EP1716948A2 - Structure composite avec surface de séparation non-planair, et procédé pour sa fabrication - Google Patents

Structure composite avec surface de séparation non-planair, et procédé pour sa fabrication Download PDF

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Publication number
EP1716948A2
EP1716948A2 EP06251484A EP06251484A EP1716948A2 EP 1716948 A2 EP1716948 A2 EP 1716948A2 EP 06251484 A EP06251484 A EP 06251484A EP 06251484 A EP06251484 A EP 06251484A EP 1716948 A2 EP1716948 A2 EP 1716948A2
Authority
EP
European Patent Office
Prior art keywords
particles
monolayer
composite structure
metallic material
composite
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.)
Withdrawn
Application number
EP06251484A
Other languages
German (de)
English (en)
Other versions
EP1716948A3 (fr
Inventor
Harold A. Sreshta
Eric F. Drake
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Grant Prideco LP
Original Assignee
Grant Prideco LP
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Grant Prideco LP filed Critical Grant Prideco LP
Publication of EP1716948A2 publication Critical patent/EP1716948A2/fr
Publication of EP1716948A3 publication Critical patent/EP1716948A3/fr
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP 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
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
    • E21B10/573—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
    • E21B10/5735—Interface between the substrate and the cutting element
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • This invention relates to a composite structure including a non-planar interface and a method of making the composite structure.
  • Metallic structures often comprise two or more joined materials that have different properties and characteristics. Often such disparate materials are joined together into one component because portions of the component are subjected to different environments.
  • the body of a drilling bit such as those used in oilfield operations, is subjected to high torsion loads during drilling, while the cutting surfaces thereof encounter very hard, abrasive materials.
  • rock drilling bit bodies are generally made of steel, while the cutting surfaces often comprise tungsten carbide or polycrystalline diamond composites. Steel provides the material properties required to endure high torsion loads, while tungsten carbide or polycrystalline diamond provides deformation- and wear-resistant material properties. Similar configurations are also found in mining bits and roadbed milling bits used to break apart old roadbeds.
  • Figure 1 illustrates two disparate material portions 102, 104 joined along an interface 106, which may be planar or non-planar.
  • Such components are often formed using powder metallurgy techniques.
  • the material portion 102 may initially comprise a mixture of steel and tungsten carbide powders and the material portion 104 may comprise a steel powder.
  • the portions 102, 104 may then be cold isostatically pressed to achieve sufficient densification providing handling strength and then either hot forged or hot isostatically pressed to achieve full density.
  • the portion 102 may initially comprise a sintered cemented carbide and the material portion 104 may initially comprise a mixture of diamond and metals powders. The portions 102, 104 may then be hot pressed at very high pressure to achieve full density.
  • densification involves the heating of the portions 102, 104 in contact with one another under high pressure such that adjacent particles within the portions 102, 104 are plastically deformed and solid state diffusion bonded, or partially melted and resolidified.
  • Such structures exhibit a mechanical discontinuity along an interface 106 of the disparate materials.
  • the effects of this discontinuity on mechanical response of the union typically limit the useful strength of these structures.
  • the portion 102 has a coefficient of thermal expansion (CTE) that is significantly lower than that of the portion 104
  • CTE coefficient of thermal expansion
  • merely cooling the joined materials from the final densification temperature may generate sufficient stress at the interface 106 to disbond/disjoin the portions 102, 104.
  • thermal residual stress in the joined portions 102, 104 were below the failure threshold, the application of external loading on the joined portions 102, 104 would result in a concentration of stress at the interface due to elastic modulus and plastic yielding differences between the portion 102, 104.
  • the superposition of thermal residual stress and concentrated load stress may disbond/disjoin the portions 102, 104.
  • one technique is to roughen the interface surface 106 between the disparate materials 102, 104 before joining. Adding topographic complexity in a dimension normal to the interface surface creates a zone of material that behaves as though its properties are intermediate the two joined disparate materials. This configuration is often referred to as a "non-planar interface", whether the interface is broadly planar or curved.
  • an interface surface 202 of the portion 104 is roughened prior to joining the portion 102 thereto.
  • localized areas of an interface surface 204 of the portion 104 are melted, for example, with an electron beam, laser, or other intense, localized heating source prior to joining the portion 102 thereto.
  • the material comprising the portion 102 fills the recesses in the roughened surfaces 202, 204 to further retain the portions 102, 104 together.
  • the techniques described in relation to Figures 2A-2B may be effective in improving the strength of the bond or joint between the portions 102, 104, they each require additional processing to prepare the interface surfaces 202, 204 for joining.
  • the additional processing may, in some instances, also be costly.
  • the electron beam, laser, or other localized, intense heat source equipment used to melt areas of the interface surface 204 may be very expensive to purchase, maintain, and operate.
  • FIGS 3A-3C illustrates one particular example of such a technique.
  • a plurality of radial grooves 302 (only one labeled for clarity) and a circumferential groove 303 are machined into a face 304 of a cutting blank 306 comprising, for example, steel.
  • the non-planar interface between the cutting blank 306 and the cutting portion 308 aids in retaining the cutting portion 308 on the cutting blank 306, as compared to an interface that omits the grooves 302, 303.
  • Some designs have further included undercut grooves, such as illustrated in Figure 3C, to further enhance retention of the cutting portion 308 on the cutting blank 306.
  • the additional machining steps required to form the grooves 302, 303 may add substantial cost and complexity to the finished product.
  • the preferred die-pressing method for creating irregular or grooved surfaces via powder fabrication is restricted to geometries that provide positive draft to allow die withdrawal. Further, it may be difficult to fully fill the grooves 302, 303, with the second material, especially if they are narrow or undercut (as illustrated in Figure 3C).
  • protrusions 402 (only one labeled for clarity) extending from a first material portion 404 and into a second material portion 406, forming a non-planar interface 408.
  • Yet another technique used to mitigate stress concentrations along such disparate material interfaces is to employ a "functional gradient design," as shown in Figure 5, wherein a third material 502 is disposed in the interface 106 between the two disparate materials 102, 104.
  • the third material 502 has properties that are generally between those of the disparate materials 102 and 104.
  • the third or gradient material 502 may have, for example, elastic plastic, thermal expansion properties intermediate between those of the first disparate material 102 those of the second disparate material 104.
  • Multiple such intermediate layers or single graduated layer may be employed to further reduce the magnitude(s) of disparities of the included interfaces. While such structures address the property compatibility issues described above, their complexity often adds prohibitive fabrication cost and may be incompatible with preferred fabrication methods.
  • the present invention is directed to overcoming, or at least reducing, the effects of one or more of the problems set forth above.
  • a composite structure in one aspect of the present invention, includes a first portion comprising a first metallic material, a monolayer of particles extending into and bonded with the first portion, and a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles.
  • an insert for a rock bit includes a substrate comprising a first metallic material, a plurality of particles bonded with the substrate, and a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.
  • a composite pick in yet another aspect of the present invention, includes a tip comprising a first metallic material, a plurality of particles bonded with the tip, and a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.
  • a method for fabricating a composite structure includes bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion and bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.
  • the present invention relates to a structure comprising disparate materials joined along a non-planar interface that exhibits, in one illustrative embodiment, an interlocking geometry and a method for fabricating the structure. While it is not so limited, the structure of the present invention is particularly applicable to cemented carbide composites and their incorporation in layered, functionally graded structures with disparate cemented carbides, diamond composites, metals, or metal alloys.
  • the non-planar interface of the present invention allows fabrication of powder preforms incorporating fully dense elements by direct pressing or cold isostatic pressing, and powder forging of such preforms. In particular, the present invention mitigates or avoids the problem of decompression cracking between fully dense and powder regions during the unload portion of an isostatic pressing cycle.
  • Figure 6 depicts one illustrative embodiment of a composite structure 600 incorporating a non-planar interface according to the present invention.
  • the structure 600 comprises a monolayer of particles 605 (only one labeled for clarity) formed integrally with a metallic substrate material 610.
  • the particles 605 define an open framework that is substantially filled with a second material 615.
  • the particles 605 may comprise the same material as the substrate 610, a chemical or metallurgical variant of the substrate 610, a metal or a metal alloy.
  • the substrate 610 comprises a sintered powder and the particles 605 are co-sintered with the substrate 610.
  • the particles 605 are attached to the substrate 610 and, in some cases to each other, primarily by metallurgical neck bonds 705 grown during sintering. In some embodiments, the particles 605 extend into the substrate 610. Mechanisms that are operative during neck bond growth include: viscous flow, plastic flow, evaporation-condensation, volume diffusion, grain boundary diffusion, and surface diffusion.
  • the particles 605 may be attached to the substrate 610 by various processes producing metallurgical bonding, such as liquid phase sintering, solid-state sintering or diffusion bonding, welding, and brazing.
  • Figure 8 illustrates an intermediate configuration, prior to adding the second material 615 to the composite structure 600.
  • the second material 615 may be formed by substantially filling the open volume between the particles 605 with a fine metallic powder 905, as shown in Figure 9, then pressure densifying the second material 615 (e.g., the fine powder 905), as shown in Figure 10.
  • the second material 615 may be formed by infiltrating the open volume between the particles 605 with liquid metal and solidifying the metal 1105 as illustrated in Figure 11, to form the second material 615 (of Figure 6).
  • the second material 615 whether formed using powder or liquid metal techniques, comprises a densified portion. Note, as depicted in Figure 12, that the particles 605 extend from the substrate 610 such that the particles 605 and the substrate 610 define recesses 1205.
  • the recesses 1205 exhibit negative draft angles (e.g., the negative draft angle 1210) or are "undercut.” Generally, a draft angle of 90 degrees is neutral. Thus, a draft angle of less than 90 degrees (as illustrated in Figure 12) is a negative draft angle. Draft angles that are greater than 90 degrees are considered positive draft angles. While the present invention is not so limited, in particular embodiments, the draft angle may be within a range of about 3 degrees to about 85 degrees.
  • the second material 615 extends into the recesses 1205, which provides mechanical locking of the second material 615 to the particles 605. Moreover, the particles 605 provide a tortuous bonding surface having substantially more bonding area for both the substrate 610 and the second material 615 as compared to a planar interface. These factors contribute to improved mechanical interlocking strength during intermediate processing steps and increased interfacial strength in the finished structure.
  • the particles 605 are illustrated in Figure 6 as being substantially spherical, the present invention is not so limited. Rather, the particles 605 may take on many other shapes, such as oblate spheroids 1305, cylinders 1310, and irregular shapes 1315, as illustrated in Figure 13, including, for example, acicular, fibrous, flaky, granular, dendritic, and blocky shapes. Further, the particles 605 may, in some embodiments, be arranged in a particular pattern or they may be randomly dispersed on the substrate material 610.
  • substrate 610 may comprise either the "soft" or “hard” portion of the composite structure 600.
  • the cemented carbide substrate 610 represents the "soft" portion of the composite structure 600.
  • the composite structure 600 may be incorporated into a yet larger composite structure 1400 including a second monolayer of particles 1405 (only one labeled for clarity) and a third material 1410 that is softer than the substrate 610.
  • the substrate 610 corresponds to the "hard” portion of the composite couple of the substrate 610 and the third material 1410.
  • the desirable thickness of the particle layer depends upon the polycrystalline diamond layer thickness and the shape of the substrate surface.
  • a particle size corresponding to about 80% of the polycrystalline diamond layer thickness may be used. Dimpled, ribbed, or faceted substrate surfaces may require smaller average particle sizes or a wider size distribution for conformation to the substrate surface. Multiple sizes or shapes of particles maybe used to enhance particle coverage and effective non-planar interface zone width.
  • the non-planar interface structure of the present invention may be implemented in various products, such as a roller-cone rock bit 1500, shown in Figure 15, or a fixed cutter rock bit 1600, shown in FIG 16.
  • the rock bits 1500, 1600 comprises a plurality of polycrystalline diamond coated inserts 1505, 1605, respectively, (only one labeled in each figure for clarity) that ablate rock formations during oilfield drilling operations.
  • Figure 17 illustrates one particular embodiment of such an insert 1705 at an intermediate stage of fabrication.
  • the insert 1705 comprises a plurality of tungsten carbide/cobalt spherical pellets 1710 sintered onto a cemented carbide substrate 1715 of the same composition.
  • the pellets 1710 have sizes corresponding to a 16/20 mesh.
  • the pellets 1710 have sizes corresponding to 80/200 mesh, 40/60 mesh, and 20/30 mesh but may comprise other sizes depending upon the particular implementation.
  • the particles or pellets may take on various shapes.
  • Figures 18-19 illustrate an exemplary insert comprising rod-shaped or cylindrical tungsten carbide/cobalt particles 1805 sintered onto a substrate 1810 of the same material.
  • the particles 1805 are arranged in a spiral fashion, while they are arranged randomly in Figure 19.
  • the interstices between the particles or pellets 1710, 1805 are filled with diamond-containing particle mixes, held in place by a formed can that defines the final external shape.
  • the assembly is subsequently densified at high temperature and pressure, achieving full density of the composite structure.
  • FIG. 20 depicts a sintered, cemented carbide tip 2005 with an integral particulate non-planar interface layer 2010 disposed on an undulant surface 2015.
  • fine nickel particles are coated on the particulate layer 2010, followed by injection co-molding with a fugitive-bound mixed cemented carbide and steel powder composite perform.
  • the assembly is placed in an elastomer mold with steel powders and a carbide particulate surface layer as described in U.S. Patent No.
  • Figure 21 illustrates the macrostructure of such a composite road or mining pick 2100, including the cemented carbide tip 2005, the particulate layer 2010, the undulant surface 2015, the steel shank 2105 formed during cold isostatic pressing, and the densified cemented carbide and steel powder 2110.
  • Figure 20 depicts the microstructure of the non-planar interface, including the cemented carbide tip 2005, nickel layer 2005, and the densified cemented carbide and steel powder 2110.
  • a composite structure in one particular embodiment, includes a first portion comprising a first metallic material, a monolayer of particles extending into and bonded with the first portion, and a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles.
  • an insert for a rock bit includes a substrate comprising a first metallic material, a plurality of particles bonded with the substrate, and a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.
  • a composite road pick in yet another particular embodiment of the present invention, includes a tip comprising a first metallic material, a plurality of particles bonded with the tip, and a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.
  • a method for fabricating a composite structure includes bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion and bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.
EP06251484A 2005-04-26 2006-03-21 Structure composite avec surface de séparation non-planair, et procédé pour sa fabrication Withdrawn EP1716948A3 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/908,040 US20060237236A1 (en) 2005-04-26 2005-04-26 Composite structure having a non-planar interface and method of making same

Publications (2)

Publication Number Publication Date
EP1716948A2 true EP1716948A2 (fr) 2006-11-02
EP1716948A3 EP1716948A3 (fr) 2006-12-20

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EP (1) EP1716948A3 (fr)
CA (1) CA2544654A1 (fr)

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