US20090301788A1 - Composite metal, cemented carbide bit construction - Google Patents

Composite metal, cemented carbide bit construction Download PDF

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Publication number
US20090301788A1
US20090301788A1 US12/136,456 US13645608A US2009301788A1 US 20090301788 A1 US20090301788 A1 US 20090301788A1 US 13645608 A US13645608 A US 13645608A US 2009301788 A1 US2009301788 A1 US 2009301788A1
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Prior art keywords
based alloys
brown
bit body
another portion
providing
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US12/136,456
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English (en)
Inventor
John H. Stevens
James L. Christie
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Baker Hughes Holdings LLC
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Individual
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Priority to US12/136,456 priority Critical patent/US20090301788A1/en
Assigned to BAKER HUGHES INCORPORATED reassignment BAKER HUGHES INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHRISTIE, JAMES L., STEVENS, JOHN H.
Priority to PCT/US2009/046810 priority patent/WO2009152194A2/fr
Priority to EP09763484.4A priority patent/EP2307659A4/fr
Priority to RU2010154503/03A priority patent/RU2010154503A/ru
Publication of US20090301788A1 publication Critical patent/US20090301788A1/en
Abandoned legal-status Critical Current

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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
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • E21B10/55—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits with preformed cutting elements
    • 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
    • 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
    • B22F7/08—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 with one or more parts not made from powder
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • 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
    • 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
    • C22C29/10—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 titanium carbide
    • 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
    • C22C29/14—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on borides
    • 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
    • C22C29/16—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on nitrides
    • 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
    • B22F2005/002—Tools other than cutting 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B22F3/15—Hot isostatic pressing
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B22F3/172—Continuous compaction, e.g. rotary hammering
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2204/00—End product comprising different layers, coatings or parts of cermet

Definitions

  • This invention relates generally to a method of manufacturing drill bits and other drilling-related structures generally used for drilling subterranean formations, and more specifically to a method of manufacturing a drill bit or drilling-related structure having a porous sintered steel powder core and a powdered tungsten carbide (WC) shell commonly infiltrated with other metals binder having cutter segments thereon or a sintered powder tungsten carbide (WC) core with other metals having cutter segments thereon.
  • a sintered, preformed blank is formed and placed in a mold configured as a bit or other drilling-related structure, the preformed blank being sized to provide space between the blank and the mold wall to accommodate a layer of WC powder therebetween.
  • cutter segments are formed having cutters thereon which are attached to the tungsten carbide shell or to the tungsten carbide bit body.
  • a typical rotary drill bit includes a bit body secured to a steel shank having a threaded pin connection for attaching the bit body to a drill string, and a crown comprising that part of the bit fitted with cutting structures for cutting into an earth formation.
  • the cutting structures include a series of cutting elements formed at least in part of a super-abrasive material, such as polycrystalline diamond.
  • the bit body is generally formed of steel, or a matrix of hard particulate material such as tungsten carbide (WC) infiltrated with a binder, generally of copper alloy.
  • bit body In the case of steel body bits, the bit body is typically machined from round stock to the desired shape. Internal watercourses for delivery of drilling fluid to the bit face and topographical features defined at precise locations on the bit face may be machined into the bit body using a computer-controlled five-axis machine tool. Hardfacing for resisting abrasion during drilling is usually applied to the bit face and to other critical areas of the bit exterior, and cutting elements are secured to the bit face, generally by inserting the proximal ends of studs, on which the cutting elements are mounted, into apertures bored in the bit face. The end of the bit body opposite the face is then threaded, made up and welded to the bit shank.
  • bit blade of steel or other suitable material for later attachment to the shank, or threaded end of the bit body matrix.
  • the blank may be merely cylindrically tubular, or may be fairly complex in configuration and include protrusions corresponding to blades, wings or other features on and extending from the bit face.
  • Other preformed elements or displacements comprised of cast resin-coated sand, or in some instances graphite may be employed to define watercourses and passages for delivery of drilling fluid to and away from the bit face, well as cutting element sockets, ridges, lands, nozzle displacements, junk slots and other external topographic features of the bit.
  • the blank and other displacements are placed at appropriate locations and orientations in the mold used to cast the bit body.
  • the blank is bonded to the matrix upon cooling of the bit body after infiltration of the tungsten carbide with the matrix alloy in a furnace.
  • the other displacements are removed once the matrix has cooled.
  • the upper end of the blank is then threaded, made up with a matingly threaded shank, and the two are welded together.
  • the cutting elements typically diamond, and most often a synthetic polycrystalline diamond compact or PDC
  • TSP's Thermally stable PDC's
  • the process of fabricating a matrix-type drill bit is a somewhat costly, complex multi-step process requiring separate fabrication of an intermediate product (the mold) before the end product (the bit) can be cast. Moreover, the blanks and preforms employed must be individually designed and fabricated.
  • the mold used to cast a matrix body is typically machined from a cylindrical graphite element.
  • bit molds were machined to a general bit profile, and the individual bit face topography defined in reverse in the mold by skilled technicians employing the aforementioned preforms and wielding dental-type drills and other fine sculpting tools.
  • many details may be machined in a mold using a computer controlled five-axis machine tool.
  • the displacement material should preferably be a mesh size of at least 400 mesh (approximately 0.001 inches) and also states that very fine powdered materials (i.e., less than 0.001 inches in diameter) such as iron may sinter and shrink during fabrication; it being undesirable for the powder to shrink substantially during the heating process.
  • a manufacturing method and drill bit having either a preformed steel powder blank or machined steel core and abrasion and erosion resistant material components attached thereon.
  • FIG. 1A is a partially cross-sectioned schematic view of a first embodiment of a drill bit manufactured in accordance with the present invention
  • FIG. 1B is a partially cross-sectioned schematic view of a second embodiment of a drill bit manufactured in accordance with the present invention
  • FIGS. 2A-2E illustrate a method of forming a shell for the bit body of the earth-boring rotary drill bit shown in FIG. 1A or 1 B;
  • FIG. 3A is a partially cross-sectioned schematic view of another embodiment of a drill bit manufactured in accordance with the present invention having segments on the blades;
  • FIG. 3B is a partially cross-sectioned schematic view of another embodiment of a drill bit manufactured in accordance with the present invention having segments on the blades;
  • FIG. 4 is a portion of a segment on a blade of the drill bit
  • FIG. 5 is a portion of a segment on a blade of the drill bit.
  • FIG. 6 is a partially cross-sections schematic view of another embodiment of a drill bit manufactured in accordance with the present invention having segments and or a shell on the blades.
  • FIG. 1A A drill bit 10 manufactured in accordance with the present invention is illustrated in FIG. 1A .
  • the drill bit 10 has a typical rotary drag bit configuration and is generally comprised of a bit body 12 including a plurality of longitudinally extending blades 14 defining junk slots 16 between the blades 14 .
  • Each blade 14 defines a leading or cutting face 18 that extends from proximate the center of the bit face around the distal end 15 of the drill bit 10 , and includes a plurality of cutting elements 20 oriented to cut into a subterranean formation upon rotation of the drill bit 10 .
  • the cutting elements 20 are secured to and supported by the blades 14 .
  • each blade 14 defines a longitudinally and radially extending gage portion 22 that corresponds to approximately the largest-diameter-portion of the drill bit 10 and, thus is typically only slightly smaller than the diameter of the hole to be drilled by cutting elements 20 of the bit 10 .
  • the proximal end 23 of the bit 10 includes a threaded portion or pin 25 to threadedly attach the drill bit 10 to a drill collar or downhole motor, as is known in the art.
  • the threaded pin portion 25 may be machined directly into the proximal end 23 of the combination shank and blank 34 that is attached and formed into the body 12 of the drill bit 10 .
  • the bit 10 is further comprised of either a machine steel core or a porous sintered blank or core 26 comprised of steel or other metal interlocked with the blank 34 , formed of any suitable material, such as steel, titanium, tungsten carbide (WC), etc., and a shell of abrasion-resistant material 28 , such as tungsten carbide (WC), infiltrated with a common metal to form a matrix of tungsten carbide and the metal.
  • the plenum 29 longitudinally extend from the proximal end 23 to the distal end 15 or crown end 15 , substantially through the blank 34 and core 26 , terminating at shell 28 . As illustrated in FIG.
  • the core 26 ′ may have a topographical exterior surface configuration 30 substantially similar to the topography 32 of a completed bit 10 ′, but smaller in size, or be different such that the shell 28 occupies a larger volume of the bit 10 (see FIG. 1A ).
  • the core 26 ′ generally may follow the contour of the drill bit 10 ′ defined by its surface topography 32 . This similarity in shape between the core 26 ′ and the topography 32 is a result of a preferred bit manufacturing method of the present invention.
  • the plenum 29 ′ may only extend partially through the core 26 ′ such that any waterways connecting the plenum 29 ′ to the nozzle ports 62 and 64 must extend through material of both the core 26 ′ and shell 28 ′.
  • the cutters 20 may be bonded to the blades 14 by brazing, mechanical affixation, or adhesive affixation.
  • the cutters 20 may be provided within the mold and bonded to the blades 14 of the shell 28 during infiltration or furnacing of the shell 28 if thermally stable synthetic diamonds, or natural diamonds, are employed.
  • green bit shell or “green segment” as used herein means an unsintered structure comprising a plurality of discrete particles held together by a binder material, the structure having a size and shape allowing the formation of a shell body suitable for use in an earth-boring drill bit from the structure by subsequent manufacturing processes including, but not limited to, machining and densification.
  • brown shell body or “brown segment” as used herein means a partially sintered structure comprising a plurality of particles, at least some of which have partially grown together to provide at least partial bonding between adjacent particles, the structure having a size and shape allowing the formation of a bit body suitable for use in an earth-boring drill bit from the structure by subsequent manufacturing processes including, but not limited to, machining and further densification.
  • Brown shell bodies may be formed by, for example, partially sintering a green shell body.
  • sining means densification of a particulate component involving removal of at least a portion of the pores between the starting particles (accompanied by shrinkage) combined with coalescence and bonding between adjacent particles.
  • [metal]-based alloy (where [metal] is any metal) means commercially pure [metal] in addition to metal alloys wherein the weight percentage of [metal] in the alloy is greater than the weight percentage of any other component of the alloy.
  • the term “material composition” means the chemical composition and microstructure of a material. In other words, materials having the same chemical composition but a different microstructure are considered to having different material compositions.
  • tungsten carbide means any material composition that contains chemical compounds of tungsten and carbon, such as, for example, WC, W 2 C, and combinations of WC and W 2 C.
  • Tungsten carbide includes, for example, cast tungsten carbide, sintered tungsten carbide, and macrocrystalline tungsten carbide.
  • the particle-matrix composite material of the shell 28 may include a plurality of hard particles randomly dispersed throughout a matrix material.
  • the hard particles may comprise diamond or ceramic materials such as carbides, nitrides, oxides, and borides (including boron carbide (B 4 C)). More specifically, the hard particles may comprise carbides and borides made from elements such as W, Ti, Mo, Nb, V, Hf, Ta, Cr, Zr, Al, and Si.
  • materials that may be used to form hard particles include tungsten carbide, titanium carbide (TiC), tantalum carbide (TaC), titanium diboride (TiB 2 ), chromium carbides, titanium nitride (TiN), aluminium oxide (Al 2 O 3 ), aluminium nitride (AlN), and silicon carbide (SiC).
  • TiC titanium carbide
  • TaC tantalum carbide
  • TiB 2 titanium diboride
  • chromium carbides titanium nitride
  • TiN titanium nitride
  • Al 2 O 3 aluminium oxide
  • AlN aluminium nitride
  • SiC silicon carbide
  • combinations of different hard particles may be used to tailor the physical properties and characteristics of the particle-matrix composite material.
  • the hard particles may be formed using techniques known to those of ordinary skill in the art. Most suitable materials for hard particles are commercially available and the formation of the remainder is within the ability of one of ordinary skill in the art.
  • the matrix material of the particle-matrix composite material may include, for example, cobalt-based, iron-based, nickel-based, iron and nickel-based, cobalt and nickel-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, and titanium-based alloys.
  • the matrix material may also be selected from commercially pure elements such as cobalt, aluminum, copper, magnesium, titanium, iron, and nickel.
  • the matrix material may include carbon steel, alloy steel, stainless steel, tool steel, Hadfield manganese steel, nickel or cobalt superalloy material, and low thermal expansion iron or nickel based alloys such as INVAR®.
  • the term “superalloy” refers to an iron, nickel, and cobalt based-alloys having at least 12% chromium by weight.
  • Additional exemplary alloys that may be used as matrix material include austenitic steels, nickel based superalloys such as INCONEL® 625M or Rene 95, and INVAR® type alloys having a coefficient of thermal expansion that closely matches that of the hard particles used in the particular particle-matrix composite material. More closely matching the coefficient of thermal expansion of matrix material with that of the hard particles offers advantages such as reducing problems associated with residual stresses and thermal fatigue.
  • Another exemplary matrix material is a Hadfield austenitic manganese steel (Fe with approximately 12% Mn by weight and 1.1% C by weight).
  • the particle-matrix composite material may include a plurality of ⁇ 400 ASTM (American Society for Testing and Materials) mesh tungsten carbide particles as the hard particle component of the particle-matrix composite material.
  • the tungsten carbide particles may be substantially composed of WC.
  • ⁇ 400 ASTM mesh particles means particles that pass through an ASTM No. 400 mesh screen as defined in ASTM specification E11-04 entitled Standard Specification for Wire Cloth and Sieves for Testing Purposes.
  • Such tungsten carbide particles may have a diameter of less than about 38 microns.
  • the matrix material forming another component of the particle-matrix composite material may include a metal alloy comprising about 50% cobalt by weight and about 50% nickel by weight.
  • the tungsten carbide particles may comprise between about 60% and about 95% by weight of the particle-matrix composite material, and the matrix material may comprise between about 5% and about 40% by weight of the particle-matrix composite material. More particularly, the tungsten carbide particles may comprise between about 70% and about 80% by weight of the particle-matrix composite material, and the matrix material may comprise between about 20% and about 30% by weight of the particle-matrix composite material.
  • the particle-matrix composite material may include a plurality of ⁇ 635 ASTM mesh tungsten carbide particles as the hard particle component of the particle-matrix composite material.
  • ⁇ 635 ASTM mesh particles means particles that pass through an ASTM No. 635 mesh screen as defined in ASTM specification E11-04 entitled Standard Specification for Wire Cloth and Sieves for Testing Purposes.
  • Such tungsten carbide particles may have a diameter of less than about 20 microns.
  • the matrix material may include a cobalt-based metal alloy comprising substantially commercially pure cobalt.
  • the matrix material forming another component of the particle-matrix composite material may include greater than about 98% cobalt by weight.
  • the tungsten carbide particles may comprise between about 60% and about 95% by weight of the particle-matrix composite material, and the matrix material may comprise between about 5% and about 40% by weight of the particle-matrix composite material.
  • FIGS. 2A-2E illustrate a method of fonning the shell 28 , which is substantially formed from and composed of a particle-matrix composite material.
  • the method generally includes providing a powder mixture, pressing the powder mixture to form a green body, and at least partially sintering the powder mixture.
  • a powder mixture 78 which forms the particle-matrix composite material that includes a hard particle component and a matrix material component, may be pressed with substantially isostatic pressure within a mold or container 80 .
  • the powder mixture 78 may include a plurality of the previously described hard particles and a plurality of particles comprising a matrix material, as also previously described herein.
  • the powder mixture 78 may further include additives commonly used when pressing powder mixtures such as, for example, binders for providing lubrication during pressing and for providing structural strength to the pressed powder component, plasticizers for making the binder more pliable, and lubricants or compaction aids for reducing inter-particle friction.
  • the container 80 may include a fluid-tight deformable member 82 .
  • the fluid-tight deformable member 82 may be a substantially cylindrical bag comprising a deformable polymer material.
  • the container 80 may further include a sealing plate 84 , which may be substantially rigid.
  • the deformable member 82 may be formed from, for example, an elastomer such as rubber, neoprene, silicone, or polyurethane.
  • the deformable member 82 may be filled with the powder mixture 78 and vibrated to provide a uniform distribution of the powder mixture 78 within the deformable member 82 .
  • At least one displacement or insert 86 may be provided within the deformable member 82 for defining features of the bit body 52 such as, for example, the longitudinal bore 40 ( FIG. 2 ).
  • the insert 86 may not be used and the longitudinal bore 40 may be formed using a conventional machining process during subsequent processes.
  • the sealing plate 84 then may be attached or bonded to the deformable member 82 providing a fluid-tight seal therebetween.
  • the container 80 (with the powder mixture 78 and any desired inserts 86 contained therein) may be provided within a pressure chamber 90 .
  • a removable cover 91 may be used to provide access to the interior of the pressure chamber 90 .
  • a fluid (which may be substantially incompressible) such as, for example, water, oil, or gas (such as, for example, air or nitrogen) is pumped into the pressure chamber 90 through an opening 92 at high pressures using a pump (not shown).
  • the high pressure of the fluid causes the walls of the deformable member 82 to deform.
  • the fluid pressure may be transmitted substantially uniformly to the powder mixture 78 .
  • the pressure within the pressure chamber 90 during isostatic pressing may be greater than about 35 megapascals (about 5,000 pounds per square inch).
  • the pressure within the pressure chamber 90 during isostatic pressing may be greater than about 138 megapascals (20,000 pounds per square inch).
  • a vacuum may be provided within the container 80 and a pressure greater than about 0.1 megapascals (about 15 pounds per square inch) may be applied to the exterior surfaces of the container (by, for example, the atmosphere) to compact the powder mixture 78 .
  • Isostatic pressing of the powder mixture 78 may form a green powder component or green shell body 94 shown in FIG. 3B , which can be removed from the pressure chamber 90 and container 80 after pressing.
  • the powder mixture 78 may be uniaxially pressed in a mold or die (not shown) using a mechanically or hydraulically actuated plunger by methods that are known to those of ordinary skill in the art of powder processing.
  • the green shell body 94 shown in FIG. 2B may include a plurality of particles (hard particles and particles of matrix material forming the particle-matrix composite material) held together by a binder material provided in the powder mixture 78 ( FIG. 2A ), as previously described.
  • Certain structural features may be machined in the green bit body 94 using conventional machining techniques including, for example, turning techniques, milling techniques, and drilling techniques. Hand held tools also may be used to manually form or shape features in or on the green shell body 94 .
  • blades 14 , junk slots 16 ( FIGS. 1A , 1 B), and any surfaces may be machined or otherwise formed in the green shell body 94 to form a shaped green shell body 98 shown in FIG. 2C .
  • the shaped green shell body 98 shown in FIG. 2C may be at least partially sintered to provide a brown bit body 102 shown in FIG. 2D , which has less than a desired final density.
  • the shaped green bit body 98 Prior to partially sintering the shaped green bit body 98 , the shaped green bit body 98 may be subjected to moderately elevated temperatures and pressures to burn off or remove any fugitive additives of any binder used that were included in the powder mixture 78 ( FIG. 2A ), as previously described.
  • the shaped green bit body 98 may be subjected to a suitable atmosphere tailored to aid in the removal of such additives.
  • Such atmospheres may include, for example, hydrogen gas at temperatures of about 500° C.
  • the brown shell body 102 may be substantially machinable due to the remaining porosity therein. Certain structural features may be machined in the brown shell body 102 using conventional machining techniques including, for example, turning techniques, milling techniques, and drilling techniques. Hand held tools also may be used to manually form or shape features in or on the brown shell body 102 . Tools that include superhard coatings or inserts may be used to facilitate machining of the brown shell body 102 . Additionally, material coatings may be applied to surfaces of the brown shell body 102 that are to be machined to reduce chipping of the brown bit body 102 . Such coatings may include a suitable fixative material or other suitable polymer materials or their like.
  • internal fluid passageways 29 , cutter pockets 36 and blades 14 may be machined or otherwise formed in the brown bit body 102 to form a shaped brown shell body 106 shown in FIG. 2E .
  • the cutters may be positioned within the cutter pockets 36 formed in the brown shell body 102 . Upon subsequent sintering of the brown bit body 102 , the cutters may become bonded to and integrally formed with the shell body 52 .
  • the shaped brown bit body 106 shown in FIG. 2E then may be fully sintered to a desired final density to provide the previously described shell 28 shown in FIG. 1A or FIG. 1B .
  • any sintering involves densification and removal of porosity within a structure, the structure being sintered will shrink during the sintering process.
  • a structure may experience linear shrinkage of between 10% and 20% during sintering from a green state to a desired final density.
  • dimensional shrinkage must be considered and accounted for when designing tooling (molds, dies, etc.) or machining features in structures that are less than fully sintered.
  • refractory structures or displacements may be used to support at least portions of the bit body during the sintering process to maintain desired shapes and dimensions during the densification process.
  • Such displacements may be used, for example, to maintain consistency in the size and geometry of the cutter pockets 36 and the internal fluid passageways 42 during the sintering process.
  • Such refractory structures may be formed from, for example, graphite, silica, or alumina.
  • the use of alumina displacements instead of graphite displacements may be desirable as alumina may be relatively less reactive than graphite, thereby minimizing atomic diffusion during sintering.
  • coatings such as alumina, boron nitride, aluminum nitride, or other commercially available materials may be applied to the refractory structures to prevent carbon or other atoms in the refractory structures from diffusing into the bit body during densification.
  • the green shell body 94 shown in FIG. 2B may be partially sintered to form a brown bit body without prior machining, and all necessary machining may be performed on the brown shell body prior to infiltrating the brown shell body and fully sintering the brown bit body to a desired final density.
  • all necessary machining may be performed on the green bit body 94 shown in FIG. 2B , which then may be infiltrated and fully sintered to a desired final density.
  • the sintering processes described herein may include conventional sintering in a vacuum furnace, sintering in a vacuum furnace followed by a conventional hot isostatic pressing process, and sintering immediately followed by isostatic pressing at temperatures near the sintering temperature (often referred to as sinter-HIP). Furthermore, the sintering processes described herein may include subliquidus phase sintering. In other words, the sintering processes may be conducted at temperatures proximate to but below the liquidus line of the phase diagram for the matrix material forming a portion of the particle-matrix composite material.
  • the sintering processes described herein may be conducted using a number of different methods known to one of ordinary skill in the art such as the Rapid Omnidirectional Compaction (ROC) process, the CeraconTM process, hot isostatic pressing (HIP), or adaptations of such processes.
  • ROC Rapid Omnidirectional Compaction
  • CeraconTM CeraconTM
  • HIP hot isostatic pressing
  • sintering a green powder compact using the ROC process involves presintering the green powder compact at a relatively low temperature to only a sufficient degree to develop sufficient strength to permit handling of the powder compact.
  • the resulting brown structure is wrapped in a material such as graphite foil to seal the brown structure.
  • the wrapped brown structure is placed in a container, which is filled with particles of a ceramic, polymer, or glass material having a substantially lower melting point than that of the matrix material in the brown structure.
  • the container is heated to the desired sintering temperature, which is above the melting temperature of the particles of a ceramic, polymer, or glass material, but below the liquidus temperature of the matrix material in the brown structure.
  • the heated container with the molten ceramic, polymer, or glass material (and the brown structure immersed therein) is placed in a mechanical or hydraulic press, such as a forging press, that is used to apply pressure to the molten ceramic or polymer material.
  • a mechanical or hydraulic press such as a forging press
  • Isostatic pressures within the molten ceramic, polymer, or glass material facilitate consolidation and sintering of the brown structure at the elevated temperatures within the container.
  • the molten ceramic, polymer, or glass material acts to transmit the pressure and heat to the brown structure.
  • the molten ceramic, polymer, or glass acts as a pressure transmission medium through which pressure is applied to the structure during sintering.
  • the sintered structure is then removed from the ceramic, polymer, or glass material.
  • the CeraconTM process which is similar to the aforementioned ROC process, may also be adapted for use in the present invention to fully sinter brown structures to a final density.
  • the brown structure is coated with a ceramic coating such as alumina, zirconium oxide, or chrome oxide. Other similar, hard, generally inert, protective, removable coatings may also be used.
  • the coated brown structure is fully consolidated by transmitting at least substantially isostatic pressure to the coated brown structure using ceramic particles instead of a fluid media as in the ROC process.
  • a more detailed explanation of the CeraconTM process is provided by U.S. Pat. No. 4,499,048, the disclosure of which patent is incorporated herein by reference.
  • the sintering processes described herein also may include a carbon control cycle tailored to improve the stoichiometry of the tungsten carbide material.
  • the sintering processes described herein may include subjecting the tungsten carbide material to a gaseous mixture including hydrogen and methane at elevated temperatures.
  • the tungsten carbide material may be subjected to a flow of gases including hydrogen and methane at a temperature of about 1,000° C.
  • the shell 28 is attached to the core 26 using any suitable bonding process, such as brazing, individual fasteners, etc.
  • the drill bit 10 includes the cutters 20 mounted on segments 14 ′ which are attached to the blades 14 .
  • the segments 14 ′ are formed in the same manner as the shell 28 described hereinbefore.
  • the segments 14 ′ may be formed of any desired length for attachment to a blade 14 , such as from the gage of the drill bit through any length of a blade 14 .
  • the segments 14 ′ are formed of particle-matrix composite material which may include a plurality of hard particles randomly dispersed throughout a matrix material.
  • the hard particles may comprise diamond or ceramic materials such as carbides, nitrides, oxides, and borides (including boron carbide (B 4 C)).
  • the hard particles may comprise carbides and borides made from elements such as W, Ti, Mo, Nb, V, Hf, Ta, Cr, Zr, Al, and Si.
  • materials that may be used to form hard particles include tungsten carbide, titanium carbide (TiC), tantalum carbide (TaC), titanium diboride (TiB 2 ), chromium carbides, titanium nitride (TiN), aluminium oxide (Al 2 O 3 ), aluminium nitride (AIN), and silicon carbide (SiC).
  • combinations of different bard particles may be used to tailor the physical properties and characteristics of the particle-matrix composite material.
  • the hard particles may be formed using techniques known to those of ordinary skill in the art. Most suitable materials for hard particles are commercially available and the formation of the remainder is within the ability of one of ordinary skill in the art.
  • the matrix material of the particle-matrix composite material may include, for example, cobalt-based, iron-based, nickel-based, iron and nickel-based, cobalt and nickel-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, and titanium-based alloys.
  • the matrix material may also be selected from commercially pure elements such as cobalt, aluminum, copper, magnesium, titanium, iron, and nickel.
  • the matrix material may include carbon steel, alloy steel, stainless steel, tool steel, Hadfield manganese steel, nickel or cobalt superalloy material, and low thermal expansion iron or nickel based alloys such as INVAR®.
  • the term “superalloy” refers to iron, nickel, and cobalt based-alloys having at least 12% chromium by weight.
  • Additional exemplary alloys that may be used as matrix material include austenitic steels, nickel based superalloys such as INCONEL® 625M or Rene 95, and INVAR® type alloys having a coefficient of thermal expansion that closely matches that of the hard particles used in the particular particle-matrix composite material. More closely matching the coefficient of thermal expansion of matrix material with that of the hard particles offers advantages such as reducing problems associated with residual stresses and thermal fatigue.
  • Another exemplary matrix material is a Hadfield austenitic manganese steel (Fe with approximately 12% Mn by weight and 1.1% C by weight).
  • the particle-matrix composite material may include a plurality of ⁇ 400 ASTM (American Society for Testing and Materials) mesh tungsten carbide particles as the hard particle component of the particle-matrix composite material.
  • the tungsten carbide particles may be substantially composed of WC.
  • ⁇ 400 ASTM mesh particles means particles that pass through an ASTM No. 400 mesh screen as defined in ASTM specification E11-04 entitled Standard Specification for Wire Cloth and Sieves for Testing Purposes.
  • Such tungsten carbide particles may have a diameter of less than about 38 microns.
  • the matrix material forming another component of the particle-matrix composite material may include a metal alloy comprising about 50% cobalt by weight and about 50% nickel by weight.
  • the tungsten carbide particles may comprise between about 60% and about 95% by weight of the particle-matrix composite material, and the matrix material may comprise between about 5% and about 40% by weight of the particle-matrix composite material. More particularly, the tungsten carbide particles may comprise between about 70% and about 80% by weight of the particle-matrix composite material, and the matrix material may comprise between about 20% and about 30% by weight of the particle-matrix composite material.
  • the particle-matrix composite material may include a plurality of ⁇ 635 ASTM mesh tungsten carbide particles as the hard particle component of the particle-matrix composite material.
  • ⁇ 635 ASTM mesh particles means particles that pass through an ASTM No. 635 mesh screen as defined in ASTM specification E11-04 entitled Standard Specification for Wire Cloth and Sieves for Testing Purposes.
  • Such tungsten carbide particles may have a diameter of less than about 20 microns.
  • the matrix material may include a cobalt-based metal alloy comprising substantially commercially pure cobalt.
  • the matrix material forming another component of the particle-matrix composite material may include greater than about 98% cobalt by weight.
  • the tungsten carbide particles may comprise between about 60% and about 95% by weight of the particle-matrix composite material, and the matrix material may comprise between about 5% and about 40% by weight of the particle-matrix composite material.
  • the segments 14 ′ are formed in the same manner as the process for forming the shell hereinbefore and illustrated in FIGS. 2A-2E . Similarly, the cutters 20 are attached to the segments 14 ′ as described hereinbefore with respect to the shell 28 .
  • the segments 14 ′ include one or more protrusions 14 ′′ extending therefrom to mate with recesses formed in the blades 14 to provide an accurate location of the segment on the blade 14 .
  • the protrusions 14 ′′ may extend from a side and the back of a segment to provide any desired number of locations for the segment 14 ′′ on a blade 14 .
  • the segment 14 ′ is attached to a blade 14 in any suitable manner, such as brazing, fasteners, etc.
  • the protrusions 14 ′′ provide additional surface area to secure the segment 14 ′ to a blade 14 when the segment 14 ′ is attached to the blade 14 by brazing a similar attachment process.
  • the protrusions 14 ′′ may be of any desired suitable geometric shape and dimension.
  • the segment 14 ′ may extend around the front face, outer edge, and back face of a portion of a blade 14 of the drill bit 10 .
  • the blade 14 of the drill bit 10 is protected on all three sides thereof by the segment 14 ′ which is constructed of material having a higher abrasion resistance than that of the blade 14 .
  • the segment 14 ′ may be attached to the blade 14 by any suitable attachment process, such as brazing, fasteners, etc.
  • the segments 14 ′ although the segments 14 ′ can be formed as a shell such as shell 106 described herein, and blank 34 are illustrated in a in a pressure chamber 90 such as described hereinbefore.
  • the blank 34 and segments 14 ′ are supported on suitable inserts 86 with a particle-matrix material powder mixture 78 , such as described herein, filling the space in the mold or container 80 , such as described herein, between the mold 80 and segments 14 ′ and blank 34 .
  • a fluid (which may be substantially incompressible) such as, for example, water, oil, or gas (such as, for example, air or nitrogen) is pumped into the pressure chamber 90 through an opening 92 at high pressures using a pump (not shown).
  • the high pressure of the fluid causes the walls of the deformable member 82 to deform.
  • the fluid pressure may be transmitted substantially uniformly to the powder mixture 78 .
  • the pressure within the pressure chamber 90 during isostatic pressing may be greater than about 35 megapascals (about 5,000 pounds per square inch). More particularly, the pressure within the pressure chamber 90 during isostatic pressing may be greater than about 138 megapascals (20,000 pounds per square inch).
  • a vacuum may be provided within the container 80 and a pressure greater than about 0.1 megapascals (about 15 pounds per square inch) may be applied to the exterior surfaces of the container (by, for example, the atmosphere) to compact the powder mixture 78 .
  • Isostatic pressing of the powder mixture 78 may form a green powder component or green shell body, such as green shell body 94 described herein, shown in FIG. 3B , which can be removed from the pressure chamber 90 and container 80 after pressing.
  • the green bit body formed into a green bit blank 34 may include a plurality of particles (hard particles and particles of matrix material forming the particle-matrix composite material) held together by a binder material provided in the powder mixture 78 ( FIG. 2A ), as previously described.
  • Certain structural features may be machined in the green bit body 94 using conventional machining techniques including, for example, turning techniques, milling techniques, and drilling techniques.
  • Hand held tools also may be used to manually form or shape features in or on the green shell body.
  • blades 14 , junk slots 16 ( FIGS. 1A , 1 B), and any surfaces may be machined or otherwise formed in the green shell body to form a shaped green shell body, generally such as green shell body 98 shown in FIG. 2C .
  • the shaped green bit body may be at least partially sintered to provide a brown bit body, generally such as brown bit body 102 shown in FIG. 2D , which has less than a desired final density.
  • the shaped green bit body Prior to partially sintering the shaped green bit body, the shaped green bit body may be subjected to moderately elevated temperatures and pressures to burn off or remove any fugitive additives of any binder used that were included in the powder mixture 78 ( FIG. 2A ), as previously described.
  • the shaped green bit body may be subjected to a suitable atmosphere tailored to aid in the removal of such additives.
  • atmospheres may include, for example, hydrogen gas at temperatures of about 500° C.
  • the brown shell body such as brown body 102 described herein, may be substantially machinable due to the remaining porosity therein.
  • Certain structural features may be machined in the brown shell body using conventional machining techniques including, for example, turning techniques, milling techniques, and drilling techniques.
  • Hand held tools also may be used to manually form or shape features in or on the brown shell body.
  • Tools that include superhard coatings or inserts may be used to facilitate machining of the brown shell body.
  • material coatings may be applied to surfaces of the brown shell body that are to be machined to reduce chipping of the brown bit body.
  • Such coatings may include a suitable fixative material or other suitable polymer materials or their like.
  • internal fluid passageways 29 and cutter pockets 36 may be machined or otherwise formed in the brown bit body to form a shaped brown bit body. If the drill bit 10 is to include additional cutters or wear knots, the cutters and wear knots may be positioned within the cutter pockets formed in the brown bit body. Upon subsequent sintering of the brown bit body, the cutters may become bonded to and integrally formed with the bit body.
  • the shaped brown bit body then may be fully sintered to a desired final density.
  • any sintering involves densification and removal of porosity within a structure, the structure being sintered will shrink during the sintering process.
  • a structure may experience linear shrinkage of between 10% and 20% during sintering from a green state to a desired final density.
  • dimensional shrinkage must be considered and accounted for when designing tooling (molds, dies, etc.) or machining features in structures that are less than fully sintered.
  • refractory structures or displacements may be used to support at least portions of the bit body during the sintering process to maintain desired shapes and dimensions during the densification process.
  • Such displacements may be used, for example, to maintain consistency in the size and geometry of the cutter pockets 36 and the internal fluid passageways 42 during the sintering process.
  • Such refractory structures may be formed from, for example, graphite, silica, or alumina.
  • the use of alumina displacements instead of graphite displacements may be desirable as alumina may be relatively less reactive than graphite, thereby minimizing atomic diffusion during sintering.
  • coatings such as alumina, boron nitride, aluminum nitride, or other commercially available materials may be applied to the refractory structures to prevent carbon or other atoms in the refractory structures from diffusing into the bit body during densification.
  • the green bit body may be partially sintered to form a brown bit body without prior machining, and all necessary machining may be performed on the brown shell body prior to infiltrating the brown bit body and fully sintering the brown bit body to a desired final density.
  • all necessary machining may be performed on the green bit body 94 shown in FIG. 2B , which then may be infiltrated and fully sintered to a desired final density.
  • the sintering processes described herein may include conventional sintering in a vacuum furnace, sintering in a vacuum furnace followed by a conventional hot isostatic pressing process, and sintering immediately followed by isostatic pressing at temperatures near the sintering temperature (often referred to as sinter-HIP). Furthermore, the sintering processes described herein may include subliquidus phase sintering. In other words, the sintering processes may be conducted at temperatures proximate to but below the liquidus line of the phase diagram for the matrix material forming a portion of the particle-matrix composite material.
  • the sintering processes described herein may be conducted using a number of different methods known to one of ordinary skill in the art such as the Rapid Omnidirectional Compaction (ROC) process, the CeraconTM process, hot isostatic pressing (HIP), or adaptations of such processes.
  • ROC Rapid Omnidirectional Compaction
  • CeraconTM CeraconTM
  • HIP hot isostatic pressing
  • teachings of the present invention are described herein in relation to embodiments of earth-boring rotary drill bits that include fixed cutters, other types of earth-boring drilling tools such as, for example, core bits, eccentric bits, bicenter bits, reamers, mills, drag bits, roller cone bits, and other such structures known in the art may embody teachings of the present invention and may be formed by methods that embody teachings of the present invention.

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EP09763484.4A EP2307659A4 (fr) 2008-06-10 2009-06-10 Construction de foret de métal composite et carbure cémenté
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EP2307659A4 (fr) 2013-08-07
RU2010154503A (ru) 2012-07-20

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