JP2012500913A - ハイブリッド超硬合金を含む土木掘削ビット部品及びその製造方法 - Google Patents
ハイブリッド超硬合金を含む土木掘削ビット部品及びその製造方法 Download PDFInfo
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- 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
-
- 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
- E21B10/08—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
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
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- 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
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- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- Physics & Mathematics (AREA)
- Geochemistry & Mineralogy (AREA)
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- Organic Chemistry (AREA)
- Earth Drilling (AREA)
- Powder Metallurgy (AREA)
Abstract
【選択図】 図1
Description
[0072]以下の粉末グレード:85重量%のATI Firth SterlingグレードFL30粉末(ハイブリッド超硬合金の連続相を形成する)及び15重量%のATI Firth SterlingグレードHU6C粉末(分散相を形成する);を混合することによって、本発明において有用なハイブリッド超硬合金を製造するために用いることができる粉末ブレンドを調製した。連続相粉末グレード(FL30粉末)は、初めは、噴霧乾燥したままの状態(「素地」粉末状態とも呼ばれる)の比較的球状の粉末細粒の形態であった。また、分散相粉末グレード(HU6C粉末)も、初めは噴霧乾燥したままの状態であったが、素地細粒をブレンドする前に約800℃において真空雰囲気中で熱処理(予備焼結)した。V−ブレンダー内において、素地FL30粉末細粒を予備焼結したHU6C粉末細粒と約45分間ブレンドした。2種類の粉末の組成及び特性を表1に列記する。ここで、TRSは抗折力である。
[0073]以下の粉末グレード:80重量%のATI Firth SterlingグレードFL25粉末(連続相を形成する)及び20重量%のATI Firth SterlingグレードP40粉末(分散相を形成する);を混合することによって、本発明において有用なハイブリッド超硬合金を製造するために用いることができる更なる粉末ブレンドを調製した。連続相粉末グレード(FL25粉末)は、初めは、噴霧乾燥したままの(素地粉末)状態の比較的球状の粉末細粒の形態であった。また、分散相粉末グレード(P40粉末)も、初めは噴霧乾燥したままの状態であった。ダブルコーンブレンダー内において、素地FL25粉末を素地HU6C粉末細粒と約60分間ブレンドした。2種類の粉末グレードの組成及び特性を表2に列記する。
[0074]以下の粉末グレード:90重量%のATI Firth SterlingグレードH20粉末(連続相を形成する)及び10重量%のATI Firth SterlingグレードH17粉末(分散相を形成する);を混合することによって、本発明において有用なハイブリッド超硬合金を製造するために用いることができる更なる粉末ブレンドを調製した。連続相粉末グレード(H20粉末)は、初めは、噴霧乾燥したままの(素地粉末)状態の比較的球状の粉末細粒の形態であった。また、分散相粉末グレード(H17粉末)も、初めは噴霧乾燥したままの状態であったが、ブレンドする前に粉末細粒を約1000℃において真空中で熱処理(予備焼結)した。V−ブレンダー内において、素地H20粉末細粒を予備焼結した粉末H17細粒と約45分間ブレンドした。2種類の粉末グレードの組成及び特性を表3に列記する。
[0075]以下の粉末グレード:80重量%のATI Firth SterlingグレードND30粉末(連続相を形成する)、10重量%のATI Firth SterlingグレードHU6C粉末(第1の分散相を形成する)、及び10重量%のATI Firth SterlingグレードAF63粉末(第2の分散相を形成する);を混合することによって、本発明において有用なハイブリッド超硬合金を製造するために用いることができる更に他の粉末ブレンドを調製した。連続相粉末グレード(ND30粉末)は、初めは、噴霧乾燥したままの「素地」状態の比較的球状の粉末細粒の形態であった。また、分散相粉末グレード(HU6C及びAF63粉末)も、初めは噴霧乾燥したままの状態であった。しかしながら、HU6C粉末細粒は、ブレンドする前に約800℃において真空中で熱処理(予備焼結)した。Turbulaブレンダー内において、素地ND30粉末細粒を予備焼結したHU6C及び素地AF63粉末細粒と約30分間ブレンドした。3種類の粉末グレードの特性を表4に列記する。
[0084]以下のようにしてハイブリッド超硬合金をベースとするフィックスドカッター土木掘削ビット本体を製造することができた。実施例1において上記に記載したようにしてハイブリッド超硬合金粉末ブレンドを調製した。25,000psiのプレス圧における冷間等方圧プレスによって、粉末ブレンドの少なくとも一部を固化して鋼片形状の「素地」粉末成形体を形成した。成形体を、水素雰囲気中700℃において予備焼結した。5軸フライス盤を用いて鋼片を機械加工して、例えば図2において一般的に示される完成フィックスドカッタービット本体の通常の形状特徴を導入した。1380℃の温度及び800psiの圧力における過圧焼結(「SinterHIP」とも呼ばれる)を用いて、機械加工した予備焼結部品を焼結して、ハイブリッド超硬合金から構成される最終ビット本体を製造した。
[0085]以下のようにして、ハイブリッド超硬合金をベースとするローラーコーン土木掘削ビット用のローラーコーンを製造することができた。上記の実施例4に記載したようにしてハイブリッド超硬合金粉末ブレンドを調製した。30,000psiのプレス圧における冷間等方圧プレスによって、粉末ブレンドの少なくとも一部を固化して鋼片形状の「素地」成形体を形成した。鋼片を、水素雰囲気中700℃において予備焼結した。5軸フライス盤を用いて鋼片を機械加工して、例えば図1においてローラーコーン14として一般的に示される完成ローラーコーンの通常の形状特徴を導入した。1380℃の温度及び800psiの圧力における過圧焼結(SinterHIP)を用いて、機械加工した予備焼結部品を焼結して、ハイブリッド超硬合金から構成される最終ローラーコーンを製造した。
Claims (59)
- 超硬合金分散相;及び
超硬合金連続相;
を含むハイブリッド超硬合金複合体;
を含む、ビット本体、ローラーコーン、及びマッドノズルから選択される製造品。 - ハイブリッド超硬合金複合体の分散相の接触率が0.48以下である、請求項1に記載の製造品。
- ハイブリッド超硬合金複合体の分散相の接触率が0.4未満である、請求項1に記載の製造品。
- ハイブリッド超硬合金複合体の分散相の接触率が0.2未満である、請求項1に記載の製造品。
- ハイブリッド超硬合金複合体の分散相の硬度がハイブリッド超硬合金複合体の連続相の硬度よりも大きい、請求項1に記載の製造品。
- ハイブリッド超硬合金複合体が第1の超硬合金分散相及び第2の超硬合金分散相を含み、第2の超硬合金分散相の組成及び物理特性の少なくとも1つが第1の超硬合金分散相と異なる、請求項1に記載の製造品。
- 物理特性が、硬度、パームクイスト靱性、及び耐摩耗性からなる群から選択される、請求項6に記載の製造品。
- ハイブリッド超硬合金の超硬合金分散相がハイブリッド超硬合金の2〜50体積%である、請求項1に記載の製造品。
- ハイブリッド超硬合金の超硬合金分散相がハイブリッド超硬合金の2〜25体積%である、請求項1に記載の製造品。
- ハイブリッド超硬合金の超硬合金分散相の硬度が少なくとも88HRAで95HRA以下である、請求項1に記載の製造品。
- ハイブリッド超硬合金の超硬合金連続相のパームクイスト靱性が10MPa・m1/2より大きい、請求項10に記載の製造品。
- ハイブリッド超硬合金の超硬合金連続相の硬度が少なくとも78HRAで91HRA以下である、請求項10に記載の製造品。
- ハイブリッド超硬合金複合体の超硬合金分散相及び超硬合金連続相が、独立して、
少なくとも1種類の、周期律表の第IVB、VB、及びVIB族から選択される金属の炭化物;及び
コバルト、コバルト合金、ニッケル、ニッケル合金、鉄、及び鉄合金の少なくとも1つを含むバインダー;
を含む、請求項1に記載の製造品。 - ハイブリッド超硬合金の超硬合金分散相及び超硬合金連続相の少なくとも1つのバインダーが、タングステン、チタン、タンタル、ニオブ、アルミニウム、クロム、銅、マンガン、モリブデン、ホウ素、炭素、ケイ素、及びルテニウムから選択される合金化剤を更に含む、請求項13に記載の製造品。
- 合金化剤が20重量%以下のバインダーを含む、請求項14に記載の製造品。
- 分散相のバインダー濃度が2重量%〜15重量%であり、連続相のバインダー濃度が6重量%〜30重量%である、請求項13に記載の製造品。
- 超硬合金分散相及び超硬合金連続相の両方が炭化タングステン及びコバルトを含む、請求項13に記載の製造品。
- 超硬合金分散相;ここで分散相の体積割合はハイブリッド超硬合金複合体の50体積%未満である;及び
超硬合金連続相;
を含み;
超硬合金分散相と超硬合金連続相の物理特性が異なり、超硬合金分散相が超硬合金分散相の体積割合の1.5倍未満の接触率を有するハイブリッド超硬合金複合体を含む土木掘削ビット部品。 - 超硬合金分散相及び超硬合金連続相が、それぞれ独立して、
少なくとも1種類の、チタン、クロム、バナジウム、ジルコニウム、ハフニウム、タンタル、モリブデン、ニオブ、及びタングステンからなる群から選択される少なくとも1種類の遷移金属の炭化物;及び
コバルト、コバルト合金、ニッケル、ニッケル合金、鉄、及び鉄合金の少なくとも1つを含むバインダー;
を含む、請求項18に記載の土木掘削ビット部品。 - バインダーが、タングステン、チタン、タンタル、ニオブ、アルミニウム、クロム、銅、マンガン、モリブデン、ホウ素、炭素、ケイ素、及びルテニウムから選択される合金化剤を更に含む、請求項19に記載の土木掘削ビット部品。
- ハイブリッド超硬合金複合体が0.7mm−3より大きい耐摩耗性及び10MPa・m1/2より大きいパームクイスト靱性を有する、請求項19に記載の土木掘削ビット部品。
- 土木掘削ビット部品が、ビット本体、ローラーコーン、及びマッドノズルから選択される、請求項18に記載の部品。
- 第1グレードの超硬合金粉末の一部と第2グレードの超硬合金粉末の一部を混合して粉末ブレンドを与え;
粉末ブレンドの少なくとも一部を素地成形体に固化し;ここで第1グレードの超硬合金粉末は素地成形体の分散相であり、第2グレードの超硬合金粉末は素地成形体の連続相であり;そして
素地成形体を少なくとも部分的か又は完全に焼結して、超硬合金分散相及び超硬合金連続相を含むハイブリッド超硬合金複合体を含む緻密化成形体を形成する;
ことを含む、土木掘削ビット用部品の製造方法。 - ハイブリッド超硬合金複合体の分散相の接触率が0.48以下である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の分散相の接触率が0.4未満である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の分散相の接触率が0.2未満である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の分散相の硬度がハイブリッド超硬合金複合体の連続相の硬度よりも大きい、請求項23に記載の方法。
- 第3グレードの超硬合金粉末を第1及び第2グレードの超硬合金粉末と混合して粉末ブレンドにし;
ハイブリッド超硬合金複合体が、超硬合金連続相、第1の超硬合金分散相、及び第2の超硬合金分散相を含み;そして
第1の超硬合金分散相の組成及び特性の少なくとも1つが第2の超硬合金分散相と異なる;
請求項23に記載の方法。 - 特性が、硬度、パームクイスト靱性、及び耐摩耗性からなる群から選択される、請求項28に記載の方法。
- ハイブリッド超硬合金の超硬合金分散相がハイブリッド超硬合金複合体の2〜50体積%である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の超硬合金分散相がハイブリッド超硬合金複合体の2〜25体積%である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の超硬合金分散相の硬度が少なくとも88HRAで95HRA以下である、請求項23に記載の方法。
- ハイブリッド超硬合金複合体の超硬合金連続相のパームクイスト靱性が10MPa・m1/2より大きい、請求項32に記載の方法。
- ハイブリッド超硬合金複合体の超硬合金連続相の硬度が少なくとも78HRAで91HRA以下である、請求項33に記載の方法。
- ハイブリッド超硬合金複合体の超硬合金分散相及び超硬合金連続相が、独立して、
少なくとも1種類の、周期律表の第IVB、VB、及びVIB族から選択される金属の炭化物;及び
コバルト、コバルト合金、ニッケル、ニッケル合金、鉄、及び鉄合金の少なくとも1つを含むバインダー;
を含む、請求項23に記載の方法。 - バインダーが、タングステン、チタン、タンタル、ニオブ、アルミニウム、クロム、銅、マンガン、モリブデン、ホウ素、炭素、ケイ素、及びルテニウムからなる群から選択される少なくとも1種類の合金化剤を更に含む、請求項35に記載の方法。
- 合金化剤が20重量%以下のバインダーを含む、請求項36に記載の方法。
- 分散相のバインダー濃度が2重量%〜15重量%であり、連続相のバインダー濃度が6重量%〜30重量%である、請求項35に記載の方法。
- 超硬合金分散相が炭化タングステン及びコバルトを含み、超硬合金連続相が炭化タングステン及びコバルトを含む、請求項35に記載の方法。
- 超硬合金分散相の体積割合がハイブリッド超硬合金複合体の50体積%未満であり;
超硬合金分散相が、ハイブリッド超硬合金複合体中の超硬合金分散相の体積割合の1.5倍未満の接触率を有する;
請求項23に記載の方法。 - ハイブリッド超硬合金複合体が0.7mm−3より大きい耐摩耗性及び10MPa・m1/2より大きいパームクイスト靱性を有する、請求項23に記載の方法。
- 土木掘削ビット用部品が、ビット本体、ローラーコーン、及びマッドノズルから選択される、請求項23に記載の方法。
- 土木掘削ビット用部品が成形されたフィックスドカッタービット本体である、請求項23に記載の方法。
- 成形されたフィックスドカッタービット本体によって画定されるポケット中に切削インサートを配置することを更に含む、請求項43に記載の方法。
- 素地成形体を部分的か又は完全に焼結することが、
素地成形体を予備焼結して脱脂成形体を形成し;そして
脱脂成形体を焼結する;
ことを含む、請求項23に記載の方法。 - 脱脂成形体を焼結する前に脱脂成形体を機械加工することを更に含む、請求項45に記載の方法。
- 脱脂成形体を機械加工することが、脱脂成形体中に少なくとも1つのカッターインサートポケットを機械加工することを含む、請求項47に記載の方法。
- 素地成形体を予備焼結する前に素地成形体を機械加工することを更に含む、請求項45に記載の方法。
- 素地成形体を機械加工することが、素地成形体中に少なくとも1つのカッターインサートポケットを機械加工することを含む、請求項47に記載の方法。
- 粉末ブレンドの少なくとも一部を固化することが、粉末ブレンドの少なくとも一部を圧縮することを含む、請求項23に記載の方法。
- 粉末ブレンドの少なくとも一部を圧縮することが、粉末ブレンドの少なくとも一部を等方圧プレスすることを含む、請求項49に記載の方法。
- 第1の超硬合金グレード及び第2の超硬合金グレードが、それぞれ独立して、炭化チタン、炭化クロム、炭化バナジウム、炭化ジルコニウム、炭化ハフニウム、炭化タンタル、炭化モリブデン、炭化ニオブ、及び炭化タングステンからなる群から選択される遷移金属炭化物を含む、請求項23に記載の方法。
- 脱脂成形体を焼結することが、脱脂成形体を液相温度において焼結することを含む、請求項45に記載の方法。
- 脱脂成形体を焼結することが、脱脂成形体を300〜2000psiの圧力及び1350℃〜1500℃の温度において焼結することを含む、請求項45に記載の方法。
- ハイブリッド超硬合金複合体が、第1のハイブリッド超硬合金複合体組成を有する第1の領域及び第2のハイブリッド超硬合金複合体組成を有する第2の領域を含む、請求項23に記載の方法。
- 固化の前に、
第1のハイブリッド超硬合金複合体組成を形成するための第1の粉末ブレンドの少なくとも一部を成形型の空洞部の第1の領域中に配置し;
第2の超硬合金複合体組成を形成するための第2の粉末ブレンドの少なくとも一部を成形型の空洞部の第2の領域中に配置する;
ことを更に含み;
粉末ブレンドの少なくとも一部を固化することが、成形型の空洞部内で粉末ブレンドを圧縮して素地成形体を与えることを含む、請求項54に記載の方法。 - 成形されたフィックスドカッタービット本体にシャンクを取り付けることを更に含む、請求項43に記載の方法。
- 成形されたフィックスドカッタービット本体が300ksiより大きい抗折力を有する、請求項43に記載の方法。
- 成形されたフィックスドカッタービット本体が55,000,000psiより大きいヤング弾性率を有する、請求項58に記載の方法。
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ZA201100879B (en) | 2014-07-30 |
RU2011110717A (ru) | 2012-09-27 |
CN102149896B (zh) | 2014-06-11 |
WO2010021801A3 (en) | 2011-01-06 |
CN102149896A (zh) | 2011-08-10 |
WO2010021801A2 (en) | 2010-02-25 |
CA2732517A1 (en) | 2010-02-25 |
EP2664688A1 (en) | 2013-11-20 |
EP2321442A2 (en) | 2011-05-18 |
US8322465B2 (en) | 2012-12-04 |
US20130037985A1 (en) | 2013-02-14 |
US20100044115A1 (en) | 2010-02-25 |
BRPI0917834A2 (pt) | 2015-11-24 |
IL210766A0 (en) | 2011-03-31 |
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