CN109630027A - 薄壁钻地工具及其制造方法 - Google Patents
薄壁钻地工具及其制造方法 Download PDFInfo
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- CN109630027A CN109630027A CN201811119848.0A CN201811119848A CN109630027A CN 109630027 A CN109630027 A CN 109630027A CN 201811119848 A CN201811119848 A CN 201811119848A CN 109630027 A CN109630027 A CN 109630027A
- Authority
- CN
- China
- Prior art keywords
- sintered hard
- hard carbide
- earth
- boring tools
- shell
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 238000005520 cutting process Methods 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 16
- 239000002245 particle Substances 0.000 claims description 82
- 229910052751 metal Inorganic materials 0.000 claims description 51
- 239000002184 metal Substances 0.000 claims description 51
- 238000000034 method Methods 0.000 claims description 40
- 239000000843 powder Substances 0.000 claims description 38
- 238000005245 sintering Methods 0.000 claims description 29
- 239000011230 binding agent Substances 0.000 claims description 19
- 239000000853 adhesive Substances 0.000 claims description 18
- 230000001070 adhesive effect Effects 0.000 claims description 18
- 150000001247 metal acetylides Chemical class 0.000 claims description 17
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 9
- 238000005516 engineering process Methods 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 6
- 241001074085 Scophthalmus aquosus Species 0.000 claims description 4
- 230000008859 change Effects 0.000 claims description 3
- 238000000110 selective laser sintering Methods 0.000 claims description 3
- 238000001513 hot isostatic pressing Methods 0.000 claims description 2
- 235000013312 flour Nutrition 0.000 claims 2
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 11
- 230000008569 process Effects 0.000 description 10
- 239000000956 alloy Substances 0.000 description 7
- 229910045601 alloy Inorganic materials 0.000 description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 6
- 239000013078 crystal Substances 0.000 description 5
- 238000013461 design Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 229920001223 polyethylene glycol Polymers 0.000 description 4
- 238000010146 3D printing Methods 0.000 description 3
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- 239000002202 Polyethylene glycol Substances 0.000 description 3
- 229910009043 WC-Co Inorganic materials 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 229910003460 diamond Inorganic materials 0.000 description 3
- 239000010432 diamond Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 230000008595 infiltration Effects 0.000 description 3
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- 238000007639 printing Methods 0.000 description 3
- 238000001878 scanning electron micrograph Methods 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- 239000010937 tungsten Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- KAESVJOAVNADME-UHFFFAOYSA-N Pyrrole Chemical compound C=1C=CNC=1 KAESVJOAVNADME-UHFFFAOYSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 238000003763 carbonization Methods 0.000 description 2
- 238000005253 cladding Methods 0.000 description 2
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- 238000010276 construction Methods 0.000 description 2
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- 238000000227 grinding Methods 0.000 description 2
- 229910021385 hard carbon Inorganic materials 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 239000003112 inhibitor Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000012071 phase Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 230000002028 premature Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000010561 standard procedure Methods 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 238000001291 vacuum drying Methods 0.000 description 2
- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 229910026551 ZrC Inorganic materials 0.000 description 1
- OTCHGXYCWNXDOA-UHFFFAOYSA-N [C].[Zr] Chemical compound [C].[Zr] OTCHGXYCWNXDOA-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000002902 bimodal effect Effects 0.000 description 1
- UQMRAFJOBWOFNS-UHFFFAOYSA-N butyl 2-(2,4-dichlorophenoxy)acetate Chemical compound CCCCOC(=O)COC1=CC=C(Cl)C=C1Cl UQMRAFJOBWOFNS-UHFFFAOYSA-N 0.000 description 1
- 150000001722 carbon compounds Chemical class 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000004210 ether based solvent Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- WHJFNYXPKGDKBB-UHFFFAOYSA-N hafnium;methane Chemical compound C.[Hf] WHJFNYXPKGDKBB-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000013178 mathematical model Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/08—Roller bits
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/5607—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on refractory metal carbides
- C04B35/5626—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on refractory metal carbides based on tungsten carbides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/50—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of roller type
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/62—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable
- E21B10/627—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable with plural detachable cutting elements
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/62—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable
- E21B10/627—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable with plural detachable cutting elements
- E21B10/633—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable with plural detachable cutting elements independently detachable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Landscapes
- Engineering & Computer Science (AREA)
- Geology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- Geochemistry & Mineralogy (AREA)
- Physics & Mathematics (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Powder Metallurgy (AREA)
- Drilling Tools (AREA)
Abstract
本发明题为“薄壁钻地工具及其制造方法”。本文描述了钻地工具,所述钻地工具采用烧结硬质碳化物组合物结合薄壁架构。在一些实施方案中,钻地工具包括钻头,所述钻头包括切削部分和主体部分,所述主体部分包括烧结硬质碳化物壳,所述烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。
Description
技术领域
本发明涉及钻地工具,并且具体地讲,涉及包括薄壁架构的钻头。
背景技术
用于石油和天然气勘探的钻地工具通常通过加工石墨模具并且用碳化钨(WC)粉末填充该模具来生产。将较低熔点的合金(通常是铜基的)放置在WC粉末的顶部上作为熔渗金属粘结剂。将模具放置到真空炉中,该真空炉熔化熔渗剂以通过毛细管力填充WC颗粒之间的空隙空间,从而将WC颗粒粘结在一起并且形成钻地工具形状的硬金属增强复合结构。该工艺限于具有有限体积分数(最多60体积%)和低熔点熔渗剂的粗粒碳化钨。Cu基熔渗WC材料相对于WC-Co等级具有较差的机械特性和耐磨性,该WC-Co等级具有更细的晶粒粒度、更高体积的WC含量和更强的钴、镍或铁金属粘结剂。石墨模具加工、芯插入件和熔渗工艺的当前技术是具有几何限制的耗时且昂贵的工艺。此外,固体碳化物结构使用过量的WC,这导致镗孔工具的重量增加。
发明内容
在一个方面,本文描述了采用烧结硬质碳化物组合物结合薄壁架构的钻地工具。简而言之,钻地工具包括钻头,该钻头包括切削部分和主体部分,该主体部分包括烧结硬质碳化物壳,该烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。在一些实施方案中,烧结硬质碳化物壳的厚度为钻头直径的10%至20%。
在另一方面,提供了制造钻地工具的方法。在一些实施方案中,制造钻地工具的钻头的方法包括通过增材制造技术将等级粉末固结到钻头中,该钻头包括切削部分和主体部分,该主体部分包括烧结硬质碳化物壳,该烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。等级粉末可包括金属碳化物和金属粘结剂。在一些实施方案中,等级粉末包括烧结硬质碳化物颗粒。
这些和其他实施方案在以下具体实施方式中进一步描述。
附图说明
图1是根据本文所述的一些实施方案的钻地工具的钻头。
图2是图1的钻头的烧结碳化物壳的内部的透视图。
图3A是根据本文所述的一些实施方案的烧结硬质碳化物颗粒的SEM图像。
图3B是比较烧结硬质碳化物颗粒的SEM图像。
图4示出根据一些实施方案的联接到钻头的烧结硬质碳化物壳的晶格结构。
具体实施方式
参考以下具体实施方式和实施例以及前述和下述内容可更容易地理解本文所述的实施方案。然而,本文所述的元素、设备和方法并不限于具体实施方式和实施例中所述的具体实施方案。应当认识到,这些实施方案仅示例性地说明本发明的原理。在不脱离本发明实质和范围的情况下,多种修改和变更对于本领域技术人员而言将是显而易见的。
I.钻地工具
本文描述了采用烧结硬质碳化物组合物结合薄壁架构的钻地工具。在一些实施方案中,钻地工具包括钻头,该钻头包括切削部分和主体部分,该主体部分包括烧结硬质碳化物壳,该烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。钻头直径由切削元件上的最大直径限定,该最大直径在土地中产生孔直径。图1示出根据本文所述的方法生产的具有薄壁烧结硬质碳化物壳的固定切削器钻头。钻头10包括形成钻头10的切削部分的多个固定切削片11。切削片11包括多个凹座15以用于接收切削刀片。主体部分12支撑切削片11并且包括烧结硬质碳化物壳13。图2是烧结硬质碳化物壳13的内部的透视图。如图1和图2所示,烧结硬质碳化物壳13包括孔14以用于将流体(诸如泥浆或浆料)传送到切削片。孔14可邻近切削片11定位以用于将流体递送到定位在切削片11的凹座15中的切削刀片(未示出)。在一些实施方案中,孔14是一个或多个喷嘴结构的一部分。此外,壳13的中空内部可充当泥浆和/或其他流体的贮存器,以通过孔14递送。钻头还包括与烧结硬质碳化物壳13相邻并且具有与固定切削片11相应的径向布置的保径衬垫16。虽然固定切削片在图1和图2中示出,但本文所述的钻头还设想到包括牙轮的切削部分。
烧结硬质碳化物壳的壁厚度可为钻头直径的5%至25%。在一些实施方案中,烧结硬质碳化物壳的壁厚度可选自表I。
表I-烧结硬质碳化物壳的壁厚度
钻头直径的百分比 |
5-25 |
5-20 |
5-15 |
5-10 |
10-25 |
10-20 |
15-25 |
15-20 |
在一些实施方案中,烧结硬质碳化物壳具有均匀的壁厚度或基本上均匀的壁厚度,该壁厚度具有选自表I的值。在基本上均匀的情况下,壁厚度相对于烧结硬质碳化物壳变化小于10%。在其他实施方案中,烧结硬质碳化物壳表现出可变的壁厚度。例如,烧结硬质碳化物壳可在一个或多个竖直和/或径向尺寸上表现出可变厚度。在表现出可变厚度时,烧结硬质碳化物壳的一个或多个区域可具有选自表I的壁厚度,而其他区域可具有在表I的参数之外的壁厚度值。在一些实施方案中,壁厚度在钻头操作期间在烧结硬质碳化物壳的经受高应力和/或磨损的区域中增加。此类区域包括钻头的冲击区域和到钻地设备的合金或钢主体的附接点。
钻头可以具有任何期望的直径以用于钻地应用。在一些实施方案中,钻头的直径为100mm至300mm。具体地讲,钻头可具有选自表II的直径。
表II-钻头直径(mm)
100 |
150 |
200 |
250 |
300 |
<100 |
>300 |
如本文所述,钻头的壳包括烧结硬质碳化物。烧结硬质碳化物包括金属碳化物晶粒和金属粘结剂。金属粘结剂(诸如钴、镍、铁或其合金)能够以0.5至30重量%的量存在于壳的烧结硬质碳化物中。
此外,合适的金属碳化物晶粒包括选自元素周期表IVB-VIB族的一种或多种过渡金属。在一些实施方案中,例如,金属碳化物晶粒包括碳化钨。碳化钨能够以至少80重量%或至少90重量%的量存在于烧结硬质碳化物中。在一些实施方案中,碳化钨是烧结硬质碳化物制品的唯一金属碳化物。作为另外一种选择,除了碳化钨之外,金属碳化物还可包括铌、钒、钽、铬、锆和/或铪中的一种或多种的碳化物。烧结硬质碳化物制品的金属碳化物晶粒可具有不违背本发明目的的任何粒度。例如,金属碳化物晶粒可具有0.5μm至50μm的平均粒度。
在一些实施方案中,在壳制造中采用的金属碳化物颗粒是烧结硬质碳化物颗粒。如本文进一步所详述,单独的烧结硬质碳化物颗粒包括与金属粘结剂结合烧结在一起的多个金属碳化物晶粒。在松散条件下,在一些实施方案中,烧结硬质碳化物颗粒可具有至少6g/cm3的表观密度。如本领域技术人员所知,表观密度是松散条件下单位体积的粉末或颗粒的质量,通常以g/cm3表示。在一些实施方案中,烧结硬质碳化物颗粒具有至少7g/cm3的表观密度。本文所述的等级粉末的烧结硬质碳化物颗粒的表观密度也可具有选自表III的值。
表III-烧结硬质碳化物颗粒的表观密度
等级粉末的烧结硬质碳化物颗粒的表观密度也可小于6g/cm3。例如,在一些实施方案中,烧结硬质碳化物颗粒的表观密度可在2-6g/cm3的范围内。烧结硬质碳化物颗粒的表观密度可使用霍尔流量计漏斗根据ASTM B212自由流动金属粉末的表观密度的标准测试方法来确定。
除了表观密度之外,在壳制造中采用的烧结硬质碳化物颗粒可具有至少7g/cm3的振实密度。在一些实施方案中,烧结硬质碳化物颗粒表现出具有选自表IV的值的振实密度。
表IV-烧结硬质碳化物颗粒的振实密度
≥7.5g/cm<sup>3</sup> |
≥8g/cm<sup>3</sup> |
≥8.5g/cm<sup>3</sup> |
≥9.5g/cm<sup>3</sup> |
7-12g/cm<sup>3</sup> |
8-12g/cm<sup>3</sup> |
9-12g/cm<sup>3</sup> |
烧结硬质碳化物颗粒的振实密度可根据ASTM B527金属粉末和化合物的振实密度的标准测试方法来确定。在一些实施方案中,烧结硬质碳化物颗粒的振实密度与表观密度的比率(Hausner比率)为1.05至1.50。在一些实施方案中,烧结硬质碳化物颗粒的Hausner比率为1.1至小于1.50。
除了表观密度和振实密度之外,烧结硬质碳化物颗粒的平均单个颗粒密度可为理论密度的至少80%。在一些实施方案中,烧结硬质碳化物颗粒的平均单独颗粒密度为理论密度的至少90%或至少95%。在一些实施方案中,烧结硬质碳化物颗粒可表现出理论密度的80%至95%的平均单独颗粒密度。在另外的实施方案中,烧结硬质碳化物颗粒可表现出理论密度的90%至98%的平均单独颗粒密度。
如本文进一步所述,上述表观密度、振实密度和单独颗粒密度可通过在颗粒形成期间施用的一个或若干个烧结过程来实现。在一些实施方案中,烧结过程不采用一种或多种烧结抑制剂来减轻颗粒粘附或粘合。本文所述的烧结硬质碳化物颗粒特性可在不存在一种或多种烧结抑制剂的情况下实现。在一些实施方案中,通过在1100℃至1400℃的温度下烧结等级粉末0.5至2小时来制备烧结硬质碳化物颗粒,以提供烧结压坯。随后研磨烧结压坯以提供单独的烧结硬质碳化物颗粒。根据颗粒形态和密度,可进一步对烧结硬质碳化物颗粒进行热处理以进一步致密化。进一步的热处理可包括等离子体致密化,诸如使用RF等离子炬或DC等离子炬的等离子体球化。作为另外一种选择,烧结硬质碳化物颗粒可被再烧结,从而形成第二压坯。研磨第二压坯以提供烧结硬质碳化物颗粒。可施用进一步的致密化处理任何期望的次数,以向烧结硬质碳化物颗粒提供期望的表观密度、振实密度和/或单独颗粒密度。烧结时间和温度可根据若干考虑因素选择,包括但不限于硬质碳化物颗粒的粘结剂含量、期望的烧结颗粒密度和烧结阶段。在一些实施方案中,在较低温度和/或较短时间下进行早期烧结阶段以促进研磨烧结压坯。例如,初始或早期烧结过程可在低于粘结剂液化的温度下施用。后期或最终烧结过程可实现较高的温度,诸如发生液相烧结的温度。
作为另外一种选择,烧结硬质碳化物颗粒已被开发以用于不相关的应用,诸如热喷涂和其他包覆应用。在一些实施方案中,可商购获得的用于这些不相关应用的烧结硬质碳化物颗粒可用于本文所述的钻头的烧结硬质碳化物壳中。例如,为热喷涂/包覆应用开发的烧结硬质碳化物颗粒可从全球钨和粉末公司(Global Tungsten and PowdersCorporation)以Powder Perfect商品名商购获得。
图3A是在固结到钻头的壳中之前烧结硬质碳化物颗粒的SEM图像。对硬质碳化物颗粒施用了两次烧结过程,得到7g/cm3的表观密度和8.5g/cm3的振实密度。出于比较的目的,图3B是表观密度为4.5g/cm3并且振实密度为5.5g/cm3的烧结硬质碳化物颗粒的SEM图像。如图3B所示,烧结硬质碳化物颗粒表现出明显更高的孔隙率,从而引起低的单独颗粒密度。
烧结硬质碳化物颗粒可通常具有1μm至100μm的平均粒度。在一些实施方案中,烧结硬质碳化物颗粒具有选自表V的平均粒度。
表V-平均烧结硬质碳化物颗粒粒度(μm)
5-90 |
5-50 |
10-75 |
10-50 |
5-40 |
20-40 |
0.5-2 |
1-5 |
1-10 |
在一些实施方案中,烧结硬质碳化物颗粒可表现出高斯粒度分布。在其他实施方案中,烧结硬质碳化物颗粒可具有多分散、双峰或多峰粒度分布。在另外的实施方案中,烧结硬质碳化物颗粒可以是单分散的或基本上单分散的。在基本上单分散的情况下,硬质碳化物颗粒在平均粒度的±10%或±5%内。在一些实施方案中,烧结硬质碳化物颗粒是球形形状或基本上球形形状的。作为另外一种选择,烧结硬质碳化物颗粒可以是不规则形状的颗粒与球形或基本上球形的颗粒的混合物。
烧结硬质碳化物颗粒包括选自由IVB族金属碳化物、VB族金属碳化物和VIB族金属碳化物构成的组的一种或多种金属碳化物。在一些实施方案中,碳化钨是烧结颗粒的唯一金属碳化物。在其他实施方案中,将一种或多种IVB族、VB族和/或VIB族金属碳化物与碳化钨结合以提供单独的烧结颗粒。例如,碳化铬、碳化钛、碳化钒、碳化钽、碳化铌、碳化锆和/或碳化铪和/或它们的固溶体可在烧结颗粒生产中与碳化钨结合。碳化钨通常能够以至少约80或85重量%的量存在于烧结颗粒中。在一些实施方案中,除碳化钨之外的IVB、VB和/或VIB族金属碳化物以0.1至5重量%的量存在于烧结颗粒中。
烧结硬质碳化物颗粒包括金属粘结剂。烧结硬质碳化物颗粒的金属粘结剂可选自由钴、镍和铁及其合金构成的组。在一些实施方案中,金属粘结剂以0.1至35重量%的量存在于烧结硬质碳化物颗粒中。金属粘结剂也能够以选自表VI的量存在于烧结硬质碳化物颗粒中。
表VI-金属粘结剂含量(重量%)
0.1-20 |
0.1-10 |
0.5-15 |
1-10 |
3-20 |
5-15 |
12-15 |
10-35 |
15-35 |
15-25 |
烧结硬质碳化物颗粒的金属粘结剂还可包括一种或多种添加剂,诸如贵金属添加剂。在一些实施方案中,金属粘结剂可包括选自由铂、钯、铼、铑和钌及其合金构成的组的添加剂。在其他实施方案中,金属粘结剂的添加剂可包括钼、硅或它们的组合。添加剂能够以不违背本发明目的的任何量存在于金属粘结剂中。例如,一种或多种添加剂能够以烧结硬质碳化物颗粒的0.1至10重量%的量存在于金属粘结剂中。
在一些实施方案中,钻头壳可表现出小于5体积%的孔隙率或小于3体积%的孔隙率。形成钻头壳的烧结硬质碳化物组合物的颗粒组成、粒度和金属粘结剂含量可根据包括期望韧性和耐磨性在内的若干考虑因素而变化。在一些实施方案中,烧结硬质碳化物在整个壳中是均匀的。作为另外一种选择,烧结硬质碳化物可在壳的一个或多个尺寸上表现出一个或多个梯度。在一些实施方案中,烧结硬质碳化物在壳的一个或多个尺寸上表现出粒度和/或金属粘结剂梯度。例如,烧结硬质碳化物的粒度和/或金属粘结剂含量可在壳的经历高磨损的区域中减小。在其他实施方案中,烧结硬质碳化物的粒度和/或粘结剂含量可在壳的接收冲击或需要增强韧性的区域中增加。烧结硬质碳化物的组成梯度可与本文所述的壁厚度变化结合,以向壳提供期望的特性。
在一些实施方案中,一个或多个晶格结构联接到钻头的烧结硬质碳化物壳。晶格结构可具有任何设计、特征和/或布置,以便为烧结硬质碳化物壳提供结构增强。在一些实施方案中,一个或多个晶格结构可跨越烧结硬质碳化物壳的内径。在其他实施方案中,支撑环可与壳一起定位,其中晶格结构在支撑环和壳的内壁之间延伸。支撑环可具有任何期望的横截面形状,包括圆形、椭圆形或多边形。另外,晶格结构可具有任何构型,包括在支撑环和壳的内壁之间延伸的直的、弯曲的和/或曲线的节段。图4示出根据一些实施方案的支撑环和相关联的晶格结构。如图4所示,曲线晶格41在壳40的内壁和支撑环42之间延伸。
在一些实施方案中,烧结硬质碳化物壳还包括在壳的内壁上的一个或多个肋结构。肋结构可沿着壳的内壁形成连续的环。在其他实施方案中,肋结构沿着壳的内壁可以是不连续的。例如,肋结构可沿着壳的内壁放置在各种间隔或位置处。在一些实施方案中,肋结构沿着内壁放置在保径衬垫之间的位置处。晶格和/或肋结构可由不违背本发明目的的任何材料形成。在一些实施方案中,晶格和/或肋结构由烧结硬质碳化物形成。晶格和/或肋结构的烧结硬质碳化物可具有本文所述的任何组成参数、特性和/或特征。
烧结硬质碳化物壳的内表面还可包括螺纹以用于接合金属或合金主体,诸如钻柱或镗头。在一些实施方案中,螺纹由烧结硬质碳化物形成。钻头的烧结碳化物壳可通过反向螺纹、钎焊、冷缩配合和/或包括螺栓、螺钉和/或普通紧固件的其他机械装置附接到金属或合金主体。
再次参见图1,切削片11包括多个凹座15以用于接收切削刀片。在一些实施方案中,凹座15包括一个或多个结构特征以用于机械地接合切削刀片。结构元件可选自由螺纹、狭槽、凸缘、锥形凹座直径以及它们的组合构成的组。切削刀片的机械接合可便于用新刀片替换磨损的刀片。切削刀片可包括多晶金刚石(PCD)刀片、碳化钨刀片、具有超耐磨表面的碳化钨刀片,诸如天然或人造金刚石、多晶金刚石、多晶立方氮化硼(PCBN),或由碳化钨和其他材料的基质构成的刀片,或它们的任何组合。
II.制造钻地工具的方法
在另一方面,提供了制造钻地工具的方法。在一些实施方案中,制造钻地工具的钻头的方法包括通过增材制造技术将等级粉末固结到钻头中,该钻头包括切削部分和主体部分,该主体部分包括烧结硬质碳化物壳,该烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。等级粉末可包括金属碳化物和金属粘结剂。在一些实施方案中,等级粉末包括烧结硬质碳化物颗粒,该烧结硬质碳化物颗粒具有上文在第I部分中描述的组成和特性。
如本文所述,等级粉末通过一种或多种增材制造技术固结到钻头中。能够采用可操作以将等级粉末形成到钻头中的任何增材制造技术。例如,根据详细描述钻头的设计参数的电子文件,可通过激光烧结将等级粉末固结到钻头中。在一些实施方案中,将等级粉末固结到生坯钻头中并且随后烧结。例如,粘结剂喷射可提供由等级粉末形成的生坯钻头。在粘结剂喷射过程中,提供了详细描述钻头的设计参数的电子文件。粘结剂喷射设备在构建箱中铺展一层等级的粉末。打印头根据该层的设计参数在粉末层上移动沉积液体粘结剂。将该层干燥,并降低构建箱。铺展新的等级粉末层,并重复该过程直到完成生坯制品。在一些实施方案中,其他3D打印设备可用于从等级粉末结合有机粘结剂构造生坯制品。
不违背本发明目的的任何有机粘结剂都可用于通过一种或多种增材制造技术形成生坯钻头。在一些实施方案中,有机粘结剂包括一种或多种聚合物材料,诸如聚乙烯吡咯烷酮(PVP)、聚乙二醇(PEG)或它们的混合物。在一些实施方案中,有机粘结剂是可固化的,其可增强生坯制品的强度。例如,生坯钻头可表现出至少10MPa的抗压强度。在一些实施方案中,生坯钻头的抗压强度在10-20MPa的范围内。根据ASTM E9室温下金属材料压缩测试的标准测试方法来确定生坯制品的压缩强度。
在一些实施方案中,生坯或半生钻头可通过选择性激光烧结来形成。选择性激光烧结条件被选择为提供具有低密度的生坯或半生钻头。然后将生坯或半生钻头烧结至全密度或接近全密度,如下所述。
由本文所述的等级粉末组合物形成的生坯钻头可在一定条件下烧结一定的时间段,以提供具有期望密度的烧结制品。生坯制品可在氢气或氩气氛下在1300℃至1560℃的温度下真空烧结或烧结。此外,烧结时间通常可为10分钟至5小时。在一些实施方案中,将热等静压(HIP)添加到烧结过程中。热等静压可作为烧结后操作或在真空烧结期间施用。热等静压可在1MPa至300MPa的压力和1300℃至1560℃的温度下施用最多2小时。本文所述的烧结钻头可表现出大于理论全密度的98%的密度。烧结钻头的密度可以是理论全密度的至少99%。此外,在一些实施方案中,烧结钻头的微观结构可以是均匀的。在烧结制品中也可以不存在非化学计量金属碳化物,诸如η相、W2C和/或W3C。作为另外一种选择,烧结硬质碳化物钻头可包含少量的一种或多种非化学计量金属碳化物(通常<5重量%或<1重量%)。此外,本文所述的烧结钻头可具有小于100μm的平均晶粒粒度。在一些实施方案中,例如,烧结钻头具有1-50μm或10-40μm的平均晶粒粒度。
在一些实施方案中,根据本文所述方法生产的烧结钻头在一个或多个尺寸上相对于生坯形式表现出小于25%的收缩率或小于20%的收缩率。烧结钻头在一个或多个尺寸上相对于生坯制品的线性收缩率也可具有选自表VII的值。
表VII-烧结制品的线性收缩率
≤15% |
≤10% |
≤5% |
5-25% |
5-10% |
1-10% |
1-5% |
根据本文描述的方法生产的烧结钻头可具有上文在第I部分中描述的任何组成、结构和/或特性,包括薄壁架构。在一些实施方案中,钻头的烧结硬质碳化物壳具有选自上表I的壁厚度。通过以下非限制性实施例对这些和其他实施方案进行进一步说明。
实施例1-钻头
如下制造具有烧结硬质碳化物的薄壁架构的钻头。3D打印系统在构建箱中使用WC-17%Co粉末的迭代铺展的分层过程中生成生坯钻头,然后根据产品的设计施加PVP-PEG粘结剂与聚乙二醇醚溶剂。将烧结硬质碳化物颗粒(WC-17%Co)装载到粘结剂喷射系统(诸如来自宾夕法尼亚州亨廷顿北部的ExOne公司(ExOne,N.Huntingdon,PA)的Innovent或M-Flex 3D打印系统)中。选择STL文件格式的钻头的3D数字模型以用于打印,并且施加适当的收缩因子以考虑烧结期间的尺寸变化。将3D CAD模型解构为100微米切片,并且为每一层创建打印图案,这些图案在后续层中重新组装。烧结硬质碳化物颗粒通过用于形成WC-Co混合物的球形团聚体的常规喷雾干燥工艺生产。粒度分布在D10(10μm)至D90(45μm)的范围内。如上文在第I部分中所述,通过烧结至高密度(85%至95%)来形成关键粉末属性,这实现粉末流动性、可印性并且降低烧结收缩率。关键工艺参数是粘结剂饱和度、打印温度和粉末铺展速度。粘结剂饱和度为80%至120%,打印温度在45℃至55℃的范围内,重涂速度在10mm/sec和20mm/sec之间的范围内。打印层的典型时间在45秒至90秒的范围内,该层以4mm/hr至8mm/hr的打印速率转换为竖直的。在打印后,将生坯钻头在200℃下在空气炉中固化,以提高生坯强度。从粉末工作箱中移除生坯钻头,并且通过压缩空气、真空移除松散粉末,并将其轻轻擦去。将薄壁WC-17Co钻头放置在石墨托盘上,并且在1460-1500℃下真空烧结/HIP0.5-1小时,并致密化至13.7g/cm3,相当于理论密度的99.3%。烧结钻头表现出大于或等于85HRA的硬度,并且显微结构分析显示没有η相并且不存在夸张的大晶粒。烧结钻头几何形状基本上重现了打印制品,尽管尺寸较小,但与施加的收缩因子相当。烧结钻头示于图1-图2中。
针对实现本发明多个目的,现已描述了本发明的多个实施方案。应当认识到,这些实施方案仅示例性地说明本发明的原理。在不脱离本发明实质和范围的情况下,其多种修改和变更对于本领域技术人员而言将是显而易见的。
Claims (36)
1.一种钻地工具,包括:
钻头,所述钻头包括切削部分和主体部分,所述主体部分包括烧结硬质碳化物壳,所述烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。
2.根据权利要求1所述的钻地工具,其中所述烧结硬质碳化物壳的壁厚度为所述钻头直径的10%至20%。
3.根据权利要求1所述的钻地工具,其中所述钻头直径为100mm至300mm。
4.根据权利要求1所述的钻地工具,其中所述壳的所述烧结硬质碳化物包含3重量%至30重量%的金属粘结剂。
5.根据权利要求1所述的钻地工具,其中所述壳的所述烧结硬质碳化物包含平均粒度为0.5μm至50μm的碳化钨颗粒。
6.根据权利要求5所述的钻地工具,其中所述碳化钨颗粒的平均粒度为10μm至30μm。
7.根据权利要求1所述的钻地工具,其中所述工作部分包括固定切削片。
8.根据权利要求1所述的钻地工具,其中所述工作部分包括牙轮。
9.根据权利要求1所述的钻地工具,其中所述烧结硬质碳化物壳的所述壁厚度在所述钻头的竖直尺寸上改变。
10.根据权利要求1所述的钻地工具,其中烧结硬质碳化物壳包括内表面上的螺纹以用于接合合金主体。
11.根据权利要求1所述的钻地工具,其中所述工作部分包括凹座以用于接收切削刀片。
12.根据权利要求11所述的钻地工具,其中所述凹座包括一个或多个结构元件以用于机械地接合所述切削刀片。
13.根据权利要求12所述的钻地工具,其中所述结构元件选自由螺纹、狭槽、凸缘、锥形凹座直径以及它们的组合组成的组。
14.根据权利要求1所述的钻地工具,还包括联接到所述烧结硬质碳化物壳的一个或多个晶格结构。
15.根据权利要求14所述的钻地工具,其中所述晶格结构包括烧结硬质碳化物。
16.根据权利要求15所述的钻地工具,其中晶格结构的所述烧结硬质碳化物在一个或多个组成或物理特性方面不同于所述壳的所述烧结硬质碳化物。
17.根据权利要求14所述的钻地工具,其中所述烧结硬质碳化物壳的所述壁厚度为所述钻头直径的5%至10%。
18.根据权利要求1所述的钻地工具,其中所述烧结硬质碳化物壳限定流体贮存器。
19.根据权利要求18所述的钻地工具,还包括孔以用于将流体从所述流体贮存器传送到所述切削部分。
20.根据权利要求1所述的钻地工具,其中所述烧结硬质碳化物壳具有小于3%的孔隙率。
21.一种制造钻地工具的钻头的方法,包括:
通过增材制造技术将等级粉末固结到所述钻头中,所述钻头包括切削部分和主体部分,所述主体部分包括烧结硬质碳化物壳,所述烧结硬质碳化物壳的壁厚度为钻头直径的5%至25%。
22.根据权利要求21所述的方法,其中所述等级粉末包含金属碳化物和金属粘结剂。
23.根据权利要求22所述的方法,其中所述金属碳化物包括碳化钨。
24.根据权利要求22所述的方法,其中所述等级粉末包含烧结硬质碳化物颗粒。
25.根据权利要求24所述的方法,其中所述烧结硬质碳化物颗粒的平均粒度为1μm至40μm。
26.根据权利要求24所述的方法,其中所述烧结硬质碳化物颗粒的平均粒度为10μm至30μm。
27.根据权利要求24所述的方法,其中所述烧结硬质碳化物颗粒为理论密度的至少85%。
28.根据权利要求21所述的方法,其中所述钻头直径为100mm至300mm。
29.根据权利要求21所述的方法,其中所述工作部分包括固定切削片。
30.根据权利要求21所述的方法,其中所述工作部分包括牙轮。
31.根据权利要求21所述的方法,其中所述钻头还包括联接到所述烧结硬质碳化物壳的一个或多个晶格结构。
32.根据权利要求21所述的方法,其中所述烧结硬质碳化物壳具有小于3%的孔隙率。
33.根据权利要求21所述的方法,其中通过有机粘结剂将所述等级粉末组合物固结并且烧结以提供所述钻头。
34.根据权利要求21所述的方法,其中通过激光烧结所述等级粉末来将所述等级粉末固结到所述钻头中。
35.根据权利要求21所述的方法,其中所述烧结硬质碳化物壳的所述壁厚度为所述钻头直径的5%至10%。
36.根据权利要求21所述的方法,其中通过选择性激光烧结将所述等级粉末组合物固结到生坯钻头中,并且将所述生坯钻头烧结或烧结-热等静压,以提供密度大于理论密度的98%的所述钻头。
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DE102018122536A1 (de) | 2019-04-11 |
US20190106941A1 (en) | 2019-04-11 |
US10662716B2 (en) | 2020-05-26 |
CN109630027B (zh) | 2022-07-22 |
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