials that have previously been described in the art, including the three component systems described in U.S. Pat. No. 5,950,064. Surprisingly, it has been found that suspensions of tungsten in bronze are more homogeneous and denser than suspensions of tungsten in other materials, particularly other metallic materials. The more even distribution of tungsten in the bronze matrix leads to superior and more consistent composite properties, such as higher impact strength and greater density. The use of tungsten in bronze also permits the use of a wider range of processing characteristics than the use of a three component system, such as those described in U.S. Pat. No. 5,950,064. When processing a three component system involving separate powders of tungsten, copper and tin, molten tin will dissolve into the copper matrix leaving non-removable voids or porosity, permitting aggregation of the tungsten particles that were next to the tin particles. As a result, the composite formed from the three component system is less homogeneous and of lower density than one formed from tungsten and bronze.
 
Other processing aids may be used during the production of tungsten/bronze composites, such as lubricants (for example, organic polymers, waxes, molybdenum disulphide, calcium difluoride, ethylene-bis-stearamide, lithium stearate, lithium carbonate, copper stearate, copper oleate, copper amines, and graphite), surfactants (for example, stearic acid) mould releasing agents (for example, zinc stearate) and wetting agents (for example, aluminum and basic polymers such as polyvinyl pyrrolidone).
 
tungsten powdertungsten powder

Deep Cryogenic Treatment Effect on Tungsten Carbide Materials

First of all, viewed from micro structure, deep cryogenic treatment has no obvious effect on the WC granularity, contiguity, and γ phase mean free path of tungsten carbide materials. Carbide without cryogenic treatment contains only a small amount of brittle η phases, by comparison, after the cryogenic treatment due to carbide long-term exposure to extreme temperatures and η phase increases. There are some experiments found that after deep cryogenic treatment, tungsten carbide has more uniform distribution, the binder Co and hard phase WC combined firmer and the overall wear resistance is significantly improved. Furthermore, the deep cryogenic treatment temperature provides greater two-phase free energy difference (High-temperature phase α-Co (fcc structure) and Low temperature phase Σ-Co (hcp structure)). At such low temperature, the atomic diffusion capacity reduced and formed no-diffusion phase transition process. In the research of deep cryogenic treatment of TW carbide inserts, we can found that the blade without deep cryogenic treatment has both of Σ-Co phase andα-Co phase, while the blade after treatment only hasΣ-Co phase. It indicates that after deep cryogenic treatment, Co of TW has a complete martensitic transformation. Overall, deep cryogenic treatment can promote binder Co transfer fcc structure to hcp structure.

Due to the great difference of the coefficient of thermal expansion and linear expansion coefficient between WC and Co phases of tungsten carbide, tungsten carbide has large thermal stress inside after cooling. And WC phase is subjected to compression stress, Co phase is subjected to tensile stress. By cryogenic treatment can make the carbide obtained two-phase thermal stress relaxation, thereby increasing the strength of carbide cutting tools. In addition, in mechanical properties, carbide cutting tools after deep cryogenic treatment, the hardness has greatly improved (from HRA90 to improve HRA92, HV1764 increased to HV2263.7). While YG6X, YG8, YG10C, YT14 four grades after deep cryogenic treatment, Various grades of alloy coercive force has been significantly improved, significantly lower than the saturation magnetization, has improved hardness, density substantially constant and flexural strength dramatically.

tungsten carbide mills

 

Tungsten Carbide Materials Deep Cryogenic Treatment

Conventional heat treatment is an important technology to improve the structure and properties of materials. And deep cryogenic treatment is a kind of new technology that develops and extends on this basis. For common steel materials, deep cryogenic treatment has many advantages, such as:

1. It can make the retained transferred, improve the hardness of the workpiece and keep the dimensions stable;
2. The precipitated ultra-fine carbides can remarkably improve the wear resistance of workpieces;
3. It can effectively refine the grains and improve the impact toughness of the workpiece;
4. It can improve the corrosion resistance of Martensitic stainless steel and the polishing properties and so on.
In addition, with the further development of liquid nitrogen cooling and insulation technology, deep cryogenic treatment has been gradually widely used in tungsten carbide materials fields.

At present, the studies of tungsten carbide material deep cryogenic treatment can be mainly divided into two types: one is contains cooling and holding two stages, which control carbide cooling from room temperature to the processing temperature. In this process, it should be noticed that the controlling of the cooling rate in case of a greater thermal shock. And then hold a day or longer at deep cryogenic treatment temperature; the other one is with tempering treatment and control the temperature rise above ambient temperature and maintained for some time. The experiment shows that the cutting force of tungsten carbide blade has been reduced, the thermal conductivity has been improved, the wear loss of blade was smaller, the surface toughness was higher and the service life has been extended. But in the state of continuous cutting, the effect of deep cryogenic treatment will disappear with the increasing cutting time. This is due to the carbide tool cryogenic treated in a metastable state, the role of the cutting tool after high temperature cryogenic treatment a long time will gradually decrease until it disappears. So in order to extend the effect of deep cryogenic treatment, we can add some cooling medium from outside.

tungsten carbide dies

 

Tungsten Powder and Non-Lead Hollow Point Bullets

The firing of small arms ammunition for training, sporting, law enforcement, and military purposes is a major source of environmental pollution, which poses a health hazard to the world population. Lead is a significant environmental and health problem at the numerous public, private, and government-operated shooting ranges. Many of the sites are contaminated with hundreds of tons of lead, the result of years of target practice and skeet shooting. The lead is tainting grounds and water, and is being ingested by wildlife, and thus has become a serious threat to the health and safety of human and animal populations. Indoor ranges pose other serious concerns such as increased lead exposure to the shooter due to the enclosed space and the subsequent need for high capacity ventilation and air filtration systems. Handling of ammunition and contaminated weapons can also produce elevated lead levels in the blood by absorption through the skin.
 
Since lead is a hazardous material, bullets are being fabricated from alternate metals such as monolithic copper, powder metals in polymer binders, and other mixtures that include powdered metals. Many of the bullets made from the alternate materials are atypical in size and shape because the materials do not have densities less than lead. Emphasis in the development of non-lead bullets has been on products for training where it is believed that these deficits in properties are not of concern. Non-lead bullets for use in service have had little attention. Though many bullet configurations have been produced using non-lead materials, no non-lead hollow-points that mimic the exact shape, design, size, and function of lead hollow-points have been developed.
 
Full-metal jacket and “soft-point” bullets are not favored for use by law enforcement and security forces. These designs do not readily expand in soft targets and thus over penetrate. The bullets can pass completely through one target and into others. The energy of the bullet is not completely deposited in the target thus less likely producing the desired effect, a one shot stop. These types of bullets also cause more collateral damage and ricochet more easily. Law enforcement and other security and protective forces prefer to use “hollow-point” (HP) bullets to overcome these issues. A hollow cavity is intentionally created in the exposed soft lead nose of the bullet. Upon engaging a soft target, the nose of the bullet quickly expands. The energy of the bullet is thus rapidly deposited in the target. More recent designs incorporate scored or serrated copper jackets, which adds additional control to the expansion process.
 
hollow point bullets
 
Maximum expansion of the head is desirable to maximize hemorrhaging and tissue damage. This maximized expansion maximizes the lethality in game animals. However, if the head expands too much, the bullet will separate into segments which limits the penetration. Accordingly, to obtain significant depth of penetration, the mass of the bullet must remain behind the head.
 
Hollow point jacketed bullets are well known and are typically made of a lead alloy with a jacket typically made of a copper alloy. The jacket generally covers at least part of the nose or ogive and all of the cylindrical body portions of the bullet. Expansion is obtained by providing a hollow in the front end of the bullet. This type of jacketed bullet produces controlled expansion in soft body tissue. The front end may also be formed with cuts and/or ribs in the jacket or with cuts or ribs in the core within the hollow tip to further control the expansion upon penetration into soft tissue. One typical hollow point jacketed bullet is described in U.S. Pat. No. 3,157,137. A jacketed bullet with a rosette type of hollow point formed entirely from the open jacket end is disclosed. Another is U.S. Pat. No. 3,349,711 describes a bullet which has external cuts in the ogive portion of the full metal jacket around the hollow tip. Another example is U.S. Pat. No. 4,550,662, in which is discussed a bullet where the hollow tip is formed with axially extending ribs in the soft metal core. Another hollow point jacketed bullet, using aluminum for the jacket, is disclosed in U.S. Pat. No. 4,610,061. In this patent, the jacket extends part way into the hollow and cuts are made in the jacket at the rim of the hollow point to control deformation and ripping of the jacket during expansion. All of the bullets provide relatively predictable expansion in soft tissue, and all are fabricated employing similar techniques; a hollow cavity is formed in a lead core which is seated in a thin metal cup or jacket.
 
The fabrication of a bullet with controlled expansion employing non-lead materials is not trivial. Functional hollow point bullets are being fabricated from copper; however, ballistic performance suffers due to the lower density of the copper as compared to lead. A hollow-point made using the plastic-bonded powder metal composite materials does not expand, but instead fragments in a soft target. Jacketed bullets are also being fabricated from bismuth and zinc; however, hollow-point or expanding bullets are not described.
 
Hollow-point bullets fabricated from mixtures of tin and tungsten or zinc and tungsten employing a sinterless powder metallurgy technique following U.S. Pat. No. 5,760,331, herein incorporated by reference, were found to fragment. This bullet, the fragmentation is undesirable for penetration is minimized and because of forensic and medical concerns. A process to produce a powder metal hunting bullet with a hollow point is described in U.S. Pat. No. 5,722,035. The disclosed embodiment was made from copper or mixtures of copper and tungsten powders, and was pressed and sintered. The performance characteristics of the materials and bullet were not discussed.
 
No-lead, full-metal jacket and hollow-point bullets are described in foreign patent WO9720185, and details a pistol bullet with a two-piece core, made using two separate materials with different properties. The first portion or segment fills the base of the bullet, and the second piece fills the nose. The first portion is hard and possibly frangible, with materials such as sintered powdered metals or plastic-bonded metals being examples of possible materials. The second is soft and ductile as to permit mushrooming. Emphasis for the nose is placed on zinc or aluminum. A hollow-point with the cavity in the softer nose section is included. The construction of the HP bullets resembles the first unsuccessful version of the bullets described in this invention. Gluing the cores together reportedly solves the problem of separation of the first and second portion of the bullet core. No teaching of shaping the cores during seating to prevent separation and enhance expansion is provided. Construction of HP bullets resembling the examples given in WO9720185 was unsuccessful.
 
A two-component core has been described for use in a soft-point rifle bullet for hunting (Brenneke TIG or TUG), but involved lead alloys with differing properties. In U.S. Pat. Nos. 5,237,930 and 5,616,642, and similar technologies, powdered metals are mixed with polymer binders, typically nylon. Bullets are formed by melting and molding of the plastic-metal mixture. Although hollow cavities are readily formed in a bullet fabricated from the materials, the plastic-metal composite does not expand. The composite is frangible thus fragments into particles. In addition the density of the polymer-metal composites is less than that of lead thus bullets made from these materials are atypical in size when trying to match the weights of similar designs.
 
Solid copper hollow-point bullets are described in U.S. Pat. Nos. 5,811,723 and 5,259,320. Annealed copper is soft and through combinations of hollow cavities, slots and grooves, expansion can be achieved. The density of copper however, is 8.9 g/cm3 which again results in bullets that are either lighter than those made with lead or atypical in size.
 
Bismuth and zinc have been used to fabricate bullets in U.S. Pat. Nos. 5,852,255 and 5,535,678 but no hollow-point are described. As with copper the densities for these metals, 9.8 and 7.1 g/cm3, respectively are lower than lead. Also, these metals are not as ductile as copper or lead. It would be expected that HP bullets made from these metals would be brittle and therefore fragment upon impact.
 
In prior lead hollow-point bullet designs, the hollow-point cavity in the lead core or in a combination of a jacket and the core is formed with a number of sharp corners or with a plurality of radial slits. In these prior designs, a punch with a polygonal shape is used instead with a smooth tapered (preferred conical) shape is used. This produces sharp edges within the cavity which enhances failure along these distinct lines. This permits better control of expansion or “petaling” of the nose of the bullet. This technique was used to produce the cavity in examples fabricated in the aforementioned non-lead bullets. When test fired into 10% ballistic gelatin, the hollow-points expanded and petaled along the radial slits.
 
The alteration of weight distribution to improve accuracy is described in U.S. Pat. No. 4,517,898 and includes a description of a simple, truncated-cone, hollow-point bullet or a bullet with layers of materials within the core with varying densities.
 
Bullets made during development of the instant invention were fabricated employing tin in the nose section and a powder metal product in the base. Upon firing from a pistol at 900-1300 ft/sec into 10% ballistic gelatin at a distance of 5-10 yards, the soft metal insert in the nose of the bullet expanded and split, and then separated from the base of the assembly. The powder metal core in the base of the bullet was exposed, and then fragmented and dispersed throughout the gelatin. This separation was noted to be unacceptable and although variations upon this theme were attempted, the problem of separation of the first and second portions of the bullet core could not be solved. Modifications to the procedure and designs were required to prevent separation of the core segments.
 
hollow point bullets

Molding Pressure Effect on Tungsten Copper Composite Materials

Except powder granularity, the molding pressure is also one of main influencing factors of tungsten copper composite materials density. The experiments show that with the increasing molding pressure, the density of sintered blank is increasing. On the one hand, it due to the increasing pressure promotes the densification in the third stage of the compaction, that is when the pressure exceeds a certain value continues to increase, if it continues to increase pressure on the powder by the pressing force and the frictional force is greater than the elastic stress. Particles have plastic deformation and fill in the gap of powder, which will further increase the density; on the other hand, due to nano-crystalline copper particles themselves have a very large surface free energy, if the pressing pressure is further increased, the copper particles are plastically deformed again, i.e., the copper particle surface free energy is further increased to further reduce the melting point, which make it infiltrate tungsten particle at low temperature and promote the densification process.

In addition, it is inevitable that copper evaporation in the process of tungsten copper manufacturing. The researcher found that when the particle size of Cu grain reaches nano scale, it will be volatile at 450℃. So under the optimum holding temperature of 1350℃, Cu phase will be easily consumed by evaporation. since tungsten copper material is a versatile material, after copper volatile, not only because of the disappearance of the binder phase becomes loose, reduce the density and strength of the material, it will make the physical as well as electrical and thermal conductivity coefficient of linear expansion and other materials significant performance degradation. There is an experiment uses two kinds of pressure 300MPa and 800MPa pressed found that with the increase of molding pressure, the material density increased wettability of liquid copper has been significantly improved, while the loss of copper in the case of the high temperature phase has also been in control. This is due to:

1. Increasing molding temperature reduces the spacing of W grains and improves the strength of W skeleton, which also make it difficult to form a copper material inside the material loss of external channels, slow volatile speed of copper particles within the material;
2. Large molding pressure increases the surface contact area of the copper, so that the original surface free energy with increase in the melting process of the copper particles and copper particles easier contact between adjacent and fused together to form larger particles, thereby reducing the fine particles volatile chance of high temperature phase, maintaining the stability of copper content.

tungsten copper contacts

 

Powder Granularity Effect on Tungsten Copper Composite Materials

Tungsten copper composite materials not only have advantages of W, such as high hardness, high strength, high density, low coefficient of thermal expansion and excellent wear and corrosion resistance, but also have good plasticity and excellent thermal and electrical conductivity of Cu, which have been widely used in electronic industry, high-temperature resistant devices fields. But there is a big difference in melting point and physical properties between W and Cu, and they are immiscible. So it makes tungsten copper composite material preparation process simpler, commonly used PM (Powder Metallurgy) process, which limits the rang of applications. Therefore, we through analyzing powder granularity effect on the density of tungsten copper composite materials, optimizing the sintering process, the properties will be further promoted.

Take mass ratio of 85% of tungsten copper composite material manufacture as example, the particle size of not more than 1.0μm nano-crystalline copper with particle size of not more than 0.8μm nano-crystalline tungsten powder mass ratio of 85:15 were mixed in a ball mill planetary, milling medium is ethanol. After ball milling, take powder and dried in a vacuum glove box under Ar protection; after drying, pressed and vacuum sintered. Viewed from SEM image, with increasing milling time, the granularity of powder reduced and the degree of mixing and mechanical alloying of the number of particles has been significantly increased. Although tungsten particle has high hardness, sharp edge portion is worn continuously, and shape gradually becomes more regular ball; Copper particles are constantly impact occurs between the ball, the tank and the tungsten particles, grinding and tearing, particle size becomes smaller. So the mutual attraction between particles become greater, the rearrangement faster. In addition, small powder size, large surface area, surface activity and lattice activity also increased, which is beneficial for sintering process and improving the density and structure of tungsten copper composite materials.

tungsten copper plates

 

Tungsten Oxide in Inverted Polymer Solar Cell

Interest in solar cells to capture sunlight and generate electricity is increasing due to oil energy crisis and rising concerns over global climate change. Inorganic solar cells can yield high power conversion efficiency but the expensive fabrication process makes them infeasible in common use. Instead, polymer solar cells PSCs are a good candidate because semiconducting polymers can be dissolved in common solvents and printed like inks so that economical roll-in-roll fabrication process can be realized. The photoactive layer composed of electron donating and accepting materials absorbs light and generates excitons. Then electrons and holes can be efficiently separated from each other due to the nanometer-scale interpenetrating network of electron donor and acceptor within the whole photoactive layer.3 However, a simple structure that sandwiched the photoactive layer between two electrodes anode and cathode is not perfect enough. The low efficiency of charge collection at the interface between the photoactive layer and electrodes results in poor performance of PSCs.4 In order to solve this problem, interfacial layers, such as a combination of poly-ethylenedioxythiophene: polystyrenesulfonate and lithium fluoride LiF, are commonly introduced between the active layer and electrodes to improve charge carrier collection and to enhance the open-circuit voltage.

WO3 Solar Cell Structure

Nevertheless, PEDOT: PSS has been demonstrated to have a side effect on the performance of PSCs due to its corrosion to indium tin oxide ITO and electrical inhomogeneities. In order to overcome this problem, one might simply introduce interfacial layer materials to improve the performance of PSCs. Recently, molybdenum oxide MoO3, vanadium oxide V2O5, and nickel oxide NiO have been demonstrated to effectively substitute PEDOT:PSS as the anodic buffer layer in PSCs. An alternative approach is to reverse the device architecture and hence to form inverted PSCs, in which MoO3 and V2O5 were usually inserted between the active layer and top electrode.

In this letter, we introduce a low-cost, nontoxitoxic, and easily evaporable tungsten oxide WO3 as a hole extraction layer in inverted PSCs with nano crystalline titanium dioxide nc-TiO2 as an electron selective layer. The device architecture is shown schematically in Fig. 1 a. and the energy level diagrams of different materials used in the device fabrication are shown in Fig. 1b. Meanwhile, transparent inverted PSCs are fabricated with thermally evaporable Ag13 nm/WO340 nm as a transparent anode when introducing a 10 nm WO3 buffer layer. After a cleaning step, TiO2-sol was spin coated on ITO-coated glass substrates at 3000 rpm. Then the samples were moved to a muffle furnace and annealed at 450 °C for 2 h. After annealing treatment, nc-TiO2 was formed. In this letter, poly3-hexylthiophene P3HT Rieke Metals was used as electron donor material, and -phenyl C61 butyric acid methyl ester PCBM Solenne BV was used as electron acceptor material. The mixed chlorobenzene solution composing of P3HT 10 mg/ml and PCBM 8 mg/ml was then spin coated on top of the nc-TiO2 layer at 700 rpm in ambient air. Then the samples were heated in low vacuum oven at approximately 150 °C for 10 min. Subsequently, the samples were pumped down in vacuum 10−3 Pa. Finally WO3 and 60 nm top electrode Ag, Au, and Al were thermally evaporated in sequence. The active area of the device was about 0.064 cm2 .

WO3 Solar Cell Curve

In summary, we have explored the use of WO3 in inverted polymer solar cells. Due to the high work function 4.8 eV, WO3 efficiently extracts holes and suppresses electrons from the active layer. The thicknesses of WO3 and different top metal electrodes on device performances are also investigated. Transparent inverted PSCs are fabricated with Ag13 nm/WO3 40 nm as a transparent top electrode when introducing a 10 nm WO3 buffer layer, which have the potential to realize a multiple device structure to absorb more solar photons by the multiple photoactive layers to achieve high device performance.

Tungsten Powder and Acoustic Sensor

The use of acoustic (e.g., ultrasonic) measurement systems in prior art downhole applications, such as logging while drilling (LWD), measurement while drilling (MWD), and wireline logging applications is well known. In known systems an acoustic sensor, typically with a substantially homogenous piezo-ceramic structure on board, operates in a pulse-echo mode in which it is utilized to both send and receive a pressure pulse in the drilling fluid (also referred to herein as drilling mud). In use, an electrical drive voltage (e.g., a square wave pulse) is applied to the transducer, which vibrates the surface thereof and launches a pressure pulse into the drilling fluid. A portion of the ultrasonic energy is typically reflected at the drilling fluid/borehole wall interface back to the transducer, which induces an electrical response therein. Various characteristics of the borehole, such as borehole diameter and measurement eccentricity and drilling fluid properties, may be inferred utilizing such ultrasonic measurements. 
 
While prior art acoustic sensors have been used in various downhole applications (as described in the previously cited U.S. Patents), their use, particularly in logging while drilling (LWD) and measurement while drilling (MWD) applications, tends to be limited by various factors. As used in the art, there is not always a clear distinction between the terms LWD and MWD, however, MWD typically refers to measurements taken for the purpose of drilling the well (e.g., navigation) whereas LWD typically refers to measurement taken for the purpose of analysis of the formation and surrounding borehole conditions. Nevertheless, these terms are hereafter used synonymously and interchangeably.
 
sensors
 
The present invention addresses one or more of the above-described drawbacks of prior art acoustic sensors used in downhole applications. Referring briefly to the accompanying figures, aspects of this invention include a downhole tool including at least one acoustic sensor having a piezo-composite transducer. The piezo-composite transducer may be configured, for example, to withstand demanding downhole environmental conditions. Various exemplary embodiments of the acoustic sensor further include a matching layer assembly for substantially matching the acoustic impedance of the piezo-composite transducer with that of the drilling fluid and for providing mechanical protection for the transducer and/or a backing layer for substantially attenuating ultrasonic energy reflected back into the acoustic sensor. Exemplary embodiments of the downhole tool of this invention include three acoustic sensors disposed substantially equidistantly around the periphery of the tool.
 
Exemplary embodiments of the present invention advantageously provide several technical advantages. Various embodiments of the acoustic sensor of this invention may withstand the extreme temperatures, pressures, and mechanical shocks frequent in downhole environments. Tools embodying this invention may thus display improved reliability as a result of the improved robustness to the downhole environment. Exemplary embodiments of this invention may further advantageously improve the signal to noise ratio of downhole acoustic measurements and thereby improve the sensitivity and utility of such measurements.
 
In one aspect the present invention includes a downhole measurement tool. The downhole measurement tool includes a substantially cylindrical tool body having a cylindrical axis. The tool further includes at least one acoustic sensor deployed on the tool body, the acoustic sensor including a piezo-composite transducer element with anterior and posterior faces. The piezo-composite transducer is in electrical communication with an electronic control module via conductive electrodes disposed on each of the faces. The piezo-composite transducer element includes regions of piezoelectric material deployed in a matrix of a substantially non piezoelectric material, the regions extending through a thickness of the transducer element in at least one dimension. In exemplary variations of this aspect, the acoustic sensor includes a laminate having a composite backing layer, at least one matching layer, and a barrier layer deployed at an outermost surface of the acoustic sensor.
 
In another aspect, this invention includes an acoustic sensor having a piezo-composite transducer element. Further aspects of this invention include a method for fabricating a downhole measurement tool and a method for fabricating an acoustic sensor.
 
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the 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 invention. It should be also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
 
Exemplary backing layers may also include substantially any suitable powder material, such as tungsten powers, tantalum powders, and/or various ceramic powders. In one useful embodiment, tungsten powders having a bimodal particle size distribution may be utilized. For example, one exemplary backing layer includes a mixture of C-8 and C-60 tungsten powders. The particle size of C8 is in the range from about 2 to about 4 microns while the particle size of C60 is in the range from about 10 to about 18 microns. 
 
sensors

Tungsten Trioxide Photocatalyst for Ocean Oil Pollution Treatment

In recent years, frequent oil spills at sea and nuclear incidents have caused serious pollution on the human environment; furthermore, these pollutants are difficult to remove in a short time. An offshore drilling platform of British Petroleum (BP) in the Gulf of Mexico exploded in 2010, causing 11 deaths of the workers, resulting in a large number of oil spilt to the sea; According to media reports at the time, the oil leak in the Gulf of Mexico last for a few months, resulting in the death of wild animals, beach being contaminated, and accompanied by secondary effects of the oil spill. The viscosity of the oil determines once it leaking out from tankers and offshore drilling rig, the removal from marine plants and animals is very difficult. Therefore, to find a way to quickly remove and degrade oil leakage is essential for the protection of the marine environment, and marine oil pollution control has become one of the world’s common concern.

tungsten trioxide and ocean oil pollution
 
For taking full advantage of solar energy, scientists coupled the titanium dioxide particles to the hollow glass microspheres which the density is much smaller than that of water by coupling agent of Silane, to form the titanium dioxide photocatalyst which can float on the surface water; also, they studied its photocatalytic decomposition of organic pollutants film on the water and obtained satisfactory results. Although, there has no yet the reports for the study of the tungsten trioxide in the oil pollution control, but I believe  that if will be in the future, because the tungsten trioxide is a photocatalyst which has the better photocatalytic effect of titanium dioxide; and moreover, ultrafine tungsten trioxide powder has a very broad application in catalysis prospects.
 
Tungsten trioxide (WO3), yellow tungsten oxide powder, not only has the properties of photochromic, gas sensing, but also has good catalytic function, and being an important radiation shielding material at the same time. Band gap of tungsten trioxide is 2.4eV ~ 2.8eV, which means that it can take full advantage of sunlight; in addition, WO3 itself has no toxicity, as a photocatalyst, if the technical support was supported, it will degrade the ocean oil pollution and make an important contribution to the marine environmental government, if with appropriate.

 

Tungsten Carbide Hob Description

Tungsten carbide hob is composed of the hard phase WC and the binder phase Co, its edges helically arranged along cylinder or cone to manufacture cutting tools, which has been widely used in cylindrical gears, worm and other toothed cylindrical workpieces fabricating. According to different applications, tungsten carbide hob can be specifically divided into gear hobs, worm hobs, fixed mounted hobs, non-involute hobs and so on. Compared with common high-speed steel hobs, tungsten carbide hobs have better performance in cutting rate and button efficiency. Solid tungsten carbide hob has been widely used in watches and some of the precision instrument manufacturing industry, such as processing a variety of small module gear; medium modulus solid carbide hob and panels have been used for machining cast iron and bakelite gear; modulus < 3 tungsten carbide hob is also used in steel gear manufacturing; in addition, tungsten carbide hob is also can be used for fabricating hardened wheel (HRC50-62).

Tungsten carbide worm hob is a kind of special tool for worm manufacturing. Its main transmission type and basic parameters of the worm (including module, pressure angle, helix angle, pitch diameter, number of thread, etc.) should work with the same worm. When the worm is large in outer diameter, shaft-mounted hob can be made; when the worm is small in outer diameter, the hob can be made integral with the mandrel shank-type structure. Tungsten carbide fixed mounted hob has different profiles, which only the last one button is the precise button. Gullet button and forming a workpiece identical to alveolar milling method of cutting a workpiece, the rest of the button are for rough cutting and the movements is as same as the gear hob. In addition, forming hob can effectively avoid the exhibition to the transition curve tooling generated the root, especially the ratchet hob. The mechanism of non-involute hob is similar to the gear hob, such as spline hob can be used for processing rectangular teeth, involute or triangular tooth spline shaft, which has better machining precision and efficiency than forming cutters. And it also can be used for arc gears, cycloid gears and sprockets manufacturing. 

tungsten carbide hob

 

 

WeChat