EP2899360B1 - Verfahren zur Reduzierung intermetallischer Verbindungen in einer Matrixbit-Klebeschicht - Google Patents

Verfahren zur Reduzierung intermetallischer Verbindungen in einer Matrixbit-Klebeschicht Download PDF

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Publication number
EP2899360B1
EP2899360B1 EP15152253.9A EP15152253A EP2899360B1 EP 2899360 B1 EP2899360 B1 EP 2899360B1 EP 15152253 A EP15152253 A EP 15152253A EP 2899360 B1 EP2899360 B1 EP 2899360B1
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EP
European Patent Office
Prior art keywords
powder
blank
tungsten carbide
shoulder
carbide powder
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.)
Not-in-force
Application number
EP15152253.9A
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English (en)
French (fr)
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EP2899360A3 (de
EP2899360A2 (de
Inventor
Gary M. Thigpen
Federico Bellin
Marvin Windsor Amundsen
Olivier Ther
Alfazazi Dourfaye
Bruno Cuillier De Maindreville
Williams GOMEZ
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Varel Europe SAS
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Varel Europe SAS
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Publication date
Priority claimed from US14/162,501 external-priority patent/US9359824B2/en
Application filed by Varel Europe SAS filed Critical Varel Europe SAS
Publication of EP2899360A2 publication Critical patent/EP2899360A2/de
Publication of EP2899360A3 publication Critical patent/EP2899360A3/de
Application granted granted Critical
Publication of EP2899360B1 publication Critical patent/EP2899360B1/de
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/06—Casting in, on, or around objects which form part of the product for manufacturing or repairing tools
    • 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
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • B22F7/06—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 workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—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 workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • 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
    • 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

Definitions

  • This invention relates generally to downhole tools and methods for manufacturing such items. More particularly, this invention relates to infiltrated matrix drilling products including, but not limited to, fixed cutter bits, polycrystalline diamond compact (“PDC”) drill bits, natural diamond drill bits, thermally stable polycrystalline (“TSP”) drill bits, bi-center bits, core bits, and matrix bodied reamers and stabilizers, and the methods of manufacturing such items.
  • PDC polycrystalline diamond compact
  • TSP thermally stable polycrystalline
  • Figure 1 shows a cross-sectional view of a downhole tool casting assembly 100 in accordance with the prior art.
  • the downhole tool casting assembly 100 consists of a thick-walled mold 110, a stalk 120, one or more nozzle displacements 122, a blank 124, a funnel 140, and a binder pot 150.
  • the downhole tool casting assembly 100 is used to fabricate a casting (not shown) of a downhole tool.
  • the thick-walled mold 110 is fabricated with a precisely machined interior surface 112, and forms a mold volume 114 located within the interior of the thick-walled mold 110.
  • the thick-walled mold 110 is made from sand, hard carbon graphite, ceramic, or other known suitable materials.
  • the precisely machined interior surface 112 has a shape that is a negative of what will become the facial features of the eventual bit face.
  • the precisely machined interior surface 112 is milled and dressed to form the proper contours of the finished bit.
  • cutters can be placed along the locations of the cutting edges of the bit and can also be optionally placed along the gage area of the bit. These cutters can be placed during the bit fabrication process or after the bit has been fabricated via brazing or other methods known to persons having ordinary skill in the art.
  • displacements are placed at least partially within the mold volume 114 of the thick-walled mold 110.
  • the displacements are typically fabricated from clay, sand, graphite, ceramic, or other known suitable materials. These displacements consist of the center stalk 120 and the at least one nozzle displacement 122.
  • the center stalk 120 is positioned substantially within the center of the thick-walled mold 110 and suspended a desired distance from the bottom of the mold's interior surface 112.
  • the nozzle displacements 122 are positioned within the thick-walled mold 110 and extend from the center stalk 120 to the bottom of the mold's interior surface 112.
  • the center stalk 120 and the nozzle displacements 122 are later removed from the eventual drill bit casting so that drilling fluid (not shown) can flow though the center of the finished bit during the drill bit's operation.
  • the blank 124 is a cylindrical steel casting mandrel that is centrally suspended at least partially within the thick-walled mold 110 and around the center stalk 120.
  • the blank 124 is positioned a predetermined distance down in the thick-walled mold 110.
  • the distance between the outer surface of the blank 124 and the interior surface 112 of the thick-walled mold 110 is typically twelve millimeters ("mm") or more so that potential cracking of the thick-walled mold 110 is reduced during the casting process.
  • tungsten carbide powder 130 which includes free tungsten, is loaded into the thick-walled mold 110 so that it fills a portion of the mold volume 114 that is around the lower portion of the blank 124, between the inner surfaces of the blank 124 and the outer surfaces of the center stalk 120, and between the nozzle displacements 122.
  • Shoulder powder 134 is loaded on top of the tungsten carbide powder 130 in an area located at both the area outside of the blank 124 and the area between the blank 124 and the center stalk 120.
  • the shoulder powder 134 is made of tungsten powder. This shoulder powder 134 acts to blend the casting to the steel blank 124 and is machinable.
  • the thick-walled mold 110 is typically vibrated to improve the compaction of the tungsten carbide powder 130 and the shoulder powder 134.
  • the vibration of the thick-walled mold 110 can be done as an intermediate step before, during, and/or after the shoulder powder 134 is loaded on top of the tungsten carbide powder 130.
  • the funnel 140 is a graphite cylinder that forms a funnel volume 144 therein.
  • the funnel 140 is coupled to the top portion of the thick-walled mold 110.
  • a recess 142 is formed at the interior edge of the funnel 140, which facilitates the funnel 140 coupling to the upper portion of the thick-walled mold 110.
  • the inside diameter of the thick-walled mold 110 is similar to the inside diameter of the funnel 140 once the funnel 140 and the thick-walled mold 110 are coupled together.
  • the binder pot 150 is a cylinder having a base 156 with an opening 158 located at the base 156, which extends through the base 156.
  • the binder pot 150 also forms a binder pot volume 154 therein for holding a binder material 160.
  • the binder pot 150 is coupled to the top portion of the funnel 140 via a recess 152 that is formed at the exterior edge of the binder pot 150. This recess 152 facilitates the binder pot 150 coupling to the upper portion of the funnel 140.
  • a predetermined amount of binder material 160 is loaded into the binder pot volume 154.
  • the typical binder material 160 is a copper alloy or other suitable known material. Although one example has been provided for setting up the downhole tool casting assembly 100, other examples can be used to form the downhole tool casting assembly 100.
  • the downhole tool casting assembly 100 is placed within a furnace (not shown) or other heating structure.
  • the binder material 160 melts and flows into the tungsten carbide powder 130 through the opening 158 of the binder pot 150.
  • the molten binder material 160 infiltrates the tungsten carbide powder 130 and the shoulder powder 134 to fill the interparticle spaces formed between adjacent particles of tungsten carbide powder 130 and between adjacent particles of shoulder powder 134.
  • a substantial amount of binder material 160 is used so that it fills at least a substantial portion of the funnel volume 144. This excess binder material 160 in the funnel volume 144 supplies a downward force on the tungsten carbide powder 130 and the shoulder powder 134.
  • the downhole tool casting assembly 100 is pulled from the furnace and is controllably cooled. Upon cooling, the binder material 160 solidifies and cements the particles of tungsten carbide powder 130 and the shoulder powder 134 together into a coherent integral mass 310 ( Figure 3 ). The binder material 160 also bonds this coherent integral mass 310 ( Figure 3 ) to the steel blank 124 thereby forming a bonding zone 190, which is formed along at least a chamfered zone area 198 of the steel blank 124 and a central zone area 199 of the steel blank 124.
  • the coherent integral mass 310 ( Figure 3 ) and the blank 124 collectively form the matrix body bit 200 ( Figure 2 ), a portion of which is shown in Figures 2 and 3 .
  • the thick-walled mold 110 is broken away from the casting.
  • the casting then undergoes finishing steps which are known to persons having ordinary skill in the art, including the addition of a threaded connection (not shown) coupled to the top portion of the blank 124.
  • the matrix body bit 200 ( Figure 2 ) has been described to be formed using the process and equipment described above, the process and/or the equipment can be varied to still form the matrix body bit 200 ( Figure 2 ).
  • Figure 2 shows a magnified cross-sectional view of the bonding zone 190 located at the chamfered zone area 198 ( Figure 1 ) within the matrix body bit 200 in accordance with the prior art.
  • Figure 3 shows a magnified cross-sectional view of the bonding zone 190 located at the central zone area 199 ( Figure 1 ) within the matrix body bit 200 in accordance with the prior art.
  • the coherent integral mass 310 is bonded to the steel blank 124 via the bonding zone 190 that is formed along and/or adjacent the surface of the steel blank 124.
  • the binder material 160 causes a portion of the iron from the steel blank 124 to diffuse into the binder material 160 and react with the free tungsten within the shoulder powder 134 and the tungsten carbide powder 130, thereby forming this bonding zone 190.
  • the bonding zone 190 includes intermetallic compounds 290. These intermetallic compounds 290 have an average hardness level of about 250 HV, which corresponds to about twice the hardness of the binder and steel matrix. According to Figure 2 , the bonding zone 190 is formed having a thickness 215 ranging from about sixty-five micrometers ( ⁇ m) to about eighty ⁇ m in the chamfered zone area 198 ( Figure 1 ).
  • the bonding zone 190 is formed having a thickness 315 ranging from about ten ⁇ m to about twenty ⁇ m in the central zone area 199 ( Figure 1 ).
  • the thicknesses 215, 315 and/or volumes of the bonding zone 190 are dependent upon the exposure time and the exposure temperature.
  • Exposure temperature is related to the type of binder material 160 that is used to cement the tungsten carbide particles to one another. Manufacturers typically use the same binder material 160 over long periods of time, such as ten year or more, because of the knowledge gained with respect to the binder material 160 used. Thus, the exposure temperature is substantially the same from one casting to another. Exposure time is not always the same, but instead, is related to the bit diameter that is to be manufactured.
  • the exposure time is relatively longer, thereby providing more time for cementing the larger volume of tungsten carbide particles.
  • the exposure temperature is the same from one casting to another, and the exposure time is the same for casting similar bit diameters, it follows that the thicknesses 215, 315 of intermetallic compounds 290 formed within the bit is consistent from one casting to another for a same bit diameter.
  • decohesion began occurring between the blank 124 and the coherent integral mass 310, or matrix, at the bonding zone 190.
  • These intermetallic compounds 290 are a source for causing mechanical stresses to occur along the bonding zone 190 during drilling applications because there is a contraction of volume occurring when the intermetallic compounds 290 are formed.
  • These intermetallic compounds are very brittle and some cracks in the intermetallic compounds could occur during the drilling process. These cracks could weaken the bit and lead to catastrophic failure.
  • the demand placed upon the bits have also increased. Bits are being drilled for more hours. Bits also are being used with much more energy, which includes energy produced from increasing the weight on bit and/or from increasing the rotational speed of the bit. This increased demand on the bits is causing the decohesion failure to become a recurring problem in the industry.
  • the thickness or volume of the intermetallic compounds 290 increases, the risk of decohesion also increases.
  • the known downhole tool in the form of a drill bit comprises a metal blank comprising a top portion, a bottom portion, and a channel extending from the top portion to the bottom portion.
  • a cemented matrix material is bonded to an exterior surface and an interior surface of the metal blank and comprises a binder material.
  • the cemented matrix material comprises a first and a second matrix material and a shoulder matrix made of tungsten powder positioned above the second matrix.
  • the material of the first matrix may be cemented carbides which may include tungsten carbide.
  • the cemented tungsten carbide powder from the matrix is coupled to the bottom portion of the metal blank and the cemented shoulder powder is coupled to the top portion of the metal blank.
  • the material of the second matrix may be macrocrystalline tungsten carbide devoid of free tungsten in metallic form.
  • This invention relates generally to downhole tools and methods for manufacturing such items. More particularly, this invention relates to infiltrated matrix drilling products including, but not limited to, fixed cutter bits, polycrystalline diamond compact (“PDC”) drill bits, natural diamond drill bits, thermally stable polycrystalline (“TSP”) drill bits, bi-center bits, core bits, and matrix bodied reamers and stabilizers, and the methods of manufacturing such items.
  • PDC polycrystalline diamond compact
  • TSP thermally stable polycrystalline
  • FIG 4 shows a cross-sectional view of a blank 400 in accordance with an exemplary embodiment.
  • the blank 400 includes an internal blank component 410 and a metal coating 420 coupled around at least a portion of the surface of the internal blank component 410.
  • the internal blank component 410 is similar to the blank 124 ( Figure 1 ) above.
  • the internal blank component 410 is a cylindrically, hollow-shaped component and includes a cavity 412 extending through the entire length of the internal blank component 410.
  • the internal blank component 410 also includes a top portion 414 and a bottom portion 416.
  • the top portion 414 has a smaller outer circumference than the bottom portion 416.
  • the internal blank component 410 is fabricated from steel; however, any other suitable material known to people having ordinary skill in the art is used in other exemplary embodiments.
  • the metal coating 420 is applied onto at least a portion of the surface of the internal blank component 410. In some exemplary embodiments, the metal coating 420 is applied onto the surface of the entire internal blank component 410. In other exemplary embodiments, the metal coating 420 is applied onto a portion of the surface of the internal blank component 410. For example, the metal coating 420 is applied onto the surface of the bottom portion 416, which is the portion that bonds to the matrix material, or a coherent integral mass 710 ( Figure 7 ), which is described below. The metal coating 420 is applied onto the internal blank component 410 using electroplating techniques.
  • the metal coating 420 is fabricated using a material that reduces the formation of intermetallic compounds 690 ( Figure 6 ) along and/or adjacent the surface of the blank 400 ( Figure 4 ). Specifically, the metal coating 420 reduces the migration of iron from the internal blank component 410 into the binder material 560 ( Figure 5 ) for reacting with the free tungsten at the temperature and exposure time during the fabrication process.
  • the metal coating 420 is fabricated from nickel according to some exemplary embodiments.
  • the metal coating 420 is fabricated using at least one of brass, bronze, copper, aluminum, zinc, cobalt, titanium, gold, refractory transitional materials such as molybdenum and tantalum, carbide, boride, oxide, metal matrix composites, a metal alloy of any previously mentioned metals, or any other suitable material that is capable of reducing the migration of iron from the internal blank component 410 into the binder material 560 ( Figure 5 ) for reacting with the free tungsten.
  • a different type of coating such as a polymer coating, is used in lieu of the metal coating.
  • the metal coating 420 is applied onto the internal blank component 410 and has a thickness 422 ranging from about five ⁇ m to about 200 ⁇ m. In another exemplary embodiment, the metal coating 420 has a thickness 422 ranging from about five ⁇ m to about 150 ⁇ m. In yet another exemplary embodiment, the metal coating 420 has a thickness 422 ranging from about five ⁇ m to about eighty ⁇ m. In a further exemplary embodiment, the metal coating 420 has a thickness 422 ranging less than or greater than the previously mentioned ranges. In certain exemplary embodiments, the thickness 422 is substantially uniform, while in other exemplary embodiments, the thickness 422 is non-uniform. For example, the thickness 422 is greater along the surface of the internal blank component 410 that would typically form a greater thickness of the intermetallic compound during the fabrication process, such as the chamfered zone area 598 ( Figure 5 ).
  • Figure 5 shows a cross-sectional view of a downhole tool casting assembly 500 using the blank 400 in accordance with the exemplary embodiment.
  • the downhole tool casting assembly 500 includes a mold 510, a stalk 520, one or more nozzle displacements 522, the blank 400, a funnel 540, and a binder pot 550.
  • the downhole tool casting assembly 500 is used to fabricate a casting (not shown) of a downhole tool, such as a fixed cutter bit, a PDC drill bit, a natural diamond drill bit, and a TSP drill bit.
  • the downhole tool casting assembly 500 is modified in other exemplary embodiments to fabricate other downhole tools, such as a bi-center bit, a core bit, and a matrix bodied reamer and stabilizer.
  • the mold 510 is fabricated with a precisely machined interior surface 512, and forms a mold volume 514 located within the interior of the mold 510.
  • the mold 510 is made from sand, hard carbon graphite, ceramic, or other known suitable materials.
  • the precisely machined interior surface 512 has a shape that is a negative of what will become the facial features of the eventual bit face.
  • the precisely machined interior surface 512 is milled and dressed to form the proper contours of the finished bit.
  • Various types of cutters (not shown), known to persons having ordinary skill in the art, are placed along the locations of the cutting edges of the bit and are optionally placed along the gage area of the bit. These cutters are placed during the bit fabrication process or after the bit has been fabricated via brazing or other methods known to persons having ordinary skill in the art.
  • displacements are placed at least partially within the mold volume 514.
  • the displacements are fabricated from clay, sand, graphite, ceramic, or other known suitable materials. These displacements include the center stalk 520 and the at least one nozzle displacement 522.
  • the center stalk 520 is positioned substantially within the center of the mold 510 and suspended a desired distance from the bottom of the mold's interior surface 512.
  • the nozzle displacements 522 are positioned within the mold 110 and extend from the center stalk 520 to the bottom of the mold's interior surface 512.
  • the center stalk 520 and the nozzle displacements 522 are later removed from the eventual drill bit casting so that drilling fluid (not shown) flows though the center of the finished bit during the drill bit's operation.
  • the blank 400 which has been previously described above, is centrally suspended at least partially within the mold 510 and around the center stalk 520.
  • the blank 400 is positioned a predetermined distance down in the mold 510.
  • the distance between the outer surface of the blank 400 and the interior surface 512 of the mold 510 is about twelve millimeters or more so that potential cracking of the mold 510 is reduced during the casting process.
  • this distance is varied in other exemplary embodiments depending upon the strength of the mold 510 or the method and/or equipment used in fabricating the casting.
  • tungsten carbide powder 530 is loaded into the mold 110 so that it fills a portion of the mold volume 514 that is around the bottom portion 416 of the blank 400, between the inner surfaces of the blank 400 and the outer surfaces of the center stalk 520, and between the nozzle displacements 522.
  • Shoulder powder 534 is loaded on top of the tungsten carbide powder 530 in an area located at both the area outside of the blank 400 and the area between the blank 400 and the center stalk 520.
  • the shoulder powder 534 is made of tungsten powder or other known suitable material. This shoulder powder 534 acts to blend the casting to the blank 400 and is machinable.
  • the mold 510 is vibrated, in some exemplary embodiments, to improve the compaction of the tungsten carbide powder 530 and the shoulder powder 534.
  • the mold 510 is vibrated after the tungsten carbide powder 530 and the shoulder powder 534 are loaded into the mold 510, the vibration of the mold 510 is done as an intermediate step before, during, and/or after the shoulder powder 534 is loaded on top of the tungsten carbide powder 530.
  • tungsten carbide material 530 is used in certain exemplary embodiments, other suitable materials known to persons having ordinary skill in the art is used in alternative exemplary embodiments.
  • the funnel 540 is a graphite cylinder that forms a funnel volume 544 therein.
  • the funnel 540 is coupled to the top portion of the mold 510.
  • a recess 542 is formed at the interior edge of the funnel 540, which facilitates the funnel 540 coupling to the upper portion of the mold 510.
  • the inside diameter of the mold 510 is similar to the inside diameter of the funnel 540 once the funnel 540 and the mold 510 are coupled together.
  • the binder pot 550 is a cylinder having a base 556 with an opening 558 located at the base 556, which extends through the base 556.
  • the binder pot 550 also forms a binder pot volume 554 therein for holding a binder material 560.
  • the binder pot 550 is coupled to the top portion of the funnel 540 via a recess 152 that is formed at the exterior edge of the binder pot 550. This recess 552 facilitates the binder pot 550 coupling to the upper portion of the funnel 540.
  • a predetermined amount of binder material 560 is loaded into the binder pot volume 554.
  • the typical binder material 560 is a copper alloy or other suitable known material.
  • the mold 510 and the funnel 540 are combined into a single component in some exemplary embodiments.
  • the downhole tool casting assembly 500 is placed within a furnace (not shown) or other heating structure.
  • the binder material 560 melts and flows into the tungsten carbide powder 530 through the opening 558 of the binder pot 550.
  • the molten binder material 560 infiltrates the tungsten carbide powder 530 to fill the interparticle space formed between adjacent particles of tungsten carbide powder 530.
  • a substantial amount of binder material 560 is used so that it fills at least a substantial portion of the funnel volume 544. This excess binder material 560 in the funnel volume 544 supplies a downward force on the tungsten carbide powder 530 and the shoulder powder 534.
  • the downhole tool casting assembly 500 is pulled from the furnace and is controllably cooled. Upon cooling, the binder material 560 solidifies and cements the particles of tungsten carbide powder 530 together into a coherent integral mass 710 ( Figure 7 ). The binder material 560 also bonds this coherent integral mass 710 ( Figure 7 ) to the blank 400 thereby forming a bonding zone 590, which is formed at least at a chamfered zone area 598 of the blank 400 and a central zone area 599 of the blank 400, according to certain exemplary embodiments.
  • the coherent integral mass 710 ( Figure 7 ) and the blank 400 collectively form the matrix body bit 600 ( Figure 6 ), a portion of which is shown in Figures 6 and 7 .
  • the mold 510 is broken away from the casting.
  • the casting then undergoes finishing steps which are known to persons of ordinary skill in the art, including the addition of a threaded connection (not shown) coupled to the top portion 414 of the blank 400.
  • a threaded connection (not shown) coupled to the top portion 414 of the blank 400.
  • Figure 6 shows a magnified cross-sectional view of the bonding zone 590 located at the chamfered zone area 598 ( Figure 5 ) within the downhole tool in accordance with the exemplary embodiment.
  • Figure 7 shows a magnified cross-sectional view of the bonding zone 590 located at the central zone area 599 ( Figure 5 ) within the downhole tool in accordance with the exemplary embodiment.
  • the blank 400 includes the internal blank component 410 and the metal coating 420, which is applied onto the surface of the internal blank component 410.
  • the coherent integral mass 710 is bonded to the blank 400 via the bonding zone 590 that is formed along and/or adjacent the surface of the blank 400.
  • the metal coating 420 is thinly applied onto the internal blank component 410 so that a portion of the iron from the blank 400 to diffuses into the binder material 560 and reacts with the free tungsten within the shoulder powder 534 and the tungsten carbide powder 530, thereby forming this bonding zone 590.
  • the bonding zone 590 includes intermetallic compounds 690, which are similar to the intermetallic compounds 290 ( Figure 2 ). According to Figure 6 , the bonding zone 590 is formed having a thickness 615 ranging from about five ⁇ m to less than sixty-five ⁇ m in the chamfered zone area 598 ( Figure 5 ).
  • the bonding zone 590 is formed having a thickness 615 ranging from about five ⁇ m to less than fifty ⁇ m in the chamfered zone area 598 ( Figure 5 ). In yet another exemplary embodiment, the bonding zone 590 is formed having a thickness 615 ranging from about five ⁇ m to less than thirty ⁇ m in the chamfered zone area 598 ( Figure 5 ). According to Figure 7 , the bonding zone 590 is formed having a thickness 715 ranging from about two pm to less than about ten ⁇ m in the central zone area 599 ( Figure 5 ).
  • the bonding zone 590 is formed having a thickness 715 ranging from about two ⁇ m to less than eight ⁇ m in the central zone area 599 ( Figure 5 ). In yet another exemplary embodiment, the bonding zone 590 is formed having a thickness 715 ranging from about two ⁇ m to less than six ⁇ m in the central zone area 599 ( Figure 5 ).
  • the thicknesses 615, 715 and/or volumes of the bonding zone 590 are dependent upon the exposure time, the temperature, and the thickness of the metal coating 420 that is applied onto the internal blank component 410. As previously mentioned, the metal coating 420 reduces the migration of iron from the blank 400 into the binder material 560, thereby decreasing the reaction with the free tungsten within the shoulder powder 534 and the tungsten carbide powder 530 during the fabrication process.
  • Figure 8 shows a magnified cross-sectional view of the bonding zone 590 located at the chamfered zone area 598 ( Figure 5 ) within the downhole tool in accordance with another exemplary embodiment.
  • Figure 9 shows a magnified cross-sectional view of the bonding zone 590 located at the central zone area 599 ( Figure 5 ) within the downhole tool in accordance with another exemplary embodiment.
  • the blank 400 includes the internal blank component 410 and the metal coating 420, which is applied onto the surface of the internal blank component 410.
  • the coherent integral mass 710 is bonded to the blank 400 via the bonding zone 590 that is formed along and/or adjacent the surface of the blank 400.
  • the metal coating 420 is applied onto the internal blank component 410 such that a smaller portion of the iron from the blank 400 diffuses into the binder material 560.
  • the diffused iron reacts with the free tungsten within the tungsten carbide powder 530 and the tungsten powder 534 to form this bonding zone 590.
  • the bonding zone 590 includes intermetallic compounds 690, which are similar to the intermetallic compounds 290 ( Figure 2 ).
  • the bonding zone 590 is formed having a thickness 815 ranging from about five ⁇ m to less than sixty-five ⁇ m in the chamfered zone area 598 ( Figure 5 ).
  • the bonding zone 590 is formed having a thickness 815 ranging from about five ⁇ m to less than fifty ⁇ m in the chamfered zone area 598 ( Figure 5 ). In yet another exemplary embodiment, the bonding zone 590 is formed having a thickness 815 ranging from about five ⁇ m to less than thirty ⁇ m in the chamfered zone area 598 ( Figure 5 ). According to Figure 9 , the bonding zone 590 is formed having a thickness 915 ranging from about two ⁇ m to less than about ten ⁇ m in the central zone area 599 ( Figure 5 ).
  • the bonding zone 590 is formed having a thickness 915 ranging from about two ⁇ m to less than eight ⁇ m in the central zone area 599 ( Figure 5 ). In yet another exemplary embodiment, the bonding zone 590 is formed having a thickness 915 ranging from about two ⁇ m to less than six ⁇ m in the central zone area 599 ( Figure 5 ).
  • the thicknesses 815, 915 and/or volumes of the bonding zone 590 are dependent upon the exposure time, the temperature, and the thickness of the metal coating 420 that is applied onto the internal blank component 410. As previously mentioned, the metal coating 420 reduces the migration of iron from the blank 400 into the binder material 560, thereby decreasing the reaction with the free tungsten within the shoulder powder 534 and the tungsten carbide powder 530 during the fabrication process.
  • Figure 10 shows a cross-sectional view of a downhole tool casting assembly 1000 in accordance with another exemplary embodiment.
  • the downhole tool casting assembly 1000 includes a mold 1010, a stalk 1020, one or more nozzle displacements 1022, a blank 1024, a funnel 1040, and a binder pot 1050.
  • the downhole tool casting assembly 1000 is used to fabricate a casting 1100 ( Figure 11 ) of a downhole tool, such as a fixed cutter bit, a PDC drill bit, a natural diamond drill bit, and a TSP drill bit.
  • the downhole tool casting assembly 1000 is modified in other exemplary embodiments to fabricate other downhole tools, such as a bi-center bit, a core bit, and a matrix bodied reamer and stabilizer.
  • the mold 1010 is similar to mold 510 and forms a mold volume 1014, which is similar to mold volume 514. Since mold 510 has been previously described above, the details of mold 1010 are not repeated again herein for the sake of brevity.
  • the center stalk 1020 and the one or more nozzle displacements 1022 are similar to the center stalk 520 and the nozzle displacements 522, respectively, and therefore the descriptions of each also are not repeated herein for the sake of brevity.
  • the blank 1024 used within the downhole tool casting assembly 1000 is similar to either the blank 124 ( Figure 1 ) or the blank 400 ( Figure 4 ) and therefore also is not repeated herein for the sake of brevity.
  • tungsten carbide powder 1030 similar to tungsten carbide powder 530, is loaded into the mold 1010 so that it fills a portion of the mold volume 1014 that is around the bottom portion 1026 of the blank 1024, between the inner surfaces of the blank 1024 and the outer surfaces of the center stalk 1020, and between the nozzle displacements 1022.
  • this tungsten carbide powder 1030 is the same as tungsten carbide powder 530 described above and includes at least W 2 C and some free tungsten. The process of fabricating W 2 C generally involves the inclusion of free tungsten.
  • this tungsten carbide powder 1030 is absent any free tungsten.
  • the tungsten carbide powder 1030, which is absent any free tungsten includes only WC in some exemplary embodiments.
  • the tungsten carbide powder 1030, which is absent any free tungsten includes W 2 C, WC, or a combination of both, while excluding any free tungsten.
  • any free tungsten is removed either during or after the fabricating process before placing the tungsten carbide powder 1030 within the mold 1010.
  • Shoulder powder 1034 is loaded on top of the tungsten carbide powder 1030 in an area located at both the area outside of the blank 1024 and the area between the blank 1024 and the center stalk 1020.
  • the shoulder powder 1034 is made of stainless steel powder or other known suitable material that is absent any free tungsten.
  • suitable materials that is usable for the shoulder powder 1034 include other steel powders, nickel powder, cobalt powder, refractory transitional materials such as molybdenum powder and tantalum powder, and/or other metals that have a higher melting temperature than the binder alloy material 1060 but are soft enough to be machined. This shoulder powder 1034 acts to blend the casting to the blank 1024 and is machinable.
  • the mold 1010 is vibrated, in some exemplary embodiments, to improve the compaction of the tungsten carbide powder 1030 and the shoulder powder 1034.
  • the mold 1010 is vibrated after the tungsten carbide powder 1030 and the shoulder powder 1034 are loaded into the mold 1010, the vibration of the mold 1010 is done as an intermediate step before, during, and/or after the shoulder powder 1034 is loaded on top of the tungsten carbide powder 1030.
  • tungsten carbide material 1030 is used in certain exemplary embodiments, other suitable materials known to persons having ordinary skill in the art are used in alternative exemplary embodiments.
  • the funnel 1040 is similar to funnel 540 and forms a funnel volume 1044 therein, which is similar to funnel volume 544. Since funnel 540 has been previously described above, the details of funnel 1040 are not repeated again herein for the sake of brevity.
  • the binder pot 1050 is similar to binder pot 550 and forms a binder pot volume 1054 therein, which is similar to binder pot volume 554, for holding a binder material 1060, which is similar to binder material 560. Since binder pot 550 and binder material 560 have been previously described above, the details of binder pot 1050 and binder material 1060 are not repeated again herein for the sake of brevity.
  • the mold 1010 and the funnel 1040 are combined into a single component in some exemplary embodiments.
  • the downhole tool casting assembly 1000 is placed within a furnace (not shown) or other heating structure.
  • the binder material 1060 melts and flows into the shoulder powder 1034 and the tungsten carbide powder 1030 through an opening 1058 of the binder pot 1050.
  • the molten binder material 1060 infiltrates the shoulder powder 1034 and the tungsten carbide powder 1030 to fill the interparticle space formed between adjacent particles of the shoulder powder 1034 and the tungsten carbide powder 1030.
  • a substantial amount of binder material 1060 is used so that it fills at least a substantial portion of the funnel volume 1044. This excess binder material 1060 in the funnel volume 1044 supplies a downward force on the tungsten carbide powder 1030 and the shoulder powder 1034.
  • the downhole tool casting assembly 1000 is pulled from the furnace and is controllably cooled. Upon cooling, the binder material 1060 solidifies and cements the particles of shoulder powder 1034 and tungsten carbide powder 1030 together into a coherent integral mass 1110 ( Figure 11 ). The binder material 1060 also bonds this coherent integral mass 1110 ( Figure 11 ) to the blank 1024 thereby forming a bonding zone 1190 ( Figure 11 ) therebetween.
  • the coherent integral mass 1110 ( Figure 11 ) and the blank 1024 collectively form the casting 1100 ( Figure 11 ) or the matrix body bit 1100 ( Figure 11 ), a portion of which is shown in Figure 11 .
  • the mold 1010 is broken away from the casting 1100 ( Figure 11 ).
  • the casting 1100 ( Figure 11 ) then undergoes finishing steps which are known to persons of ordinary skill in the art, including the addition of a threaded connection (not shown) to the casting 1100 ( Figure 11 ).
  • finishing steps which are known to persons of ordinary skill in the art, including the addition of a threaded connection (not shown) to the casting 1100 ( Figure 11 ).
  • the casting 1100 ( Figure 11 ), or the matrix body bit 1100 ( Figure 11 ) has been described to be formed using the process and equipment described above, the process and/or the equipment can be varied to still form the matrix body bit 1100 ( Figure 11 ).
  • Figure 11 shows a partial cross-sectional view of a downhole tool casting 1100 formed using the downhole tool casting assembly 1000 of Figure 10 in accordance with the exemplary embodiment.
  • the downhole tool casting 1100 includes the coherent integral mass 1110, the blank 1024, and the passageways 1120 formed from the removal of the displacements 1020, 1022.
  • the coherent integral mass 1110 is formed using the tungsten carbide material 1030, as described above, and the shoulder powder 1034, also as described above.
  • the shoulder powder 1034 is absent of free tungsten material and the tungsten carbide material 1030 is the same as tungsten carbide powder 530 described above and includes at least W 2 C and some free tungsten.
  • this tungsten carbide powder 1030 is absent any free tungsten.
  • the tungsten carbide powder 1030, which is absent any free tungsten includes only WC in some exemplary embodiments.
  • the tungsten carbide powder 1030, which is absent any free tungsten includes W 2 C, WC, or a combination of both, while excluding any free tungsten.
  • the intermetallic compounds are formed when iron reacts with free tungsten.
  • the typical shoulder powder 134 having free tungsten is replaced with shoulder powder 1034, thereby reducing and/or eliminating the formation of these intermetallic compounds, which is very brittle.
  • the shoulder powder 1034 occupies the area adjacent a chamfered portion 1198 of the blank 1024, similar to chamfered portion 598 ( Figure 5 ), which experiences high stresses.
  • the casting or bit 1100 is more durable and has a greater longevity.
  • a type of tungsten carbide powder 1030 which also is tungsten free may be used in place of the typical tungsten carbide powder 130, which includes free tungsten.
  • the tungsten carbide powder 1030 occupies the area adjacent a central zone area 1199 of the blank 1024, similar to central zone area 599 ( Figure 5 ), which also experiences high stresses.
  • the casting or bit 1100 is more durable and has a greater longevity.
  • either or both shoulder powder 1034 and tungsten carbide powder 1030 (which are tungsten free) may be used in lieu of the typical shoulder powder 134 and typical tungsten carbide powder 130.
  • Figure 12 shows a cross-sectional view of a downhole tool casting assembly 1200 in accordance with a non-inventive embodiment.
  • the downhole tool casting assembly 1200 includes a mold 1210, a stalk 1220, one or more nozzle displacements 1222, a blank 1224, a funnel 1240, and a binder pot 1250.
  • the downhole tool casting assembly 1200 is used to fabricate a casting 1300 ( Figure 13 ) of a downhole tool, such as a fixed cutter bit, a PDC drill bit, a natural diamond drill bit, and a TSP drill bit.
  • the downhole tool casting assembly 1200 is modified in other exemplary embodiments to fabricate other downhole tools, such as a bi-center bit, a core bit, and a matrix bodied reamer and stabilizer.
  • the mold 1210 is similar to mold 510 and forms a mold volume 1214, which is similar to mold volume 514. Since mold 510 has been previously described above, the details of mold 1210 are not repeated again herein for the sake of brevity.
  • the center stalk 1220 and the one or more nozzle displacements 1222 are similar to the center stalk 520 and the nozzle displacements 522, respectively, and therefore the descriptions of each also are not repeated herein for the sake of brevity.
  • the blank 1224 used within the downhole tool casting assembly 1200 is similar to either the blank 124 ( Figure 1 ) or the blank 400 ( Figure 4 ) and therefore also is not repeated herein for the sake of brevity.
  • tungsten carbide powder 1230 is loaded into the mold 1210 so that it fills a portion of the mold volume 1214 that is around the bottom portion 1226 of the blank 1224, between the inner surfaces of the blank 1224 and the outer surfaces of the center stalk 1220, and between the nozzle displacements 1222.
  • this tungsten carbide powder 1230 is absent any free tungsten, and includes W 2 C, WC, or a combination of both, while excluding any free tungsten.
  • the tungsten carbide powder 1230, which is absent any free tungsten includes only WC.
  • Shoulder powder 1234 is loaded on top of the tungsten carbide powder 1230 in an area located at both the area outside of the blank 1224 and the area between the blank 1224 and the center stalk 1220.
  • the shoulder powder 1234 is tungsten powder according to some exemplary embodiments; however, in other exemplary embodiments the shoulder powder 1234 is made of stainless steel powder or other known suitable material that is absent any free tungsten.
  • suitable materials that is usable for the shoulder powder 1234 include other steel powders, nickel powder, cobalt powder, and/or other metals that have a higher melting temperature than the binder alloy material 1260 but are soft enough to be machined. This shoulder powder 1234 acts to blend the casting to the blank 1224 and is machinable.
  • the mold 1210 is vibrated, in some exemplary embodiments, to improve the compaction of the tungsten carbide powder 1230 and the shoulder powder 1234.
  • the mold 1210 is vibrated after the tungsten carbide powder 1230 and the shoulder powder 1234 are loaded into the mold 1210, the vibration of the mold 1210 is done as an intermediate step before, during, and/or after the shoulder powder 1234 is loaded on top of the tungsten carbide powder 1230.
  • tungsten carbide material 1230 is used in certain exemplary embodiments, other suitable materials known to persons having ordinary skill in the art are used in alternative exemplary embodiments.
  • the funnel 1240 is similar to funnel 540 and forms a funnel volume 1244 therein, which is similar to funnel volume 544. Since funnel 540 has been previously described above, the details of funnel 1240 are not repeated again herein for the sake of brevity.
  • the binder pot 1250 is similar to binder pot 550 and forms a binder pot volume 1254 therein, which is similar to binder pot volume 554, for holding a binder material 1260, which is similar to binder material 560. Since binder pot 550 and binder material 560 have been previously described above, the details of binder pot 1250 and binder material 1260 are not repeated again herein for the sake of brevity.
  • the mold 1210 and the funnel 1240 are combined into a single component in some exemplary embodiments.
  • the downhole tool casting assembly 1200 is placed within a furnace (not shown) or other heating structure.
  • the binder material 1260 melts and flows into the shoulder powder 1234 and the tungsten carbide powder 1230 through an opening 1258 of the binder pot 1250.
  • the molten binder material 1260 infiltrates the shoulder powder 1234 and the tungsten carbide powder 1230 to fill the interparticle space formed between adjacent particles of the shoulder powder 1234 and the tungsten carbide powder 1230.
  • a substantial amount of binder material 1260 is used so that it fills at least a substantial portion of the funnel volume 1244.
  • This excess binder material 1260 in the funnel volume 1244 supplies a downward force on the tungsten carbide powder 1230 and the shoulder powder 1234.
  • the downhole tool casting assembly 1200 is pulled from the furnace and is controllably cooled.
  • the binder material 1260 solidifies and cements the particles of shoulder powder 1234 and tungsten carbide powder 1230 together into a coherent integral mass 1310 ( Figure 13 ).
  • the binder material 1260 also bonds this coherent integral mass 1310 ( Figure 13 ) to the blank 1224 thereby forming a bonding zone 1390 ( Figure 13 ) therebetween.
  • the coherent integral mass 1310 ( Figure 13 ) and the blank 1224 collectively form the casting 1300 ( Figure 13 ) or the matrix body bit 1300 ( Figure 13 ), a portion of which is shown in Figure 13 .
  • the mold 1210 is broken away from the casting 1300 ( Figure 13 ).
  • the casting 1300 ( Figure 13 ) then undergoes finishing steps which are known to persons of ordinary skill in the art, including the addition of a threaded connection (not shown) to the casting 1300 ( Figure 13 ).
  • the casting 1300 ( Figure 13 ), or the matrix body bit 1300 ( Figure 13 ) has been described to be formed using the process and equipment described above, the process and/or the equipment can be varied to still form the matrix body bit 1300 ( Figure 13 ).
  • Figure 13 shows a partial cross-sectional view of a downhole tool casting 1300 formed using the downhole tool casting assembly 1200 of Figure 12 in accordance with the non-inventive embodiment.
  • the downhole tool casting 1300 includes the coherent integral mass 1310, the blank 1224, and the passageways 1320 formed from the removal of the displacements 1220, 1222.
  • the coherent integral mass 1310 is formed using the tungsten carbide material 1230, as described above, and the shoulder powder 1234, also as described above.
  • the shoulder powder 1234 includes tungsten powder and the tungsten carbide material 1030 is absent free tungsten and includes either WC, W 2 C, or a combination of both.
  • this shoulder powder 1234 is absent any free tungsten.
  • the shoulder powder 1234 which is absent any free tungsten, includes stainless steel powder or any other suitable material described above.
  • the intermetallic compounds are formed when iron reacts with free tungsten.
  • the typical tungsten carbide powder 130 having free tungsten is replaced with tungsten carbide powder 1230 which is absent of free tungsten, thereby reducing and/or eliminating the formation of these intermetallic compounds, which is very brittle.
  • the tungsten carbide powder 1230 occupies the area adjacent a central zone area 1399 of the blank 1024, similar to central zone area 599 ( Figure 5 ), which experiences high stresses.
  • the casting or bit 1300 is more durable and has a greater longevity.
  • the shoulder powder 1234 which is tungsten free may be used in place of the typical shoulder powder 134, which includes free tungsten.
  • the shoulder powder 1234 occupies the area adjacent a chamfered portion 1398 of the blank 1224, similar to chamfered portion 598 ( Figure 5 ), which also experiences high stresses.
  • the casting or bit 1300 is more durable and has a greater longevity.
  • either or both shoulder powder 1234 and tungsten carbide powder 1230 (which are tungsten free) may be used in lieu of the typical shoulder powder 134 and typical tungsten carbide powder 130.
  • Figure 14 shows a cross-sectional view of a downhole tool casting assembly 1400 in accordance with yet another exemplary embodiment.
  • the downhole casting assembly 1400 is similar to downhole casting assembly 1000 ( Figure 10 ) and/or downhole casting assembly 1200 ( Figure 12 ) except an intermediate layer 1438 is disposed between the shoulder powder 1434 and the tungsten carbide powder 1430.
  • the intermediate layer 1438 is meant to minimize stresses caused by thermal expansion according to some exemplary embodiments.
  • the shoulder powder 1434 is similar to shoulder powder 1034, 1234 ( Figures 10 and 12 , respectively) and the tungsten carbide powder 1430 is similar to tungsten carbide powder 1030, 1230 ( Figures 10 and 12 , respectively).
  • At least one of the shoulder powder 1434 and the tungsten carbide powder 1430 is absent of free tungsten.
  • the intermediate layer 1438 is formed by including an amount of tungsten carbide powder 1430 that is used to the shoulder powder 1434 that is used thereby transitioning from the tungsten carbide powder 1430 to the shoulder powder 1434.
  • the amount of tungsten carbide powder 1430 that is included with the shoulder powder 1434 in the intermediate layer 1438 is about twenty percent to thirty percent by volume with respect to the shoulder powder 1434. According to some other exemplary embodiments, the amount of tungsten carbide powder 1430 that is included in the intermediate layer 1438 is between ten percent and less than fifty percent by volume.
  • the composition of the intermediate layer 1438 gradually varies from the bottom of the intermediate layer 1438 to the top of the intermediate layer 1438, where the composition at the bottom of the intermediate layer 1438 is close to the composition of the tungsten carbide powder 1430 and the composition at the top of the intermediate layer 1438 is close to the composition of the shoulder powder 1434.
  • This intermediate layer 1438 is harder than the areas where the shoulder powder 1434 is, but is still machinable according to certain exemplary embodiments.
  • FIG 15 shows a partial cross-sectional view of a downhole tool casting 1500 formed using the downhole tool casting assembly 1400 of Figure 14 in accordance with the exemplary embodiment.
  • the downhole tool casting 1500 is similar to downhole tool casting 1100 ( Figure 11 ) and/or downhole tool casting 1300 ( Figure 13 ) except an intermediate layer 1438 is disposed between the shoulder powder 1434 and the tungsten carbide powder 1430, as described above.

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Claims (11)

  1. Bohrlochwerkzeug, aufweisend:
    eine Metallkomponente (410), welche einen oberen Abschnitt (414), einen unteren Abschnitt (416), und einen Kanal aufweist, der sich von dem oberen Abschnitt zu dem unteren Abschnitt erstreckt, wobei die Metallkomponente aus mindestens einem Eisenmaterial gefertigt ist; und
    ein zementiertes Matrixmaterial, welches an eine äußere und eine innere Fläche der Metallkomponente gebunden ist, wobei das zementierte Matrixmaterial ein Bindematerial (560) aufweist, welches ein Wolframkarbidpulver (530) und ein Schulterpulver (534) in sich zementiert, wobei das Wolframkarbidpulver mindestens mit dem unteren Abschnitt der Metallkomponente verbunden ist und das zementierte Schulterpulver wenigstens mit dem oberen Abschnitt der Metallkomponente verbunden ist, wobei das Schulterpulver oberhalb des Wolframkarbidpulvers positioniert ist,
    wobei das zur Herstellung des Bohrlochwerkzeugs verwendete Schulterpulver frei von jeglichem freien Wolfram ist, und
    wobei das Schulterpulver aus mindestens einem der Folgenden ausgewählt ist: Edelstahlpulver, Nickelpulver, Kobaltpulver, Tantalpulver, Molybdänpulver oder einem beliebigen anderen Stahlpulver.
  2. Ein Verfahren zur Herstellung eines Bohrlochwerkzeugs, aufweisend:
    Platzieren eines Rohlings (400) innerhalb einer Bohrlochwerkzeuggussanordnung, wobei der Rohling einen oberen Abschnitt (414), einen unteren Abschnitt (416) und einen Kanal aufweist, der sich von dem oberen Abschnitt zu dem unteren Abschnitt erstreckt, wobei der Rohling aus mindestens einem Eisenmaterial gefertigt ist;
    Platzieren einer Mischung um wenigstens einen Abschnitt der Fläche des Rohlings innerhalb der Bohrlochwerkzeuggussanordnung, wobei die Mischung ein Wolframkarbidpulver (530) und ein Schulterpulver (534) aufweist, wobei das Wolframkarbidpulver mindestens benachbart zu dem unteren Abschnitt des Rohlings positioniert wird und das Schulterpulver mindestens benachbart zu dem oberen Abschnitt des Rohlings positioniert wird, wobei das Schulterpulver oberhalb des Wolframkarbidpulvers positioniert wird;
    Schmelzen eines Bindematerials (560) in die Mischung hinein;
    Ausformen eines zementierten Matrixmaterials aus der Mischung und dem Bindematerial; und
    Binden des zementierten Matrixmaterials an den Rohling, wobei das Schulterpulver frei von jeglichem freien Wolfram ist, und
    wobei das Schulterpulver aus mindestens einem der Folgenden ausgewählt ist: Edelstahlpulver, Nickelpulver, Kobaltpulver, Tantalpulver, Molybdänpulver oder einem beliebigen anderen Stahlpulver.
  3. Das Werkzeug oder Verfahren nach einem der vorhergehenden Ansprüche, wobei das Wolframkarbidpulver frei von jeglichem freien Wolfram ist.
  4. Das Werkzeug nach einem der Ansprüche 1 und 3, wobei die Metallkomponente ferner einen internen Rohling aufweist, oder das Verfahren nach einem der Ansprüche 2 und 3, wobei der Rohling ferner aufweist:
    eine interne Rohlingskomponente, welche den sich durch sie hindurch erstreckenden Kanal definiert; und
    eine Beschichtung, die mit mindestens einem Abschnitt der Oberfläche der internen Rohlingskomponente verbunden ist.
  5. Das Werkzeug oder Verfahren nach Anspruch 4, wobei die Beschichtung eine Metallbeschichtung umfasst.
  6. Das Werkzeug oder Verfahren nach Anspruch 5, wobei die Metallbeschichtung aus mindestens einem der Folgenden hergestellt ist: Nickel, Messing, Bronze, Kupfer, Aluminium, Zink, Gold, einem refraktären Übergangsmaterial, Molybdän, Tantal, Karbid, Borid, Oxid, ein Metallmatrixverbundwerkstoff, und einer Metalllegierung.
  7. Das Werkzeug oder Verfahren nach einem der Ansprüche 4 bis 6, wobei sich die Dicke der Beschichtung von etwa 5 µm bis unterhalb von etwa 200 µm reicht.
  8. Das Werkzeug oder Verfahren nach einem der Ansprüche 4 bis 7, wobei die Beschichtung auf die interne Rohlingskomponente unter Verwendung eines der Folgenden aufgebracht wird: einer Galvano-Technik, einer Plasmaspritztechnik, einer Ionenbeschusstechnik und einer elektrochemischen Abscheidetechnik.
  9. Das Werkzeug oder Verfahren nach einem der vorhergehenden Ansprüche, wobei das Wolframkarbidpulver ausgewählt ist aus WC, W2C, oder einer Kombination aus WC und W2C.
  10. Das Verfahren nach einem der vorhergehenden Ansprüche, wobei die Mischung weiterhin eine Zwischenschicht aufweist, die benachbart zwischen dem Wolframkarbidpulver und dem Schulterpulver angeordnet ist, wobei die Zwischenschicht das Wolframkarbidpulver und das Schulterpulver aufweist, wobei das Wolframkarbidpulver innerhalb der Zwischenschicht von 10 Volumenprozent bis unterhalb von 50 Volumenprozent reicht, bevorzugt zwischen 20 Volumenprozent und 30 Volumenprozent.
  11. Das Bohrlochwerkzeug nach Anspruch 1, wobei das zementierte Matrixmaterial weiterhin das Bindematerial aufweist, welches eine Zwischenschicht, die benachbart zwischen dem Wolframkarbidpulver und dem Schulterpulver angeordnet ist, zementiert, wobei die Zwischenschicht das Wolframkarbidpulver und das Schulterpulver aufweist, wobei das Wolframkarbidpulver innerhalb der Zwischenschicht von 10 Volumenprozent bis unterhalb von 50 Volumenprozent reicht, bevorzugt zwischen 20 Volumenprozent und 30 Volumenprozent.
EP15152253.9A 2014-01-23 2015-01-23 Verfahren zur Reduzierung intermetallischer Verbindungen in einer Matrixbit-Klebeschicht Not-in-force EP2899360B1 (de)

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US14/162,501 US9359824B2 (en) 2011-05-23 2014-01-23 Method for reducing intermetallic compounds in matrix bit bondline

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Publication number Priority date Publication date Assignee Title
US6287360B1 (en) * 1998-09-18 2001-09-11 Smith International, Inc. High-strength matrix body
US8517125B2 (en) * 2007-05-18 2013-08-27 Smith International, Inc. Impregnated material with variable erosion properties for rock drilling
US8381845B2 (en) * 2009-02-17 2013-02-26 Smith International, Inc. Infiltrated carbide matrix bodies using metallic flakes
RU2596932C2 (ru) * 2011-05-23 2016-09-10 Варель Ероп С.А.С. Матричная буровая коронка для работы в тяжелых условиях
US20130312927A1 (en) * 2012-05-24 2013-11-28 Halliburton Energy Services, Inc. Manufacturing Process for Matrix Drill Bits

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EP2899360A2 (de) 2015-07-29

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