CN106216689A - 一种pdc钻头胎体制备工艺 - Google Patents
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Abstract
本发明公开了一种PDC钻头胎体制备工艺。制备工艺包括:模具制作,钢体制作,粉料制作,装料,胎体无压浸渍烧结,胎体加压浸渍烧结,脱模和清理胎体。本发明采用加压浸渍烧结PDC钻头胎体能使铜合金更充分地渗透入粉料中,铜合金更饱满地填充在粉料间隙中能大幅提高烧结出的胎体的整体强度;在钻井中,采用本发明提供的PDC胎体钻头具有更高强度,钻头使用寿命大幅提高,节约了大量起下钻时间,缩短了钻井周期提高了钻井效率;本发明的工艺其流程更加完备、质量更加稳定、性价比高、生产效率高和适用范围广泛。
Description
技术领域
本发明属于地质钻探设备设计制造技术领域,尤其属于一种在深井或硬地层中使用的石油、地质用回转钻进钻头,特别涉及一种高抗冲蚀性的PDC钻头胎体制备工艺。
背景技术
目前,在石油、地质等领域使用PDC齿作为切削齿的回转钻进钻头(简称PDC钻头)很广泛。与其他类别钻头,如牙轮钻头、刮刀钻头和天然金刚石钻头等相比较,PDC钻头具有机械钻速高,钻头进尺寿命长等优点。PDC胎体钻头在井底工作时,承受着高强度的扭矩负荷和来自轴向、法向和周向的各种冲击负荷。随着钻井深度的不断增加,扭矩负荷和冲击负荷也越来越强烈,上述情况会加剧钻头胎体的损坏,大幅度降低了钻头使用寿命。如果负荷过载,甚至会出现断刀翼等钻井事故。钻头使用寿命低和处理短刀翼钻井事故都必须要进行起下钻工作,频繁起下钻大幅增加了钻井周期,钻井效率极低。因此PDC钻头胎体强度不足是钻头使用寿命低的一个瓶颈所在,对钻井周期和钻井效率影响极大。而目前PDC钻头胎体基本都采用无压浸渍烧结工艺,该工艺在提高PDC钻头胎体强度方面没有太大的工艺改进效果,这是目前PDC钻头普遍存在又没有解决的难题。
发明内容
本发明根据现有技术的不足公开了一种PDC钻头胎体制备工艺。本发明要解决的问题是提供一种生产效率高、胎体强度高的加压浸渍烧结PDC钻头胎体制备工艺,改进PDC钻头性能,延长PDC钻头使用时间,提高钻进效率。
本发明通过以下技术方案实现:
一种PDC钻头胎体制备工艺;
所述PDC钻头胎体由胎体烧结粉料与铜合金烧结制成;粉料是包括各种直径颗粒的碳化钨粉、镍粉等金属粉料的混合物。
制作工艺包括:
1)模具制作:按照图纸加工出全套模具,包括钻头形状模具和辅助烧结模具,并在模具上相应的位置安装切削齿、喷嘴的石墨替代模块;
2)钢体制作:按照图纸加工出钻头烧结用钢体,其结构依据所设计的钻头结构制作;
3)粉料制作:将粉料称重后装入混粉机进行充分混粉;粉料混好后装入干燥罐在50~80摄氏度进行加温保存;
4)装料:在振动台上用装料环将钢体固定在钻头形状模具相应的空间位置,装入粉料,采用间歇性震动将粉料震实;然后安装上辅助烧结模具;
5)胎体无压浸渍烧结:将全套模具放置在预热炉内进行预热,粉料的预热温度设定在350~400摄氏度,预热时间为1.5~6小时;预热完成后加入铜合金,然后将全套模具放置到烧结炉中进行烧结,烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时胎体烧结;
6)胎体加压浸渍烧结:无压浸渍烧结完成后将模具移入到钢制加压烧结炉中,灌入氮气使钢制加压烧结炉保持4~6MPa的压力,将烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时;
7)冷却:将模具移出烧结炉,盖上隔热罩,从模具底部用水冲刷对模具进行降温并帮助粉料定向凝固结晶形成胎体;
8)脱模和清理胎体:将全套模具移除得到烧结的胎体半成品,用喷砂机清理掉切削齿和喷嘴的石墨替代模块,去除胎体表面毛刺。
与现有技术相比,本发明具有的有益效果是:
1)采用加压浸渍烧结PDC钻头胎体能使铜合金更充分地渗透入粉料中,铜合金更饱满地填充在粉料间隙中能大幅提高烧结出的胎体的整体强度。
2)在钻井中,采用本发明提供的PDC胎体钻头具有更高强度,钻头使用寿命大幅提高,节约了大量起下钻时间,缩短了钻井周期提高了钻井效率。
3)本发明的工艺其流程更加完备、质量更加稳定、性价比高、生产效率高和适用范围广泛。
具体实施方式
下面通过实施例对本发明进行具体的描述,本实施例只用于对本发明进行进一步的说明,但不能理解为对本发明保护范围的限制,本领域的技术人员根据上述本发明的内容作出的一些非本质的改进和调整也属于本发明保护的范围。
PDC钻头胎体制备工艺;
所述PDC钻头胎体由胎体烧结粉料与铜合金烧结制成;
制作工艺包括:
1)模具制作:按照图纸加工出全套模具,包括钻头形状模具和辅助烧结模具,并在模具上相应的位置安装切削齿、喷嘴的石墨替代模块;
2)钢体制作:按照图纸加工出钻头烧结用钢体,其结构依据所设计的钻头结构制作;
3)粉料制作:将粉料称重后装入混粉机进行充分混粉;粉料混好后装入干燥罐在50~80摄氏度进行加温保存;
4)装料:在振动台上用装料环将钢体固定在钻头形状模具相应的空间位置,装入粉料,采用间歇性震动将粉料震实;然后安装上辅助烧结模具;
5)胎体无压浸渍烧结:将全套模具放置在预热炉内进行预热,粉料的预热温度设定在350~400摄氏度,预热时间为1.5~6小时;预热完成后加入铜合金,然后将全套模具放置到烧结炉中进行烧结,烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时胎体烧结;
6)胎体加压浸渍烧结:无压浸渍烧结完成后将模具移入到钢制加压烧结炉中,灌入氮气使钢制加压烧结炉保持5MPa的压力,将烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时;
7)冷却:将模具移出烧结炉,盖上隔热罩,从模具底部用水冲刷对模具进行降温并帮助粉料定向凝固结晶形成胎体;
8)脱模和清理胎体:将全套模具移除得到烧结的胎体半成品,用喷砂机清理掉切削齿和喷嘴的石墨替代模块,去除胎体表面毛刺。
胎体抗弯强度试验对比
试验方法:横向断裂强度试验和冲击韧性试验
横向断裂强度试验:将上述工艺烧结的胎体和常规工艺烧结的胎体分别取样5件,试样尺寸为20*6.5*5.25mm。按国标GB3851标准做横向断裂强度试验,试验数据如下:由上述实验对比数据可以看出,新胎体配方和工艺制造的钻头胎体耐冲蚀程度提高30.04%。耐冲蚀性能得到显著提高。钻头在井下工作时耐冲蚀寿命得到大幅提高,钻头综合使用寿命得到充分保障。
由上述实验对比数据可以看出,新工艺试样的横向断裂强度比常规工艺试样的横向断裂强度提高34.9%。
冲击韧性试验:将上述工艺烧结的胎体和常规工艺烧结的胎体分别取样5件,试样尺寸为55*10*10mm。按国标GB/T229标准做冲击韧性试验,试验数据如下:
由上述实验对比数据可以看出,新工艺试样承受的冲击能量比常规工艺试样承受的冲击能量提高122.3%。
综上横向断裂试验数据和冲击韧性试验数据的对比分析,可以看出钻头强度得到大幅提高,钻头综合使用寿命得到充分保障。
Claims (1)
1.一种PDC钻头胎体制备工艺,其特征在于:
所述PDC钻头胎体由胎体烧结粉料与铜合金烧结制成;
制作工艺包括:
1)模具制作:按照图纸加工出全套模具,包括钻头形状模具和辅助烧结模具,并在模具上相应的位置安装切削齿、喷嘴的石墨替代模块;
2)钢体制作:按照图纸加工出钻头烧结用钢体,其结构依据所设计的钻头结构制作;
3)粉料制作:将粉料称重后装入混粉机进行充分混粉;粉料混好后装入干燥罐在50~80摄氏度进行加温保存;
4)装料:在振动台上用装料环将钢体固定在钻头形状模具相应的空间位置,装入粉料,采用间歇性震动将粉料震实;然后安装上辅助烧结模具;
5)胎体无压浸渍烧结:将全套模具放置在预热炉内进行预热,粉料的预热温度设定在350~400摄氏度,预热时间为1.5~6小时;预热完成后加入铜合金,然后将全套模具放置到烧结炉中进行烧结,烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时胎体烧结;
6)胎体加压浸渍烧结:无压浸渍烧结完成后将模具移入到钢制加压烧结炉中,灌入氮气使钢制加压烧结炉保持10~20MPa的压力,将烧结温度设置为1100~1180摄氏度,烧结时间1.5~6小时;
7)冷却:将模具移出烧结炉,盖上隔热罩,从模具底部用水冲刷对模具进行降温并帮助粉料定向凝固结晶形成胎体;
8)脱模和清理胎体:将全套模具移除得到烧结的胎体半成品,用喷砂机清理掉切削齿和喷嘴的石墨替代模块,去除胎体表面毛刺。
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CN108817406A (zh) * | 2018-08-09 | 2018-11-16 | 中铁工程服务有限公司 | 一种烧结碳化钨胎体刀圈的配方和制备工艺 |
CN109795012A (zh) * | 2019-04-08 | 2019-05-24 | 成都惠灵丰金刚石钻头有限公司 | Pdc胎体钻头制模工艺 |
CN114082955A (zh) * | 2020-08-25 | 2022-02-25 | 成都百施特金刚石钻头有限公司 | 一种高性能胎体钻头的制造方法 |
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