LIGHT WEIGHT CEMENTED CARBIDE GRADE WITH IMPROVED MECHANICAL PROPERTIES FIELD OF THE DISCLOSURE [0001] The present disclosure relates to low weight cemented carbide punches for manufacturing metal beverage cans, and to associated methods for producing such low weight cemented carbide punches. BACKGROUND [0002] The can industry is continuously evolving, and about 400 billion cans are produced every year world-wide. A single production-line can manufacture up to 800,000,000 cans per year in a continuous process from, for example, an aluminum, or a steel strip. [0003] The body of a two-piece can is manufactured by a drawing, redrawing, and a wall ironing process. The body of a two-piece can is typically manufactured involving a process by first stamping out metal discs from a metal plate. Next, a metal cup is formed from the cut metal discs. A high-quality metal can body begins with a good metal cup. The successful production of defect-free cups starts with a proper tool design that accounts for an adequate clearance between the tools, known as match gaps. The formed metal cup is pushed through a can-forming ironing die having a plurality of annular rings, which is referred in the art as drawing, or redrawing the metal cup. The clearance between the can-forming punch, and the plurality of annular rings progressively become smaller, such that the thickness of the cup-wall is reduced, and the metal cup is elongated. This operation is generally known as the wall ironing process. As an example, further detailing the foregoing process, the cup which is pressed from the metal plate is formed into a can-body in one continuous punch-stroke in typically about one fifth of a second. This forms the inside diameter of the can of approximately 66 millimeters (mm), which is followed by increasing the height of the can from about 33 mm to 57 mm, and then stretching the wall to about 130 mm high before forming a concave dome at the lower base of the can.
[0004] This is a particularly multi-step demanding operation, which causes a high wear and tear on the tools applied in the can-forming process, and the operation is especially sensitive to the dimensional changes, as well as lubrication conditions. Because the can industry is intensively growing with a significant amount of beverage cans being manufactured each year, optimizations in the manufacturing process of each step are continuously sought out. This can potentially deliver significant savings to the overall can manufacturing process. [0005] Tools for imparting a desired shape, form, or finish to a material, such as ironing dies, can forming punches, and the like, are ideally characterized by demonstrating a favorably good hardness, fracture toughness, compressive strength, and stiffness. This is particularly necessary when shaping beverage cans constructed from metals, or from such equivalent materials. Commercially applicable punches, and dies for mass production of beverage cans should ideally also be resistant to wear and tear, and chipping from the repeated and continuous stress, and abrasion imparting process steps. Moreover, these tools should also demonstrate a good corrosion-resistance, in order not to be damaged by the surrounding corrosive liquid media (i.e., coolant/lubricant). [0006] Still other requirements are further of great importance for operating punching tools exhibiting a desired functionality. As the punching tools move rapidly, any reduction of the weight of the punching tools will result in significant improvements with respect to the cost, and the lifetime of the punching tools. Indeed, if the punching tools are lighter having a lower density, much less energy would be required to run the overall process, and the bending of the ram would be reduced. This effect would deliver a much better alignment of the punch within the tool-pack, and less damages would be propagated to the ironing dies. Thus, both the punch, and the ironing dies would be less damaged during the process due to reduction of the bending effect imparted on the ram. [0007] Thus, with the above in mind, it is clear that there is a need for low weight cemented carbide punches in the manufacturing of metal beverage cans, and this disclosure thus fulfills such a need.
SUMMARY [0008] Provided is a low weight punch for manufacturing of metal beverage cans with a sintered cemented carbide punch composition including a carbide hard phase having tungsten carbide (WC) in an amount of from about 67 weight percent (wt.%) to about 76 wt.% based on a total weight of the sintered cemented carbide punch composition, and a gamma phase having at least titanium (Ti) and niobium (Nb) as gamma phase constituents in an amount of from about 10 wt.% to about 17 wt.% based on a total weight of the sintered cemented carbide punch composition. The cemented carbide punch composition further includes a binder phase including at least cobalt (Co) and chromium (Cr) in an amount of from about 12 wt.% to about 13 wt.% based on a total weight of the sintered cemented carbide punch composition, and a balance of carbon. [0009] Optionally, the HV30 Vickers hardness of the sintered cemented carbide punch composition ranges from about 1520 HV30 to about 1570 HV30. [0010] Optionally, the fracture toughness of the sintered cemented carbide punch composition ranges from about 10.2 MPa √m to about 10.6 MPa √m. [0011] Optionally, the density of the sintered cemented carbide punch composition ranges from about 11.2 g/cm3 to about 12.5 g/cm3. [0012] Optionally, the WC has a grain size when sintered from about 0.3 µm to about 0.8 µm. [0013] Optionally, the gamma phase constituents have a grain size when sintered from about 0.85 µm to about 1.65 µm. [0014] Also provided is a method of manufacturing of metal beverage cans comprising using a sintered punch with a cemented carbide composition in a drawing or a wall ironing operation, thus forming the metal beverage cans. The sintered cemented carbide punch composition includes a carbide hard phase having WC in an amount of from about 67 wt.% to about 76 wt.% based on a total weight of the sintered cemented carbide punch composition, and a gamma phase including at least Ti and Nb as gamma
phase constituents in an amount of from about 10 wt.% to about 17 wt.% based on a total weight of the sintered cemented carbide punch composition. The cemented carbide punch composition further includes a binder phase including at least Co and Cr in an amount of from about 12 wt.% to about 13 wt.% based on a total weight of the sintered cemented carbide punch composition, and a balance of carbon. [0015] Other systems, features and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, features and advantages be included within this description, be within the scope of the present disclosure, and be protected by the following claims. Nothing in this section should be taken as a limitation on those claims. Further aspects and advantages are discussed below in conjunction with the examples of the disclosure. It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are examples and explanatory and are intended to provide further explanation of the disclosure as claimed. BRIEF DESCRIPTION OF THE DRAWINGS [0016] The accompanying drawings, which are included to provide a further understanding of the subject matter and are incorporated in and constitute a part of this specification, illustrate implementations of the subject matter and together with the description serve to explain the principles of the disclosure. [0017] FIG. 1 is a flow diagram showing the individual steps in spray-drying by atomization in the preparation of low weight cemented carbide punch samples in accordance with the present subject matter. [0018] FIG. 2A shows the hardness (HV30) as a function of the density of different low weight cemented carbide punch compositions, and a reference material having the composition 78.41 wt.% WC, 4.00 wt.% TiC, 5.87 wt.% NbC, 11.22 wt.% Co, and 0.50 wt.% Cr3C2 in accordance with the present subject matter.
[0019] FIG. 2B shows the fracture toughness (KIc) as a function of the density of different low weight cemented carbide punch compositions, and a reference material having the composition 78.41 wt.% WC, 4.00 wt.% TiC, 5.87 wt.% NbC, 11.22 wt.% Co, and 0.50 wt.% Cr3C2 in accordance with the present subject matter. DETAILED DESCRIPTION [0020] Unless defined otherwise all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently described subject matter pertains. [0021] Where a range of values is provided, for example, concentration ranges, percentage ranges, or ratio ranges, it is understood that each intervening value, to the tenth of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the described subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and such examples are also encompassed within the described subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the described subject matter. [0022] The following definitions set forth the parameters of the described subject matter. [0023] As used herein, the terms “about” and “close” refer to plus or minus 5% of the numerical value of the number with which it is being used in the claims and herein this disclosure. Thus, “about” may be used to provide flexibility to a numerical range endpoint, in which, a given value may be “above” or “below” the given value. As such, for example a value of 50% may be intended to encompass a range, which may be defined by for example ranges like 47.5%-52.25%, 47.5%-52.5%, 47.75%-50%, 50%-52.5%, 48%- 48.5%, 48%-48.75%, 48%-49%, 48%-49.5%, 48%-49.75%, 48%-50%, 48%-50.25%, 48%-50.5%, 48%-50.75%, 48%-51%, 48%-51.5%, 48%-51.75%, 48%-52%, 48%-
52.25%, 48%-52.5%, 48.25%-48.5%, 48.25%-48.75%, 48.25%-49%, 48.25%-49.5%, 48.25%-49.75%, 48.25%-50%, 48.25%-50.25%, 48.25%-50.5%, 48.25%-50.75%, 48.25%-51%, 48.25%-51.25%, 48.25%-51.5%, 48.25%-51.75%, 48.25%-52%, 48.25%- 52.25%, 48.25%-52.5%, 48.5%-48.75%, 48.5%-49%, 48.5%-49.5%, 48.5%-49.75%, 48.5%-50%, 48.5%-50.25%, 48.5%-50.5%, 48.5%-50.75%, 48.5%-51%, 48.5%-51.25%, 48.5%-51.5%, 48.5%-51.75%, 48.5%-52%, 48.5%-52.25%, 48.5%-52.5%, 49%-49.25%, 49%-49.5%, 49%-49.75%, 49%-50%, 49%-50.25%, 49%-50.5%, 49%-50.75%, 49%- 51%, 49%-51.25%, 49%-51.5%, 49%-51.75%, 49%-52%, 49%-52.25%, 49%-52.5% 49.5%-49.75%, 49.5%-50%, 49.5%-50.25%, 49.5%-50.5%, 49.5%-50.75%, 49.5%-51%, 49.5%-51.5%, 49.5%-51.75%, 49.5%-52%, 49.5%-52.25%, 49.5%-52.5%, 49.75%-50%, 49.75%-50.25%, 49.75%-50.5%, 49.75%-50.75%, 49.75%-51%, 49.75%-51.25%, 49.75%-51.5%, 49.75%-51.75%, 49.75%-52%, 49.75%-52.25%, 49.75%-52.5%, 50%- 50.25%, 50%-50.5%, 50%-50.75%, 50%-51%, 50%-51.25%, 50%-51.5%, 50%-52%, 50%-52.25%, 50%-52.5% etc. As used herein this disclosure, the term “predominantly” is meant to encompass at least 95% of a given entity. [0024] As used herein, the terms “ambient condition” and “room temperature” refer to 25ºC, 298.15 K at a pressure of 101.325 kPa (1.01325 bar). [0025] As used herein, the terms “depegged” and “dewaxed” are used interchangeably with one another. [0026] As used herein, the term “fracture toughness” i.e., (KIc), refers to the ability of a material with pre-cracks to resist further crack propagation upon absorbing energy. Fracture toughness (KIc) is calculated according to: where A is a constant of 0.0028, HV is the hardness (N/mm2), P is the
applied load (N) and ΣL is the sum of crack lengths (mm) of imprints. [0027] As used herein, “gamma phase” refers to a phase constituted of metal carbides, optionally metal nitrides, and/or optionally metal carbonitrides, which is advantageous for grain refinement of the gamma phase with respect to the hard WC containing phase. Optionally, nitrogen may be added in the form Me(C, N), where Me is
any one of or a combination of Ti, Ta, V, Nb, Zr, Hf, W, Mo, Cr. Optionally, the metal carbides, the metal nitrides, and/or the metal carbonitrides may include anyone, or a combination of Ti, Ta, V, Nb, Zr, Hf, thus forming the gamma phase. Optionally, the cemented carbide may include TiC, NbC, TaC, and/or TiCN, thus forming the gamma phase. In particular, the gamma phase of the cemented carbide may include a cubic mixed carbide such as e.g., (Ti, Ta, Nb, W)C. Such a composition is advantageous in order to improve the strength, the fracture toughness, and the wear resistance, and in turn, may provide better performance as a tool for metal forming, processing, and/or machining. Some grains of the gamma phase may be richer in one particular chemical element, while some other grains of the gamma phase may have a greater amount of a combination of other chemical elements. Moreover, it is also possible to have a core-rim structure in the gamma phase indicating the formation of a gradient of chemical elements in a given grain of the gamma phase. [0028] Wherever used throughout the disclosure, the term “generally” has the meaning of “approximately”, “typically” or “closely” or “within the vicinity or range of”. [0029] As used herein, the term “green body” refers to a material being in the form of a compacted powder, or compacted plates, before the material has physically been sintered. [0030] As used herein, the term “HV30 Vickers hardness” (i.e., applying a 30 kgf load) is a measure of the resistance of a sample to localized plastic deformation, which is obtained by indenting the sample with a Vickers tip at 30 kgf. [0031] As used herein, the terms “ironing die” or simply “die”, which is used interchangeably, and “punch” refer to specialized tools used in manufacturing industries, in order to form a material into a desired shape. [0032] As used herein, the ISO 28079-2009 standard specifies a method for measuring the fracture toughness and the hardness of hardmetals, cermets and cemented carbides at room temperature by an indentation method. The ISO 28079-2009 standard applies to a measurement of the fracture toughness, and the hardness
calculated by using the diagonal lengths of indentations and cracks emanating from the corners of a Vickers hardness indentation, and it is intended for use with metal-bonded carbides and carbonitrides (e.g., hardmetals, cermets or cemented carbides). The test procedures proposed in the ISO 28079-2009 standard are intended for use at ambient temperatures but can be extended to higher or lower temperatures by agreement. The test procedures proposed in the ISO 28079-2009 standard are also intended for use in a normal laboratory-air environment. They are typically not intended for use in corrosive environments, such as strong acids or seawater. The ISO 28079-2009 standard is directly comparable to the standard ASTM B771 as disclosed for example in “Comprehensive Hard Materials book”, 2014, Elsevier Ltd. Page 312. Thus, it can be assumed that the measured fracture toughness and the hardness using the ISO 28079- 2009 standard will be the same as the measured values employing the ASTM B771 standard. [0033] As used herein, the term “low weight” refers to any density typically spanning a density range of from about 11.2 g/cm3 to about 12.5 g/cm3, such as e.g., from about 11.2 g/cm3 to about 11.4 g/cm3, from about 11.4 g/cm3 to about 11.6 g/cm3, from about 11.6 g/cm3 to about 11.8 g/cm3, from about 11.2 g/cm3 to about 11.6 g/cm3, from about 11.2 g/cm3 to about 11.8 g/cm3, from about 11.2 g/cm3 to about 12.0 g/cm3, from about 11.2 g/cm3 to about 12.2 g/cm3, from about 11.8 g/cm3 to about 12.0 g/cm3, from about 12.0 g/cm3 to about 12.2 g/cm3, from about 12.2 g/cm3 to about 12.5 g/cm3 , from about 11.4 g/cm3 to about 12.5 g/cm3, from about 11.6 g/cm3 to about 12.5 g/cm3, from about 11.8 g/cm3 to about 12.5 g/cm3, from about 12.0 g/cm3 to about 12.5 g/cm3, from about 12.2 g/cm3 to about 12.5 g/cm3, or from about 12.4 g/cm3 to about 12.5 g/cm3. [0034] As used herein, the term “sintering” refers to a process, where heating under a controlled pressure is conducted to minimize the surface area of a particulate system, which is associated with generation of bonds between neighboring small particles or granules, and subsequent shrinkage of the aggregated particles or granules. Densifying a dense solid bulk mass is performed by heating the particles under a controlled pressure.
[0035] As used herein, the term “particle” refers to a discrete body or bodies. [0036] As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. [0037] As used herein, “spherical” refers to the grains having a substantially “round” shape. [0038] The sidewall of the body of a metal beverage can may usually have two different thicknesses. In the lower and the mid area section, a mid wall thickness is present, which is also commonly referred to as the ‘thin wall’, because it is the thinnest wall of the entire can body. In the upper area section, a top wall thickness is present, which is also called the ‘thick wall’, because it is thicker than the mid wall. The main reason is that, an overall thicker thickness is needed in the upper area section for the subsequent necking process to take place. Otherwise, the necking forming process cannot be accomplished successfully. [0039] The transition between the thin wall and the top wall is controlled by the step on the punch. The deeper the step, the higher the difference between the thin wall and the top wall. A typical step value is about 0.0020" (0.05 mm). [0040] For a successful necking process to occur, it is important to have a homogeneous thickness in the top wall area section reaching all the way around the circumference of the can. As used herein, the variation between the thinnest section and the thickest section in the top wall is commonly referred to as the “can top wall thickness variation.” [0041] As used herein, the term “vacuum” refers to a free space, which is devoid of any physical matter. As used herein, the term “vacuum” is a region with a gaseous pressure, which is significantly less than atmospheric pressure under ambient conditions, i.e. at a temperature of 25º C, 298.15 K, and a pressure of 101.325 kPa (1.01325 bar).
[0042] As used herein, unless specifically stated otherwise, “wt.%” refers to a given weight percent of the total weight of a batch of powdered materials of a cemented carbide composition to form a low weight punch in the manufacturing of metal beverage cans. To give a total 100 wt.%, unless specified otherwise, carbon may be used as a base in the sintered cemented carbide punch composition. Low weight cemented carbide punches for manufacturing metal beverage cans [0043] The current disclosure relates to novel low weight cemented carbides for producing punches in the manufacturing of metal beverage cans. Thus, the use of a lighter punching tool for can-makers is logically of great interest, as it will potentially help the can-makers reduce the bodymaker maintenance and setup. Further, it will improve the can-wall thickness consistency, which is especially critical when downgauging metal, i.e., reducing the aluminum thickness to reduce the can weight and therefore the aluminum consumption. Lastly, it will reduce the energy consumption per produced can. Reduction of the cemented carbide density may potentially be achieved ideally by way of increasing the ductile soft metallic binder phase, or by adding cubic carbides such as e.g., niobium carbide (NbC), i.e., thus forming a gamma phase. By specifically adopting this strategy, the density has significantly been decreased below 12.6 g/cm3, which is the density characterized by the used reference cemented carbide material. A density optimum range has been discovered particularly spanning a range of from about 11.2 g/cm3 to about 12.5 g/cm3, where both the HV30 Vickers hardness, and the fracture toughness have surprisingly been robustly maintained. Targeting a balance of a low density for the cemented carbides forming the punches disclosed herein, while maintaining a good hardness together with a good fracture toughness simultaneously is surprising. [0044] Thus, especially in a density range spanning from about 11.2 g/cm3 to about 12.5 g/cm3, the disclosure overcomes previous inherent limitations in the art characterized by the notion, that increasing the amount of the soft ductile binder content will decrease the HV30 Vickers hardness, and increasing the gamma phase content by
adding cubic carbides will promote fragility and embrittlement in the material, and thus decrease the fracture toughness. [0045] The carbide hard phase of the cemented carbide composition forming the low weight punch may typically include WC in an amount of from about 59 weight percent (wt.%) to about 76 wt.% based on a total amount of the cemented carbide composition. In some examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes WC in an amount of from about 62 wt.% to about 76 wt.% based on a total amount of the cemented carbide composition. In other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes WC in an amount of from about 65 wt.% to about 76 wt.% based on a total amount of the cemented carbide composition. In still other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes WC in an amount of from about 68 wt.% to about 76 wt.% based on a total amount of the cemented carbide composition. In yet other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes WC in an amount of from about 71 wt.% to about 76 wt.% based on a total amount of the cemented carbide composition. In even other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes WC in an amount of from about 74 wt.% to about 76 wt.% based on a total amount of the cemented carbide composition. [0046] The carbide hard phase of the cemented carbide composition forming the low weight punch may also include WC in an amount of from 59 wt.% to about 62 wt.%, from about 62 wt.% to about 65 wt.%, from about 65 wt.% to about 68 wt.%, from about 59 wt.% to about 71 wt.%, from about 62 wt.% to about 71 wt.%, from about 65 wt.% to about 71 wt.%, from about 68 wt.% to about 71 wt.%, from about 68 wt.% to about 74 wt.%, from about 62 wt.% to about 68 wt.%, from about 62 wt.% to about 70 wt.%, or from about 71 wt.% to about 74 wt.%, based on a total amount of the cemented carbide composition. [0047] The carbide hard phase of the cemented carbide composition forming the low weight punch may include titanium carbide (TiC) in an amount of from about 5 wt.%
to about 11 wt.% based on a total amount of the cemented carbide composition. In some examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes TiC in an amount of from about 6 wt.% to about 11 wt.% based on a total amount of the cemented carbide composition. In other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes TiC in an amount of from about 7 wt.% to about 11 wt.% based on a total amount of the cemented carbide composition. In still other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes TiC in an amount of from about 8 wt.% to about 11 wt.% based on a total amount of the cemented carbide composition. In yet other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes TiC in an amount of from about 9 wt.% to about 11 wt.% based on a total amount of the cemented carbide composition. In even other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes TiC in an amount of from about 10 wt.% to about 11 wt.% based on a total amount of the cemented carbide composition. [0048] The carbide hard phase of the cemented carbide composition forming the low weight punch may also include TiC in an amount of from about 5 wt.% to about 6 wt.%, from about 6 wt.% to about 7 wt.%, from about 7 wt.% to about 8 wt.%, from about 5 wt.% to about 7 wt.%, from about 5 wt.% to about 8 wt.%, from about 5 wt.% to about 9 wt.%, from about 5 wt.% to about 10 wt.%, from about 6 wt.% to about 8 wt.%, from about 6 wt.% to about 9 wt.%, from about 6 wt.% to about 10 wt.%, from about 8 wt.% to about 9 wt.%, from about 8 wt.% to about 10 wt.%, or from about 9 wt.% to about 10 wt.%, based on a total amount of the cemented carbide composition. [0049] The carbide hard phase of the cemented carbide composition forming the low weight punch may include NbC in an amount of from about 7 weight percent (wt.%) to about 16 wt.% based on a total amount of the cemented carbide composition. In some examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes NbC in an amount of from about 9 wt.% to about 16 wt.% based on a total amount of the cemented carbide composition. In other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes
NbC in an amount of from about 11 wt.% to about 16 wt.% based on a total amount of the cemented carbide composition. In still other examples, the carbide hard phase of the cemented carbide composition forming the low weight punch includes NbC in an amount of from about 13 wt.% to about 16 wt.% based on a total amount of the cemented carbide composition. [0050] The carbide hard phase of the cemented carbide composition forming the low weight punch may also include NbC in an amount of from about 7 wt.% to about 9 wt.%, from about 9 wt.% to about 11 wt.%, from about 11 wt.% to about 13 wt.%, from about 7 wt.% to about 10 wt.%, from about 7 wt.% to about 11 wt.%, from about 7 wt.% to about 12 wt.%, from about 7 wt.% to about 13 wt.%, from about 7 wt.% to about 14 wt.%, from about 7 wt.% to about 15 wt.%, from about 8 wt.% to about 10 wt.%, from about 8 wt.% to about 11 wt.%, from about 8 wt.% to about 12 wt.%, from about 8 wt.% to about 13 wt.%, from about 8 wt.% to about 14 wt.%, from about 8 wt.% to about 15 wt.%, or from about 8 wt.% to about 16 wt.%, from about 9 wt.% to about 10 wt.%, from about 9 wt.% to about 12 wt.%, from about 9 wt.% to about 13 wt.%, from about 8 wt.% to about 14 wt.%, or from about 9 wt.% to about 15 wt.%, based on a total amount of the cemented carbide composition. [0051] The ductile binder phase of the cemented carbide composition forming the low weight punch may usually include Co in an amount of from about 11 wt.% to about 14 wt.% based on a total amount of the cemented carbide composition. In some examples, the binder phase of the cemented carbide composition forming the low weight punch includes Co in an amount of from about 12 wt.% to about 14 wt.% based on a total amount of the cemented carbide composition. In other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Co in an amount of from about 13 wt.% to about 14 wt.% based on a total amount of the cemented carbide composition. In still other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Co in an amount of from about 11 wt.% to about 12 wt.% based on a total amount of the cemented carbide composition. In even other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Co in an amount of from about 11 wt.% to about 13 wt.% based
on a total amount of the cemented carbide composition. In further other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Co in an amount of from about 12 wt.% to about 13 wt.% based on a total amount of the cemented carbide composition. [0052] The ductile binder phase of the cemented carbide composition forming the low weight punch may include Cr2C3 in an amount of from about 0.50 wt.% to about 0.60 wt.% based on a total amount of the cemented carbide composition. In some examples, the binder phase of the cemented carbide composition forming the low weight punch includes Cr2C3 in an amount of from about 0.52 wt.% to about 0.60 wt.% based on a total amount of the cemented carbide composition. In other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Cr2C3 in an amount of from about 0.54 wt.% to about 0.60 wt.% based on a total amount of the cemented carbide composition. In still other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Cr2C3 in an amount of from about 0.56 wt.% to about 0.60 wt.% based on a total amount of the cemented carbide composition. In even other examples, the binder phase of the cemented carbide composition forming the low weight punch includes Cr2C3 in an amount of from about 0.58 wt.% to about 0.60 wt.% based on a total amount of the cemented carbide composition. In further other examples, the binder phase of the cemented carbide composition forming the low weight punch may include Cr2C3 in an amount of from about 0.50 wt.% to about 0.51 wt.%, 0.50 wt.% to about 0.52 wt.%, from about 0.52 wt.% to about 0.54 wt.%, from about 0.54 wt.% to about 0.56 wt.%, from about 0.50 wt.% to about 0.53 wt.%, from about 0.50 wt.% to about 0.54 wt.%, from about 0.50 wt.% to about 0.55 wt.%, from about 0.50 wt.% to about 0.56 wt.%, from about 0.50 wt.% to about 0.57 wt.%, from about 0.50 wt.% to about 0.58 wt.%, from about 0.50 wt.% to about 0.59 wt.%, from about 0.51 wt.% to about 0.52 wt.%, from about 0.51 wt.% to about 0.53 wt.%, from about 0.51 wt.% to about 0.54 wt.%, from about 0.51 wt.% to about 0.55 wt.%, from about 0.51 wt.% to about 0.56 wt.%, from about 0.51 wt.% to about 0.57 wt.%, from about 0.51 wt.% to about 0.58 wt.%, from about 0.51 wt.% to about 0.59 wt.%, from about 0.52 wt.% to about 0.53 wt.%, from about 0.52 wt.% to about 0.55 wt.%, from about 0.52 wt.% to about 0.57 wt.%, from about 0.52 wt.% to about 0.58 wt.%, from about 0.52 wt.% to about 0.59 wt.%, from about 0.52 wt.% to about
0.56 wt.%, or from about 0.56 wt.% to about 0.58 wt.%, based on a total amount of the cemented carbide composition. [0053] The WC grain size, once sintered, may generally exhibit an average grain size ranging from about 0.3 µm to about 0.8 µm. In some examples, the WC grain size may range from about 0.4 µm to about 0.8 µm. In other examples, the WC grain size may range from about 0.5 µm to about 0.8 µm. In still other examples, the WC grain size may range from about 0.6 µm to about 0.8 µm. In yet other examples, the WC grain size may range from about 0.7 µm to about 0.8 µm. [0054] The WC grain size may also range from about 0.3 µm to about 0.4 µm, from about 0.4 µm to about 0.5 µm, from about 0.4 µm to about 0.6 µm, from about 0.4 µm to about 0.7 µm, from about 0.5 µm to about 0.6 µm, from about 0.3 µm to about 0.5 µm, from about 0.3 µm to about 0.6 µm, from about 0.3 µm to about 0.7 µm, from about 0.4 µm to about 0.7 µm, from about 0.5 µm to about 0.7 µm, or from about 0.6 µm to about 0.7 µm. [0055] The gamma phase forming cubic carbides based on NbC and TiC, once sintered, may typically have an average grain size ranging from about 0.85 µm to about 1.65 µm. In some examples, the gamma phase forming cubic carbides may have a grain size ranging from about 1.00 µm to about 1.65 µm. In other examples, the gamma phase forming cubic carbides may have a grain size ranging from about 1.15 µm to about 1.65 µm. In still other examples, the gamma phase forming cubic carbides may have a grain size ranging from about 1.30 µm to about 1.65 µm. In yet other examples, the gamma phase forming cubic carbides many have a grain size ranging from about 1.45 µm to about 1.65 µm. [0056] The gamma phase forming cubic carbides based on NbC and TiC may also demonstrate a grain size ranging from about 0.85 µm to about 1.00 µm, from about 1.00 µm to about 1.15 µm, from about 1.15 µm to about 1.30 µm, from about 0.85 µm to about 1.15 µm, from about 0.87 µm to about 1.15 µm, from about 0.90 µm to about 1.15 µm, from about 0.92 µm to about 1.15 µm, from about 0.94 µm to about 1.15 µm, from about 0.96 µm to about 1.15 µm, from about 0.98 µm to about 1.15 µm, from about 1.02 µm to
about 1.15 µm, from about 1.04 µm to about 1.15 µm, from about 1.06 µm to about 1.15 µm, from about 1.08 µm to about 1.15 µm, from about 1.10 µm to about 1.15 µm, from about 1.12 µm to about 1.15 µm, from about 0.85 µm to about 1.30 µm, from about 0.87 µm to about 1.30 µm, from about 0.90 µm to about 1.30 µm, from about 0.92 µm to about 1.30 µm, from about 0.94 µm to about 1.30 µm, from about 0.96 µm to about 1.30 µm, from about 0.98 µm to about 1.30 µm, from about 1.02 µm to about 1.30 µm, from about 1.04 µm to about 1.30 µm, from about 1.06 µm to about 1.30 µm, from about 1.08 µm to about 1.30 µm, from about 1.10 µm to about 1.30 µm, from about 1.12 µm to about 1.30 µm, from about 1.14 µm to about 1.30 µm, from about 1.16 µm to about 1.30 µm, from about 1.18 µm to about 1.30 µm, from about 1.20 µm to about 1.30 µm, from about 1.22 µm to about 1.30 µm, from about 1.24 µm to about 1.30 µm, from about 1.26 µm to about 1.30 µm, from about 1.28 µm to about 1.30 µm, from about 0.85 µm to about 1.30 µm, from about 0.85 µm to about 1.45 µm, from about 0.87 µm to about 1.45 µm, from about 0.90 µm to about 1.45 µm, from about 0.92 µm to about 1.45 µm, from about 0.94 µm to about 1.30 µm, from about 0.96 µm to about 1.30 µm, from about 0.98 µm to about 1.45 µm, from about 1.02 µm to about 1.45 µm, from about 1.04 µm to about 1.45 µm, from about 1.06 µm to about 1.45 µm, from about 1.08 µm to about 1.45 µm, from about 1.10 µm to about 1.45 µm, from about 1.12 µm to about 1.45 µm, from about 1.14 µm to about 1.45 µm, from about 1.16 µm to about 1.45 µm, from about 1.18 µm to about 1.45 µm, from about 1.20 µm to about 1.45 µm, from about 1.22 µm to about 1.45 µm, from about 1.24 µm to about 1.45 µm, from about 1.26 µm to about 1.45 µm, from about 1.28 µm to about 1.45 µm, from about 1.30 µm to about 1.45 µm, from about 1.32 µm to about 1.45 µm, from about 1.34 µm to about 1.45 µm, from about 1.36 µm to about 1.45 µm, from about 1.38 µm to about 1.45 µm, from about 1.40 µm to about 1.45 µm, from about 1.42 µm to about 1.45 µm from about 0.85 µm to about 1.30 µm, from about 1.00 µm to about 1.30 µm, from about 1.00 µm to about 1.45 µm, or from about 1.30 µm to about 1.45 µm. [0057] The WC or gamma phase grain size defined by the cemented carbide may be determined by a linear-intercept technique using a line drawn across a calibrated scanning electron microscope (SEM) image of the cemented carbide. A length of the line may be measured by using a calibrated rule, where the line intercepts a grain of WC or a grain of the gamma phase, and the linear-intercept technique is repeated for at least 100
WC or gamma phase grains to obtain an average grain size of the WC or the gamma phase. Alternatively, for determining a specific grain size, one having ordinary skill in the art may typically employ either sieve analysis, dynamic digital image analysis (DIA), static laser light scattering (SLS) also known as laser diffraction, or by visual measurement by electron microscopy, a technique known as image analysis and light obscuration. Each method covers a characteristic size range within which measurement is possible. These ranges partly overlap. However, the results for measuring the same sample may vary all depending on the particular method that is used. A skilled artisan who wants to determine grain sizes, or grain size distributions would readily know how each mentioned method is commonly performed and practiced. [0058] The low weight cemented carbide for manufacturing the punches disclosed herein this disclosure may typically demonstrate a density spanning a range of from about 11.2 g/cm3 to about 12.5 g/cm3. In some examples, the density spans a range of from about 11.2 g/cm3 to about 11.4 g/cm3. In other examples, the density spans a range of from about 11.4 g/cm3 to about 11.6 g/cm3. In yet other examples, the density spans a range of from about 11.6 g/cm3 to about 11.8 g/cm3. In still other examples, the density spans a range of from about 11.2 g/cm3 to about 11.6 g/cm3. In even other examples, the density spans a range of from about 11.2 g/cm3 to about 11.8 g/cm3. In further other examples, the density may span a range of from about 11.2 g/cm3 to about 12.0 g/cm3, from about 11.2 g/cm3 to about 12.2 g/cm3, or from about 11.2 g/cm3 to about 12.4 g/cm3. In even further other examples, the density may span a range of from about 11.8 g/cm3 to about 12.0 g/cm3. In other examples, the density may span a range of from about 12.0 g/cm3 to about 12.2 g/cm3. In yet other examples, the density may span a range of from about 11.4 g/cm3 to about 12.0 g/cm3, from about 11.4 g/cm3 to about 12.3 g/cm3, or from about 11.4 g/cm3 to about 12.5 g/cm3. In still other examples, the density may span a range of from about 11.6 g/cm3 to about 12.0 g/cm3, from about 11.6 g/cm3 to about 12.3 g/cm3, or from about 11.6 g/cm3 to about 12.5 g/cm3. In further other examples, the density may span a range of from about 11.8 g/cm3 to about 12.3 g/cm3 11.8 g/cm3 to about 12.5 g/cm3. In even further other examples, the density may span a range of from about 12.0 g/cm3 to about 12.5 g/cm3, from about 12.2 g/cm3 to about 12.5 g/cm3, or from about 12.4 g/cm3 to about 12.5 g/cm3.
[0059] The low weight cemented carbide for manufacturing the punches described herein may typically display HV30 Vickers hardness values ranging from about 1520 HV30 to about 1570 HV30. In some examples, HV30 Vickers hardness values range from about 1525 HV30 to about 1570 HV30. In other examples, HV30 Vickers hardness values range from about 1530 HV30 to about 1570 HV30. In yet other examples, HV30 Vickers hardness values range from about 1535 HV30 to about 1570 HV30. In still other examples, HV30 Vickers hardness values range from about 1540 HV30 to about 1570 HV30. In further other examples, HV30 Vickers hardness values range from about 1545 HV30 to about 1570 HV30. In other examples, HV30 Vickers hardness values range from about 1550 HV30 to about 1570 HV30. In still other examples, HV30 Vickers hardness values range from about 1555 HV30 to about 1570 HV30. In yet other examples, HV30 Vickers hardness values range from about 1560 HV30 to about 1570 HV30. In even other examples, HV30 Vickers hardness values range from about 1565 HV30 to about 1570 HV30. [0060] The HV30 Vickers hardness values for the low weight cemented carbide for manufacturing the punches described herein may also range from about 1520 HV30 to about 1525 HV30, from about, 1525 HV30 to about 1530 HV30, from about 1530 HV30 to about 1535 HV30, from about 1520 HV30 to about 1530 HV30, from about 1520 HV30 to about 1535 HV30, from about 1520 HV30 to about 1540 HV30, from about 1520 HV30 to about 1545 HV30, from about 1520 HV30 to about 1550 HV30, from about 1520 HV30 to about 1555 HV30, from about 1520 HV30 to about 1560 HV30, from about 1520 HV30 to about 1565 HV30, from about 1525 HV30 to about 1535 HV30, from about 1525 HV30 to about 1540 HV30, from about 1525 HV30 to about 1545 HV30, from about 1525 HV30 to about 1550 HV30, from about 1525 HV30 to about 1555 HV30, from about 1525 HV30 to about 1560 HV30, from about 1525 HV30 to about 1565 HV30, from about 1530 HV30 to about 1540 HV30, from about 1530 HV30 to about 1545 HV30, from about 1530 HV30 to about 1550 HV30, from about 1530 HV30 to about 1555 HV30, from about 1530 HV30 to about 1560 HV30, from about 1530 HV30 to about 1565 HV30, from about 1535 HV30 to about 1540 HV30, from about 1535 HV30 to about 1545 HV30, from about 1535 HV30 to about 1550 HV30, from about 1535 HV30 to about 1555 HV30, from about 1535 HV30 to about 1560 HV30, from about 1535 HV30 to about 1565 HV30, from about 1540 HV30
to about 1545 HV30, from about 1540 HV30 to about 1550 HV30, from about 1540 HV30 to about 1555 HV30, from about 1540 HV30 to about 1560 HV30, from about 1540 HV30 to about 1565 HV30, from about 1545 HV30 to about 1550 HV30, from about 1520 HV30 to about 1550 HV30, from about 1525 HV30 to about 1550 HV30, from about 1530 HV30 to about 1550 HV30, from about 1535 HV30 to about 1550 HV30, from about 1540 HV30 to about 1550 HV30, from about 1550 HV30 to about 1555 HV30, from about 1555 HV30 to about 1560 HV30, from about 1560 HV30 to about 1565 HV30, from about 1550 HV30 to about 1560 HV30, from about 1550 HV30 to about 1565 HV30. [0061] The low weight cemented carbide for manufacturing the punches described herein may exhibit fracture toughness values spanning from about 10.2 MPa √m to about 10.6 MPa √m. In some examples, the fracture toughness values span from about 10.3 MPa √m to about 10.6 MPa √m. In other examples, the fracture toughness values span from about 10.4 MPa √m to about 10.6 MPa √m. In still other examples, the fracture toughness values span from about 10.5 MPa √m to about 10.6 MPa √m. [0062] The fracture toughness values for the low weight cemented carbide for manufacturing the punches described herein may also span from about 10.2 MPa √m to about 10.3 MPa √m, from about 10.3 MPa √m to about 10.4 MPa √m, from about 10.4 MPa √m to about 10.5 MPa √m, from about 10.2 MPa √m to about 10.4 MPa √m, from about 10.2 MPa √m to about 10.5 MPa √m, or from about 10.3 MPa √m to about 10.5 MPa √m. Methods of preparing low weight cemented carbide punches for manufacturing metal beverage cans [0063] A specifically targeted WC or a gamma phase grain size of the cemented carbide composition for manufacturing the low weight punches described herein can be produced by subjecting WC, TiC, NbC, and Cr3C2 hard phase powders (i.e. thus forming at least two different carbide hard phases e.g. constituted of at least a WC containing hard phase, and a gamma hard phase when sintered formed by addition of cubic NbC and TiC), and a Co based metallic binder phase powder to wet milling for several hours (e.g., 4, 8, 16, 32, 64 hours) under ambient conditions (i.e.25º C, 298.15 K and a pressure
of 101.325 kPa in a ball mill, an attritor mill, or a planetary mill) to form a powder blend. In some examples, instead of using a ball, an attritor mill, or a planetary mill as the physical blending apparatus, any other mixing method, which would be known by a skilled artisan in powder processing such as e.g. ultrasonic mixing may instead suitably be the choice of the blending method. Thus, in this case, ultrasonic mixing uses sound energy to effectively process for example powders, pastes, liquids, and combinations thereof with a breakthrough speed, quality and repeatability. Powders of nearly any size, material characteristic, or morphology are rapidly and thoroughly mixed using for example an acoustic mixer. Acoustic processing is frequently orders of magnitude faster than traditional technologies. Here, the acoustic mixer may for example employ a 60Hz motion, which then causes each particle to randomly collide with adjacent particles, diverting their paths, colliding and then re-colliding with other particles behaving in equally chaotic fashion. [0064] The main purpose of doing the wet milling is to facilitate a uniform, and an even Co based metallic binder phase powder distribution within the carbide hard phase powders, and a favorably good wettability of the WC, TiC, NbC, and Cr3C2 hard phase, and the Co metallic binder phase powder constituents. Subjecting the powder mixture to wet milling is essentially imperative to strengthening the physical integrity of the blended WC, TiC, NbC, and Cr3C2 hard phase, and the Co based metallic binder phase powders. This is further done to deagglomerate the WC, TiC, NbC, and Cr3C2 hard phase, and the Co based metallic binder phase powders. An acceptably uniform, and an even Co based metallic binder phase powder distribution, as well as a good quality of wettability of the WC, TiC, NbC, and Cr3C2 hard phase, and the Co metallic binder phase powder constituents are key to obtaining cemented carbides of stellar physical quality for producing the low weight punches in aluminum and steel beverage can-production. On the other hand, if the Co based metallic binder phase powder distribution, and the wettability of the binder and carbide hard phase powder constituents are of a bad quality, pores and cracks may potentially unfavorably emerge as a result of this in the final sintered body of the low weight punches, which would detrimentally affect the overall can- production process.
[0065] As would be apparent to a person having ordinary skill in the art for making punches for beverage can manufacturing, wet milling (i.e., blending) is made by first adding a milling liquid to the powder mixture to form a milling powder slurry composition. The milling liquid may suitably be water, an alcohol such as but not limited to ethanol, methanol, isopropanol, butanol, cyclohexanol, another organic solvent in the likes of for example acetone or toluene, an alcohol mixture, an alcohol and another solvent mixture, or like constituents. The properties of the milling powder slurry composition are dependent on, among other things, the amount of the milling liquid that is added. Because the drying of the milling powder slurry composition requires substantial amount of energy, the amount of the used milling liquid should be minimized to keep costs down. However, enough milling liquid needs to be added to achieve an easily pumpable milling powder slurry composition, and avoid clogging of the blending system. Moreover, other compounds commonly known in the art to a skilled artisan can be added to the slurry composition e.g., dispersion agents, pH-adjusters, lubricants, and anti-flocculating agents. Non-limiting example of organic binder(s), such as e.g. polyethylene glycol (PEG), paraffin, polyvinyl alcohol (PVA), long chain fatty acids, wax, or any combinations thereof, or such like components may be added to the milling powder slurry composition prior to the wet milling typically in amounts from for example about 2 wt.% to about 3.5 wt.%, like e.g., from about 2.25 wt.% to about 3.5 wt.%, from about 2.5 wt.% to about 3.5 wt.%, from about 2.75 wt.% to about 3.5 wt.%, from about 3 wt.% to about 3.5 wt.%, from about 3.25 wt.% to about 3.5 wt.%, from about 2 wt.% to about 2.25 wt.%, from about 2.25 wt.% to about 2.5 wt.%, from about 2.25 wt.% to about 2.75 wt.%, from about 2.25 wt.% to about 3 wt.%, from about 2.25 wt.% to about 3.25 wt.%, from about 2 wt.% to about 2.5 wt.%, from about 2 wt.% to about 2.75 wt.%, from about 2 wt.% to about 3 wt.%, or from about 2 wt.% to about 3.25 wt.% based on a total weight of the material composition. This is substantially done to function as a pressing agent, and to add toughness, and allow easy handling of the prepared green body in the following pressing/forming steps further described hereinafter. [0066] The wet milled powder slurry composition can next be spray-dried, freeze- dried, air-dried, furnace-dried, or vacuum-dried, and granulated to form free-flowing ready-to-press (RTP) powder blend aggregates of granules typically displaying a
spherical shape, or a substantially spherical-like shape. Any drying method can in theory be implemented that is not inconsistent and incompatible with the objectives of the present subject matter. As used herein this disclosure, the term “free-flowing” refers to loosely packed cemented carbide powders that are exhibiting a pore space between each free-flowing carbide particle of the cemented carbide powder with no physical restrictions, or barriers created whatsoever, suppressing the free-flowing capability of the particles of the cemented carbide powder. [0067] Particularly, in the case of spray-drying as shown in FIG. 1, the wet milled powder slurry composition constituted of the WC, TiC, NbC, and Cr3C2 hard phase powders 5, and the Co based metallic binder phase powder 3 mixed with the organic liquid, and the organic binder(s) may be atomized through an appropriate nozzle 1 or a rotary atomizer 1 in a drying tower by forming a spray. The formed small discrete droplets 4 are instantaneously dried after forming liquid bridges 4A by a horizontal inflow of a stream of hot gas into the drying tower, for instance in a stream of nitrogen (N2), argon (Ar), or air to form spherical, or substantially spherical-like powder agglomerates 5A of granules with free-flowing properties. As used herein, “atomization” refers to a process, where a bulk liquid feed is converted into discrete droplets 4 by forming a spray by nozzles 1 or rotary atomizers 1, thus ultimately increasing the surface area of the formed discrete droplets 4, and thereby significantly increasing the potentially achievable rates of evaporation of a given solvent (i.e., milling liquid). The atomization stage is designed to create optimum conditions for evaporation of the given solvent from the milled powder slurry composition. Nozzles 1 and rotary atomizers 1 are used in drying towers to form sprays. Drying towers may be equipped with just one such nozzle 1 and rotary atomizer 1, or alternatively with a plurality of such nozzles 1 and rotary atomizers 1 to form granules of spherical, or substantially spherical-like powder blend agglomerates 5A with free- flowing properties (i.e., RTP powder). [0068] The ready-to-press (RTP) powder is next pressed/formed, or otherwise consolidated into a green body in the preparation for the sintering procedure described hereinafter. A green body is formed of the cemented carbide powder blend by using conventional pressing/forming techniques in the powder metallurgy art, such as the
following, but without limitation cold tool pressing technology including multi axial pressing (MAP), extruding, or metal injection molding (MIM), cold isostatic pressing (CIP, i.e., isostatic pressure is applied in 3 directions or axis), pill pressing, additive manufacturing (AM), additive layer manufacturing (ALM), tape casting, and other pressing/forming methods generally known in the powder metallurgy art. Any pressing/forming consolidation method can in theory be utilized that is not inconsistent and incompatible with the objectives of the present subject matter. Pressing/forming yields a green density, and/or strength that permits easy handling, and green machining due to the processed material essentially being in the form of a compacted powder. In one example of the present disclosure, the forming is done by a pressing operation. Here, the pressing may be conducted by a uniaxial pressing consolidation operation at a force commonly used from 5 ton to 300 ton. Additionally, machining in the green state may be required to achieve a desired green body shape. [0069] The green body may be subjected to a pre-sintering temperature elevation procedure, to completely remove the organic binder(s) in a sintering furnace, which is also referred to as depegging or dewaxing of the organic binder(s) in the appropriate art. This may be done in the same sintering furnace when eventually conducting the sintering process further described hereinbelow. Suitable temperatures for the complete removal of the organic binder(s) may be employed starting from 150°C and ending at 450°C, starting from 150°C and ending at 500°C, starting from 150°C and ending at 550°C, starting from 200°C and ending at 600°C, starting from 250°C and ending at 450°C, starting from 250°C and ending at 500°C, starting from 250°C and ending at 550°C, starting from 250°C and ending at 600°C, starting from 300°C and ending at 450°C, starting from 300°C and ending at 500°C, starting from 300°C and ending at 550°C, or starting from 300°C and ending at 600°C. A dwell-time may be introduced employed at a maximum temperature in an operated temperature range, which may typically be from about 1 minute to about 60 minutes. Alternatively, the dwell time may be introduced at the maximum temperature in the applied temperature range and at the specific pressure range, which may typically be from 20 minutes to 60 minutes, from 25 minutes to 60 minutes, from 30 minutes to 60 minutes, from 35 minutes to 60 minutes, from 40 minutes to 60 minutes, from 45 minutes to 60 minutes, from 50 minutes to 60 minutes, or from 55
minutes to 60 minutes. This may typically be performed in a reactive H2 atmosphere with a hydrogen (H2) flow rate applied at about 1000 liters/hour to about 10000 liters/hour, applied at about 3000 liters/hour to about 10000 liters/hour, applied at about 6000 liters/hour to about 10000 liters/hour, or applied at about 9000 liters/hour to about 10000 liters/hour. The temperature may typically be increased constantly at a rate of for example about 0.70°C/min. In some examples, after the organic binder(s) removal, the temperature may be increased in tandem sequentially at a rate of about 2°C/min. shifted to about 10°C/min., when a certain temperature in an operated temperature range has been reached, or at a rate of about 2°C/min., changed to about 7°C/min., or at a rate of about 2°C/min., changed to about 5°C/min., again when a particular temperature in an operated temperature range has been reached. The aforementioned temperature ranges for the depegging or dewaxing (i.e., complete debinding of the organic binder) may generally be reached after heating the green body for about 60 minutes to about 90 minutes, or alternatively, for about 60 minutes to about 7 hours in the sintering furnace. Thus, in general, the particular type of heating-pattern chosen is determined and performed, and for the particular amount of time, in a manner, which confers and thereby imparts a desired complete dewaxed phase-transformation (i.e., 100% depegging of the green body). In general, the pre-sintering cycle for complete dewaxing of the organic binder(s) may be conducted in a reactive (H2) atmosphere, under vacuum conditions, or in a non-reactive inert atmosphere e.g., nitrogen (N2) or argon (Ar). [0070] Next, the pre-sintered fully debinded green bodies subsequently undergo a sintering consolidation process in a sintering furnace to ultimately form the sintered cemented carbide of the low weight punches. As used herein this disclosure, the term “consolidation process” is meant to either include any process that in combination compacts (i.e., presses), and consolidates (i.e., densifies, thus sinters the material by a high temperature heating operation) the cemented carbide powder simultaneously, or densifies only by a high temperature heating operation as applied solely during vacuum sintering, which vacuum sintering does not have any compaction/pressure taking place during the vacuum sintering operation.
[0071] The sintering consolidation process may be performed typically by using a pressure from 50 bar to 75 bar, from 50 bar to 80 bar, from 50 bar to 85 bar, from 50 bar to 90 bar, from 60 bar to 75 bar, from 60 bar to 80 bar, from 60 bar to 85 bar, from 60 bar to 90 bar, from 70 bar to 75 bar, from 70 bar to 80 bar, from 70 bar to 85 bar, or from 70 bar to 90 bar. Depending however on the composition, this pressure range might be lowered to a range from 35 bar to 60 bar at a temperature starting from 1200°C and ending at 1500°C, starting from 1200°C and ending at 1600°C, starting from 1200°C and ending at 1700°C, starting from 1200°C and ending at 1800°C, starting from 1400°C and ending at 1500°C, starting from 1400°C and ending at 1600°C, starting from 1400°C and ending at 1700°C, starting from 1400°C and ending at 1800°C, starting from 1500°C and ending at 1600°C, starting from 1500°C and ending at 1700°C, or starting from 1500°C and ending at 1800°C. A dwell-time may be introduced employed at a maximum temperature in an operated temperature range, which may typically range from about 1 minute to about 60 minutes. Alternatively, the dwell time may be introduced at the maximum temperature in the applied temperature range and at a specific pressure range, which may typically be from 20 minutes to 60 minutes, from 25 minutes to 60 minutes, from 30 minutes to 60 minutes, from 35 minutes to 60 minutes, from 40 minutes to 60 minutes, from 45 minutes to 60 minutes, from 50 minutes to 60 minutes, or from 55 minutes to 60 minutes. [0072] In the conducted sintering operation, the particular sintering temperature range is chosen, in a manner that will result in a sufficient melting of the Co based metallic binder phase during the sintering. Without being bound by any particular theory, the Co may have a plurality of elements dissolved in it, such as e.g., Cr, W, C, Ti, and/or Nb when forming the binder matrix after sintering is fully complete. During this process, the formed Co based metallic binder phase will eventually enter the liquid stage due to melting, while the carbide grains having a much higher melting point will remain in a solid stage. As a result of a coating process of the carbide grains with the formed Co based metallic binder, the melted Co based metallic binder matrix is anchoring, and thereby cementing the carbide grains. Thus, this forms a cemented carbide composite displaying a Co based metallic binder matrix with its distinct material properties for preparing the low weight punches. The temperature may typically be elevated constantly at a rate of for
example about 0.70°C/min. In some examples, the temperature may be increased in tandem sequentially at a rate of about 2°C/min., switched to about 10°C/min., when a certain particular temperature in an operated temperature range has been reached, or for instance at a rate of about 2°C/min., changed to about 7°C/min., or at a rate of about 2°C/min., switched to about 5°C/min., again when a certain particular temperature in an operated temperature range has been reached. After having performed the dwell-time employed at the maximum temperature in an operated temperature range, a cooling procedure may be performed typically via conducting a first temperature drop characterized by a drop rate of about 50°C/min., generally for about 3 minutes, 4 minutes to 5 minutes, or for 6 minutes. Next, all heating energy may be terminated, and dissipated via a rapid temperature drop, by way of ideally using coolants to eventually an ambient temperature of about 25°C. [0073] The pre-sintered green body may alternatively be subjected to vacuum- sintering in a non-reactive inert atmosphere supplied with e.g., argon (Ar), or nitrogen (N2) at a minuscule pressure typically ranging from 10-2 millibar (mbar) to 10-4 millibar (mbar). During vacuum-sintering, the pre-sintered green body is placed in a vacuum-furnace, and sintered at a temperature starting from 1200°C and ending at 1500°C, starting from 1200°C and ending at 1600°C, starting from 1200°C and ending at 1700°C, starting from 1200°C and ending at 1800°C, starting from 1400°C and ending at 1500°C, starting from 1400°C and ending at 1600°C, or starting from 1400°C and ending at 1700°C. A dwell- time may be introduced employed at a maximum temperature in an operated temperature range, which may typically be from about 1 minute to about 60 minutes. Alternatively, the dwell time may be introduced at the maximum temperature in the applied temperature range and at the specific pressure range, which may typically be from 20 minutes to 60 minutes, from 25 minutes to 60 minutes, from 30 minutes to 60 minutes, from 35 minutes to 60 minutes, from 40 minutes to 60 minutes, from 45 minutes to 60 minutes, from 50 minutes to 60 minutes, or from 55 minutes to 60 minutes. [0074] For example, hot isostatic pressing (HIP) may be performed on the pre- sintered cemented carbide, or alternatively, as an extra post consolidation step performed sequentially on an already vacuum sintered cemented carbide. HIP is a relatively slow
process, and compacting is isostatic, i.e., pressure is applied isostatically in 3 directions or axis. Heating is performed at the same time by elements that are integrated in the press. Thus, HIP subjects the cemented carbide powder simultaneously to both an elevated temperature, and an isostatic gas pressure in for example a high pressure containment vessel. The pressurizing gas that is used may for example be argon (Ar). An inert gas such as argon (Ar) is most typically used, so that the material undergoing HIP does not chemically react. The chamber is heated causing the pressure inside the vessel to increase. The pressure is applied to the cemented carbide powder from all 3 directions or axis. The inert argon (Ar) gas may be applied typically from about 7,350 psi (about 50.7 MPa) to about 45,000 psi (about 310 MPa), with about 14,500 psi (about 100 MPa) generally being the most typical applied pressure, or alternatively from about 800 bar (80 MPa) to about 1200 bar (120 MPa). In such a case, cemented carbide powder will be wet milled, dried, and pressed to form a green body as described previously, and will typically then be vacuum sintered in a non-reactive inert argon (Ar), or N2 atmosphere. Next, the vacuum sintered cemented carbide may undergo an additional sequential post vacuum sintering HIP-treatment step from typically 30 minutes to about 60 minutes, thus yielding a high-pressure HIP-process. This additional HIP-step fulfils the significant purpose of eliminating the presence of any potential porosity that may still be present in the vacuum sintered cemented carbide. The applied temperature may, for example, range starting from 1300°C and ending at 1500°C, starting from 1300°C and ending at 1600°C, starting from 1300°C and ending at 1700°C, starting from 1300°C and ending at 1800°C, starting from 1300°C and ending at 1900°C, starting from 1300°C and ending at 2000°C, starting from 1400°C and ending at 1500°C, starting from 1400°C and ending at 1600°C, starting from 1400°C and ending at 1700°C, starting from 1400°C and ending at 1800°C, starting from 1400°C and ending at 1900°C, starting from 1400°C and ending at 2000°C, starting from 1500°C and ending at 1600°C, starting from 1500°C and ending at 1700°C, starting from 1500°C and ending at 1800°C, starting from 1500°C and ending at 1900°C, or starting from 1500°C and ending at 2000°C with an applied pressure typically ranging from about 7,350 psi (about 50.7 MPa) to about 45,000 psi (about 310 MPa), with about 14,500 psi (about 100 MPa) generally being the most typical applied pressure, or alternatively from about from about 800 bar (80 MPa) to about 900
bar (90 MPa), from about 800 bar (80 MPa) to about 1000 bar (100 MPa), from about 800 bar (80 MPa) to about 1100 bar (110 MPa), 800 bar (80 MPa) to about 1200 bar (120 MPa), from about 900 bar (90 MPa) to about 1000 bar (100 MPa), from about 900 bar (90 MPa) to about 1100 bar (110 MPa), from about 900 bar (90 MPa) to about 1200 bar (120 MPa), from about 1000 bar (100 MPa) to about 1100 bar (110 MPa), from about 1000 bar (100 MPa) to about 1200 bar (120 MPa), or from about 1100 bar (110 MPa) to about 1200 bar (120 MPa). [0075] It should however be emphasized that the overall concept of sintering generally falls under the standard umbrella of processes defined by depegging, solid state sintering, or liquid phase sintering, and ultimately cooling the sintered material down to ambient conditions after the sintering operation is fully complete. Thus, a person having ordinary skill in the art would know that the aforementioned steps in the sintering processes described before can be performed all at once in the same sintering furnace equipment. Alternatively, a person having ordinary skill in the appropriate art would also know that they may equally be performed one straight after the other in different sintering furnace equipments. EXAMPLES [0076] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the described subject matter and are not intended to limit the scope of what the inventors regard as their disclosure nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used but some experimental errors and deviations should be accounted for. Unless indicated otherwise, parts are by weight, molecular weight is weight average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
EXAMPLE 1 PREPARATION OF LOW WEIGHT CEMENTED CARBIDE PUNCH SAMPLES [0077] Low weight cemented carbide punch samples A-H with the specific powder compositions in weight (wt.) % according to Table 1 were prepared according to known manufacturing methods. A cemented carbide powder giving a final average WC grain size of from about 0.3 µm to about 0.8 µm, and a final gamma phase grain size spanning from about 0.85 µm to about 1.65 µm of the sintered material was used. The low weight cemented carbide punch samples were prepared from powders including hard constituents of WC, TiC, NbC, Cr3C2, and a Co based metallic binder phase, thus ultimately forming a sintered soft ductile binder matrix constituted of Co having a plurality of elements dissolved in it, such as e.g., Cr, W, C, Ti, and/or Nb. The powder mixture was wet milled together with about 2 wt.% polyethylene glycol (PEG) based on a total weight of the powder mixture in a ball mill for about 8 hours in an ethanol milling solvent media together with a lubricant, and an anti-flocculating agent until a homogeneous mixture was obtained. This was granulated by spray-drying in order to form a ready-to- press (RTP) powder, which was then sieved through a sieve with an appropriate mesh- size (such as e.g., a 2500 mesh screen) to separate the flowthrough, while retaining the formed RTP powder. The RTP powder was isostatically pressed to form a green body before depegging at 450°C, and next followed by sintering the depegged cemented carbide compact with zirconia crucibles to increase the density. The sintering was performed at 1410°C for about 1 hour under vacuum conditions in a non-reactive inert atmosphere supplied with e.g., argon (Ar), or nitrogen (N2) at a minuscule pressure typically ranging from 10-2 millibar (mbar) to 10-4 millibar (mbar). This was subsequently followed by applying a sequential 50 bar argon (Ar) at the sintering temperature of 1410°C for another 30 minutes by performing a HIP process to ultimately obtain a fully densified structure (i.e., up to a density of about 12.5 g/cm3), before eventually cooling the densified structure down to ambient conditions at a temperature of about 25°C. In certain particular examples of the subject matter, the weight of the sole chemical components of the powders in the composition of the low weight cemented carbide punch samples A-H are those listed below in Table 1 (i.e. plus or minus 5% of each numerical value shown in
Table 1). Further, Table 2 shows the amount of the chemical components in the final sintered cemented carbide punch samples A-H (i.e. plus or minus 5% of each numerical value shown in Table 2). [0078] FIG. 2A shows the hardness (HV30) as a function of the density of different low weight cemented carbide punch samples prepared as described above, and a reference material having the composition 78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co, and 0.5 wt.% Cr3C2 in accordance with the present subject matter. FIG. 2B shows the fracture toughness as a function of the density of the different low weight cemented carbide punch samples prepared as described above, and again the same reference material in accordance with the current subject matter. Essentially the prepared light weight cemented carbide punch samples demonstrated an optimized density range spanning from substantially about 11.2 g/cm3 to about 12.5 g/cm3, and further had a HV30 Vickers hardness spanning a range of from about 1520 to about 1570, and a fracture toughness spanning a range of from about 10.2 MPa √m to about 10.6 MPa √m. Importantly, as shown in FIG. 2A and FIG. 2B, the obtained fracture toughness for the light weight cemented carbide samples was stabilized, and robustly maintained with the HV30 Vickers hardness particularly in the density range covering 11.2 g/cm3 to about 12.5 g/cm3. The obtained optimized density range covering 11.2 g/cm3 to about 12.5 g/cm3 for the low weight cemented carbide punch samples was essentially decreased below the density of the reference material, which was 12.6 g/cm3. [0079] Increasing the soft ductile binder content increases the fracture toughness, while at the same time, decreases the HV30 hardness. Despite this, FIG.2A shows that the hardness stays in a tight range, i.e., HV30 from about 1520 to about 1570. This is due to compensation by increasing the amount of the gamma phase, i.e. thus caused by increased addition of cubic carbides like e.g., NbC, which is generally known to be a more brittle phase. According to FIG.2B, at densities lower than for example a density of 11.2 g/cm3 for sample E, which is the lower density cutoff endpoint, the fracture toughness begins to dramatically decrease, thus indicating that the increase of the gamma phase formation caused by the increased addition of cubic carbides essentially leads to a material fragility, and material embrittlement. However, particularly in the tight density
range spanning from 11.2 g/cm3 to 12.5 g/cm3 (i.e., samples A-E), both the hardness and the fracture toughness were robustly maintained. Importantly, with sample E representing the optimized lower density cutoff endpoint, a lower density range spanning from 11.2 g/cm3 to 12.5 g/cm3 is thus demonstrated with samples A-E. This is compared to the reference material having a density of 12.6 g/cm3 with substantially a similar hardness, and an equivalent fracture toughness as the tested reference sample. [0080] [TABLE 1] Sample WC TiC NbC Co Cr3C2 Total Density (Wt. %) (Wt.%) (Wt.%) (Wt. %) (Wt.%) (Wt.%) (Wt.%) (g/cm3) A 76.5 4.7 6.8 11.5 0.5 100.0 12.5 B 74.3 5.5 8.0 11.7 0.5 100.0 12.2 C 72.0 6.3 9.2 12.0 0.5 100.0 11.9 D 69.6 7.1 10.4 12.3 0.6 100.0 11.6 E 67.1 8.0 11.7 12.6 0.6 100.0 11.2 F 64.4 8.9 13.1 13.0 0.6 100.0 10.9 G 61.6 9.9 14.5 13.4 0.6 100.0 10.7 H 58.6 11.0 16.1 13.7 0.6 100.0 10.4 Ref. 78.4 4.0 5.9 11.2 0.5 100.0 12.6 [0081] [TABLE 2] Sample WC Ti Nb Co C (Wt.%) (Wt.%) (Wt.%) (Wt.%) Cr (Wt.%) arbon Total Density (Wt.%) (Wt.%) (g/cm3) A 76.50 3.76 6.05 11.50 0.44 Balance 100.00 12.5
B 74.30 4.40 7.12 11.70 0.44 Balance 100.00 12.2 C 72.00 5.04 8.19 12.00 0.44 Balance 100.00 11.9 D 69.60 5.68 9.26 12.30 0.52 Balance 100.00 11.6 E 67.10 6.40 10.41 12.60 0.52 Balance 100.00 11.2 F 64.40 7.12 11.66 13.00 0.52 Balance 100.00 10.9 G 61.60 7.92 12.91 13.40 0.52 Balance 100.00 10.7 H 58.60 8.80 14.33 13.70 0.52 Balance 100.00 10.4 Ref. 78.40 3.20 5.25 11.20 0.44 Balance 100.00 12.6 EXAMPLE 2 IMPROVEMENT OF THE CAN-PRODUCTION EFFICIENCY BY DECREASING THE CAN TOP WALL THICKNESS VARIATION [0082] The wear performance, and the lifetime of the sample E punch representing the optimized lower density cutoff endpoint were evaluated in two different ways in accordance with the present subject matter. This was done by testing a punch with the same weight as the reference material (78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co, and 0.50 wt.% Cr3C2), i.e., sample E “Same weight as Ref.” type punch seen in Table 3 below, and by testing a punch with the same geometry, but lighter than the reference material, i.e., sample E “Same geometry lighter than Ref.” type punch seen in Table 3. The inside diameter of the produced cans was 66 mm, and they were 33 cl cans. [0083] The wear resistance performance was not detrimentally affected by the increased presence of the brittle gamma phase in the sample E punch. As demonstrated in Table 3, sample E “Same geometry lighter than Ref.”, and sample E “Same weight as Ref.” type punches, and the reference material punch all demonstrated an average wear of 0.4 microns per million produced cans. Further, as demonstrated in Table 3, the average number of cans produced with sample E “Same weight as Ref.” type punch was greater compared to the reference material punch, i.e., 41.89 million cans versus 36.00 million cans. The sample E “Same geometry lighter than Ref.” type punch produced 39.73 million cans, which was also greater than 36.00 million cans produced with the reference material punch.
[0084] Importantly, a clear improvement was observed in the can top wall thickness variation produced with sample E “Same geometry lighter than Ref.” type punch in comparison to the reference material punch. Sample E “Same geometry lighter than Ref.” type punch surprisingly resulted in a can top wall thickness variation of 4.87 µm. On the other hand, the reference material punch, and sample E “Same weight as Ref.” type punch displayed a can top wall thickness variation, of respectively, 6.00 µm, and 6.10 µm. Here, the critical reduction of the can top wall thickness variation for sample E “Same geometry lighter than Ref.” type punch by about 19% compared to the reference material punch has important implications for the overall can-production process. The lower can top wall thickness variation for sample E “Same geometry lighter than Ref.” type punch improves the overall can-production efficiency essentially by decreasing the percentage of the can spoilage during the necking process. [0085] [TABLE 3] Reference punch Sample E (Same Sample E (Same (Ref.) weight as Ref.) geometry lighter than Ref.) Punch weight (Kg.) 3.30 3.30 2.88 Million cans produced 36.00 41.89 39.73 Average wear (µm)/million cans 0.4 0.4 0.4 Can top wall thickness variation (µm) 6.00 6.10 4.87 Can top wall thickness variation standard deviation (µm) 2.30 2.30 2.15 EXAMPLE 3
LOW WEIGHT CEMENTED CARBIDE PUNCH CONSUMES LOW ENERGY IN THE MANUFACTURING OF CANS [0086] Total energy consumption was evaluated in two different can-production plants for sample E “Same geometry lighter than Ref.” type punch representing the optimized lower density cutoff endpoint, which was compared to the reference material punch (78.4 wt.% WC, 4.0 wt.% TiC, 5.9 wt.% NbC, 11.2 wt.% Co, and 0.50 wt.% Cr3C2) in the manufacturing of cans. Collected data represented energy consumption per million of cans produced shown below in Table 4. The inside diameter of the produced cans was 66 mm, and they were 33 cl cans. [0087] It was demonstrated that sample E “Same geometry lighter than Ref.” type punch consumed 3901.2 kWh per million cans produced and 2626.6 kWh per million cans respectively produced in plant 1 and plant 2. In contrast, the reference material punch respectively consumed higher energy levels characterized by 3904.8 kWh per million cans produced and 2642.5 kWh per million cans produced in plant 1 and plant 2. This resulted in energy consumption savings of approximately 0.1 % and 0.7 % respectively in plant 1 and plant 2. Thus, in sum, the sample E “Same geometry lighter than Ref.” type punch having a density of 11.2 g/cm3 representing the optimized lower density cutoff endpoint of all the tested low density punch grades favorably consumed less energy than the reference material punch exhibiting a density of 12.6 g/cm3 as would be advantageously targeted by can-makers. [0088] [TABLE 4] Plant Grade Punch Savings KWh per Machine Time- Machine mass (%) million speed length of operation (Kg.) cans (cpm) power during can- produced recorded production Plant 1 Reference 3.3 0 % 3904.8 280 20 min Running punch continuously for (Ref.) 20 minutes after Sample E 2.9 -0.1 % 3901.2 a 20-minute (Same warm up geometry lighter than Ref.)
Plant 2 Reference 4.0 0 % 2642.5 0 to 6 days Start and stop punch 260 - as required by (Ref.) 320 production Sample E 3.6 -0.7% 2626.6 (Same geometry lighter than Ref.) [0089] Although the present disclosure has been described in connection with examples thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departure from the spirit and scope of the disclosure as defined in the appended claims. [0090] 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 are not expressly set forth herein for sake of clarity. [0091] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting, and/or logically interactable components.
[0092] In some instances, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Those skilled in the art will recognize that such terms (e.g., “configured to”) can generally encompass active- state components and/or inactive-state components and/or standby-state components, unless context requires otherwise. [0093] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. 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 claims 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. [0094] 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). [0095] 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.). [0096] It will be further understood by those within the art that typically a 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 unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.” [0097] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.
[0098] Those skilled in the art will appreciate that the foregoing specific exemplary processes and/or devices and/or technologies are representative of more general processes and/or devices and/or technologies taught elsewhere herein, such as in the claims filed herewith and/or elsewhere in the present application. [0099] While various aspects and examples have been disclosed herein, other aspects and examples will be apparent to those skilled in the art. The various aspects and examples 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. [00100] The illustrative examples described in the detailed description, drawings, and claims are not meant to be limiting. Other examples may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. [00101] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. The upper and lower limits of these smaller ranges which can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either both of those included limits are also included in the disclosure. [00102] One skilled in the art will recognize that the herein described components (e.g., operations), devices, objects, and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific exemplars set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components (e.g., operations), devices, and objects should not be taken as limiting.
[00103] Additionally, for example any sequence(s) and/or temporal order of sequence of the system and method that are described herein this disclosure are illustrative and should not be interpreted as being restrictive in nature. Accordingly, it should be understood that the process steps may be shown and described as being in a sequence or temporal order, but they are not necessarily limited to being carried out in any particular sequence or order. For example, the steps in such processes or methods generally may be carried out in various different sequences and orders, while still falling within the scope of the present disclosure. [00104] Finally, the discussed application publications and/or patents herein are provided solely for their disclosure prior to the filing date of the described disclosure. Nothing herein should be construed as an admission that the described disclosure is not entitled to antedate such publication by virtue of prior disclosure.