WO2016028662A1 - Application automatisée d'un revêtement dur pour des applications d'outils de fond de trou - Google Patents

Application automatisée d'un revêtement dur pour des applications d'outils de fond de trou Download PDF

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Publication number
WO2016028662A1
WO2016028662A1 PCT/US2015/045460 US2015045460W WO2016028662A1 WO 2016028662 A1 WO2016028662 A1 WO 2016028662A1 US 2015045460 W US2015045460 W US 2015045460W WO 2016028662 A1 WO2016028662 A1 WO 2016028662A1
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WO
WIPO (PCT)
Prior art keywords
hardfacing
tiles
thermal energy
hardfacing material
tile
Prior art date
Application number
PCT/US2015/045460
Other languages
English (en)
Inventor
Giuseppe MUZZI
Anthony Griffo
Cary A. Roth
Alysia C. White
Alessandro BERTINI
Claudiano PORCIANI
Renato MICHELOTTI
Alessio CECHI
Original Assignee
Smith International, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Smith International, Inc. filed Critical Smith International, Inc.
Publication of WO2016028662A1 publication Critical patent/WO2016028662A1/fr

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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
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/10—Wear protectors; Centralising devices, e.g. stabilisers
    • E21B17/1085—Wear protectors; Blast joints; Hard facing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/22—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for drills; for milling cutters; for machine 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2251/00—Treating composite or clad material
    • C21D2251/04—Welded or brazed overlays
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2261/00—Machining or cutting being involved

Definitions

  • Components in extractive applications, excavating applications, drilling applications, and other applications involving heavy machinery may be exposed to abrasive conditions and the potential for rapid rates of wear on particular components.
  • the exterior surfaces of stabilizers in drilling applications may be exposed to abrasive motion in direct contact with surrounding rock formations or with an interior surface of casing strings within a wellbore.
  • a protective surface may be applied to components that experience exposure to high wear potential, such as by hardfacing.
  • Hardfacing includes the application of a harder or tougher material to a softer, underlying material.
  • the underlying material is a metal, such as steel, nickel, titanium, or other alloy and the harder material (“superhard material”), is a harder metal, carbide, ceramic, or diamond material.
  • the hardfacing material may be a continuous single material or a composite material including distributed particles or components.
  • the hardfacing process may include different temperatures, materials, and processes to optimize the hardness and/or toughness of the protective surface.
  • a protective surface having a high hardness value may be more wear resistant, but may become too brittle.
  • a protective surface having a high toughness value may withstand or dissipate vibration or deformation more effectively than a high hardness protective surface, but may compromise overall wear resistance.
  • a method for hardfacing includes preparing a surface and a applying a base layer. A plurality of tiles is secured to the base layer and the plurality of tiles defines a plurality of gaps between the tiles. The method also includes at least partially filling the plurality of gaps with a hardfacing material and applying thermal energy to the hardfacing material using a thermal energy source by automatically moving the plurality of gaps and the thermal energy source relative to one another according to a predetermined or set pattern.
  • a method for hardfacing includes cleaning a surface, applying a base layer on the surface, and positioning at least one tile including a superhard material relative to the base layer before securing the at least one tile to the base layer.
  • the method also includes positioning a hardfacing material adjacent to and surrounding the at least one tile and heating the hardfacing material by automatically moving a thermal energy source and the surface relative to one another in a predetermined or set pattern to fuse the hardfacing material and then applying an overlying layer over the hardfacing material and the at least one tile.
  • a method for hardfacing includes cleaning a surface, applying a base layer on the surface, and securing a plurality of tiles including a superhard material to the base layer in a first predetermined or set pattern with each of the tiles laterally spaced a distance from each other tile.
  • Hardfacing material is positioned laterally adjacent to and between the plurality of tiles and the hardfacing material is heated with an automated plasma torch by moving the plasma torch and hardfacing material in a second predetermined or set pattern to raise a hardfacing material temperature above 900 degrees Celsius while a tile temperature does not exceed 1200 degrees Celsius.
  • the second predetermined or set pattern is at least partially based on the first predetermined or set pattern.
  • the method also includes applying a overlying layer over the top surface of at least one of the plurality of tiles and removing at least a portion of the overlying later to produce an outside surface of a finished product.
  • FIG. 1 illustrates a perspective view of an embodiment of a finished hardfaced stabilizer pad manufactured in accordance with an embodiment of a method described herein;
  • FIG. 2 illustrates an embodiment of a method of hardfacing a body as described herein;
  • FIG. 3 illustrates a cross-sectional side view of an embodiment of a finished hardfaced metal component manufactured in accordance with an embodiment of a method described herein;
  • FIG. 4 illustrates another embodiment of a method of hardfacing a body as described herein;
  • FIG. 5 illustrates a cross-sectional side view of an embodiment of a prepared surface of a metal component in accordance with an embodiment of a method described herein;
  • FIG. 6 illustrates a cross-sectional side view of an embodiment of a substrate layer in accordance with an embodiment of a method described herein;
  • FIG. 7 illustrates a perspective view of securing tiles of superhard material in accordance with an embodiment of a method described herein;
  • FIG. 8 illustrates a cutaway perspective view of an embodiment of a system for hardfacing a body as described herein;
  • FIG. 9 illustrates an embodiment of a method for securing at least one tile to a body using an automated arm as described herein;
  • FIG. 10 illustrates another embodiment of a method for securing a plurality of tiles to a body as described herein;
  • FIG. 11 illustrates a top view of an embodiment of partially grouted tiles of superhard material in accordance with an embodiment of a method described herein;
  • FIG. 12 illustrates a perspective view of an embodiment of a preassembled hardfacing sheet as described herein;
  • FIG. 13 illustrates a perspective view of an embodiment of a snake pattern according to which thermal energy may be applied to hardfacing material as described herein;
  • FIG. 14 illustrates a perspective view of an another embodiment of a stripe pattern according to which thermal energy may be applied to hardfacing material as described herein;
  • FIG. 15 illustrates a perspective view of a further embodiment of a spiral pattern according to which thermal energy may be applied to hardfacing material as described herein;
  • FIG. 16 illustrates a cross-sectional side view of an embodiment of a metal component after partial application of grout material in accordance with an embodiment of a method described herein;
  • FIG. 17 illustrates a cross-sectional side view of an embodiment of an application of an overlying layer in accordance with an embodiment of a method described herein;
  • FIG. 18 illustrates a cross-sectional side view of an embodiment of a hardfaced metal component manufactured in accordance with an embodiment of a method described herein.
  • This disclosure generally relates to devices, systems, and methods for hardfacing components to improve wear resistance and/or operating lifetime. More particularly, the present disclosure relates to devices, systems, and methods for the application of a composite protective surface to a body and/or metal component to improve wear resistance, corrosion resistance, and/or operating lifetime. Even more particularly, at least one embodiment of the present disclosure relates to devices, systems, and methods for the automated application of a consistent and reproducible composite protective surface to a body to increase the wear resistance, hardness, and/or toughness of a surface of the body to improve wear resistance and/or operating lifetime.
  • Mechanical devices and systems may include metal components that may be exposed to abrasive or corrosive environments during operation of the device or system.
  • the metal components may include a body having one or more surfaces that may be exposed to abrasive and/or erosive environments.
  • a bucket on an earthmover may have penetrative teeth that are exposed to rock or sand under high forces for a period of time.
  • the peripheral surfaces of a stabilizer pad used in a downhole environment while drilling may experience nearly continuous abrasion by surrounding rock formations for extended periods of time. In either case, the wear resistance and/or operational lifetime of the body may be extended by increasing the hardness and/or the toughness of one or more surfaces of the metal component.
  • the hardfacing of a body may increase the hardness and/or the toughness of one or more surfaces of the body.
  • the hardfacing process includes the manual application, securing, and coating of tiles of superhard materials.
  • Hardfacing material is applied between, around, and/or over the tiles of superhard material manually.
  • the hardfacing material may act as a "grout" material around the tiles of superhard material.
  • Thermal energy may be applied manually to fuse the grout material before finishing to smooth the surface of the hardfaced component.
  • each manual application of material or energy is an opportunity for defects, damage, imperfections, or variations in the protective surface.
  • the manual placement of tiles upon a surface to be hardfaced may create variations in the orientation or spacing of the tiles resulting in degradation in performance of the protective surface.
  • variations in the orientation and/or spacing of the tiles may result in non-optimal orientation of the tiles during later use in protecting components.
  • variations in the orientation and/or spacing of the tiles may result in different amounts of hardfacing material applied between and/or around the tiles.
  • Different amounts of hardfacing material applied between and/or around the tiles may change a fill-rate of hardfacing material between the tiles (e.g., the space between the tiles may fill with powder or other applied hardfacing material more or less quickly).
  • Different amounts of hardfacing material may also change the thermal mass of the hardfacing material between the tiles. Variations in thermal mass at different points on the hardfacing surface may create additional challenges to properly heating the hardfacing material without causing thermal damage to the tiles.
  • the application of thermal energy to a piece may include an operator manually moving a torch or other thermal energy source for an extended time, e.g., for six to eight hours.
  • the application of hardfacing material may be conducted manually and/or by an operator's visual judgment creating opportunities for variation.
  • the application of hardfacing material by a blow and fuse method may apply hardfacing material to any portion of the device near the torch.
  • Unintended operator movement, operator fatigue, inconsistent dwell times, or inhibited vision due a welding mask may all introduce variabilities between operators and/or defects in a finished product.
  • tiles of superhard material may be placed and secured more precisely and more quickly through the automation of relative movements of a body, each tile, and an energy source.
  • the hardfacing material may be placed and secured more precisely and quickly through the automation of relative movements of a body, the hardfacing material, a thermal energy source, or combinations thereof.
  • FIG. 1 illustrates a hardfaced stabilizer pad 100 including a body 102 having an exterior surface 104 and an interior surface 106.
  • the hardfaced stabilizer pad 100 may be connected to a variety of downhole tools to protect the downhole tools from abrasion and/or other mechanical damage and/or as a pad in a rotary steerable system.
  • an embodiment of a hardfaced stabilizer pad manufactured in accordance with the present disclosure may be connected to a bottomhole assembly.
  • the hardfaced stabilizer pad 100 may include a plurality of tiles 108 of superhard material secured to the exterior surface 104 of the body 102.
  • a superhard material should be understood to be a material has a hardness greater than or equal to 40 gigapascals.
  • the tiles 108 may be laterally surrounded and at least partially retained by hardfacing material 110 secured to the tiles 108 and the exterior surface 104.
  • the hardfacing material 1 10 may be laterally adjacent to and/or surround each tile 108 from a bottom to a top of the tile, from the bottom over the top, and/or from the bottom past a midpoint in a height of the tile as will be discussed in relation to FIGS. 11 through 13.
  • the hardfacing material 110 may have a surface that is parallel with the exterior surface 104. In some embodiments, the hardfacing material 110 may have an uneven surface that is not parallel with the exterior surface 104.
  • the body 102 may include (e.g., be made of) steel alloys, titanium alloys, superalloys, other metals, or combinations thereof.
  • the body 102 may include a steel alloy including alloying elements such as a carbon, manganese, nickel, chromium, molybdenum, tungsten, vanadium, silicon, boron, lead, another appropriate alloying element, or combinations thereof.
  • the body 102 may include a titanium alloy including alloying elements such as aluminum, vanadium, palladium, nickel, molybdenum, ruthenium, niobium, silicon, oxygen, iron, another appropriate alloying element, or combinations thereof.
  • the body 102 may include a superalloy including elements such as nickel, cobalt, iron, chromium, molybdenum, tungsten, tantalum, aluminum, titanium, zirconium, rhenium, yttrium, boron, carbon, another appropriate alloying element, or combinations thereof.
  • the body 102 may include austenitic iron and may be non-magnetic. A nonmagnetic body 102 may allow the hardfaced stabilizer pad 100 to be used in environments and/or applications in which the presence of a magnetic field may interfere and/or complicate operations.
  • a non-magnetic body 102 may allow the hardfaced stabilizer pad 100 to be used in environments and/or applications in proximity to a magnetic component without magnetically interacting with the magnetic component. It may be desirable to retain a non-magnetic property of the body 102 during the hardfacing process.
  • the tiles 108 may include a superhard material such as tungsten carbide, metal- WC (including nickel, cobalt, etc.), cubic boron nitride, polycrystalline diamond, rhenium boride, boron carbide, another material with a hardness value exceeding 40 gigapascals, or combinations thereof.
  • the tiles 108 may include thermally stable polycrystalline diamond ("TSP").
  • TSP thermally stable polycrystalline diamond
  • the tiles 108 may also initially include a coating thereon.
  • a coating e.g., electroless nickel
  • the tiles 108 may include and/or may be impregnated with a material to increase electrical conductivity such that the tiles 108 may be electrically conductive.
  • the hardfacing material 110 may include tungsten carbide or other superhard material particles and a matrix of metal and/or alloying components.
  • the hardfacing material 110 may include a plurality of tungsten carbide particles suspended in a matrix such as a low temperature Ni- Cr-Si-B matrix.
  • the tiles 108 may be formed of the same material or of different materials.
  • the method 201 may include securing 203 one or more tiles, filling 205 a space between the tiles with hardfacing material, and applying 207 thermal energy to the hardfacing material.
  • the tiles and/or hardfacing material may be the same or similar to the tiles 108 described in relation to FIG. 1.
  • Securing 203 the one or more tiles may be automated by relative movement between an energy source and/or automated arm and the surface through a first pattern of locations (e.g., a first predetermined or set pattern of locations), as will be described in more detail in relation to FIGS. 7 through 12.
  • Filling 205 space between the tiles with hardfacing material may be automated by relative movement of a hardfacing material source and the surface through a second pattern of locations (e.g., a second predetermined or set pattern of locations), as will be described in more detail in relation to FIGS. 12 through 15.
  • Applying 207 thermal energy may be automated by relative movement of a thermal energy source, which may be the same as the hardfacing material source, and the surface through a third pattern of locations (e.g., a third predetermined or set pattern of locations), as will be described in more detail in relation to FIGS. 12 through 15.
  • one or more of securing 203 the one or more tiles, filling 205 between the tiles with hardfacing material, and applying 207 the thermal energy to the hardfacing material may be automated.
  • one or more of securing 203 the one or more tiles, filling 205 between the tiles with hardfacing material, and applying 207 the thermal energy to the hardfacing material may be performed manually.
  • a plurality of tiles 308 and a hardfacing material 310 may form a coherent surface on an outside surface 31 1 of a hardfaced stabilizer pad 300.
  • a coherent surface should be understood to be a surface formed by multiple pieces that form a substantially continuous surface without seams, gaps, spaces, or other discontinuities in the surface.
  • the tiles 308 and the hardfacing material 310 may form a planar surface without any curvature as shown in FIG. 3.
  • the tiles 108 and the hardfacing material 1 10 may be applied or finished to have an outside surface 1 1 1 including a curvature in at least one direction as depicted in FIG. 1.
  • the tiles and the hardfacing material may form a coherent surface that exhibits curvature in two directions (e.g., a section of a sphere).
  • the tiles and the hardfacing material may form a coherent surface that includes multiple radii of curvature, such as a surface with one or more curved portions adjacent one or more planar portions.
  • the outside surface 31 1 may be an incoherent surface.
  • the outside surface 31 1 may include gaps or spaces therein.
  • the outside surface 31 1 may include recessed portions, such as the hardfacing material 310, that are below other portions of the outside surface 31 1 , such as the tiles 308.
  • the outside surface 31 1 may include hardfacing material 310 that extends over the tiles 308 substantially or partially covering the tiles 308.
  • the hardfaced stabilizer pad 300 may include a base layer 312 that acts as a substrate.
  • the base layer 312 may include a softer material than the underlying body 302 or the overlying tiles 308 and hardfacing material 310.
  • the base layer 312 may form a relief layer that increases adhesion and decreases lamination of the tiles 308 and the hardfacing material 310 during manufacturing and/or during use of the hardfaced stabilizer pad 300.
  • the base layer 312 may also perform a smoothing function over the exterior surface 304 and provide a smoother surface to which the tiles 308 and the hardfacing material 310 may be affixed.
  • FIG. 4 illustrates another embodiment of a method of hardfacing a surface.
  • the method 401 may include applying 426 a base layer to the surface, positioning 427 a tile adjacent the base layer, and securing 428 the tile to the base layer.
  • securing 428 the tile to the base layer may be performed in the same or a similar way as securing 203 tiles as described in relation to FIG. 2.
  • the base layer and tile may be the same as or similar to the base layer 312 and tile 308 depicted in FIG. 3.
  • the method 401 may include positioning 429 hardfacing material adjacent to and/or surrounding the tile, heating 430 the hardfacing material using a thermal energy source, and moving 431 the thermal energy source and/or surface relative to one another.
  • positioning 429 hardfacing material and/or heating 430 the hardfacing material may be performed in the same or a similar way as filling 205 between tiles and/or applying 207 thermal energy as described in relation to FIG. 2, respectively.
  • the method 401 may include applying 432 an overlying layer to the hardfacing material.
  • the hardfacing material and the overlying layer may each be the same as or similar to the hardfacing material 310 depicted in FIG. 3.
  • FIG. 5 depicts an embodiment of a surface prepared for hardfacing according to an embodiment of a method as described herein.
  • a method for the production of a hardfaced component may include a preparation of a body 502.
  • the body 502 may be any portion of any component of a mechanical device or system. While reference has been made to exterior surfaces of components, such as a stabilizer pad in drilling applications, internal components, such as hinges, axles, slides, or other components susceptible to abrasion may receive a protective surface according to an embodiment of the present disclosure.
  • the body 502 may be prepared by grinding, polishing, and/or cleaning of the body to produce an exterior surface 504 that is substantially smooth and/or free of debris.
  • the exterior surface 504 may be prepared such that the exterior surface 504 has one or more surface features to promote adherence of a base layer, tiles, or other materials affixed thereto.
  • the exterior surface 504 may be prepared with steel wool or a steel brush such to impart imperfections to the exterior surface 504 and thereby increase a surface area of the exterior surface 504.
  • a base layer 612 may be applied to an exterior surface 604 of the body 602.
  • An application of a base layer 612 may include welding or otherwise fixing a low temperature metal alloy to the exterior surface 604.
  • the low temperature metal alloy and/or the body 602 may be preheated to facilitate the application of the base layer 612.
  • the body 602 may be preheated by application of thermal energy to the exterior surface 604 (e.g. , by a torch or other localized thermal energy source) for a predetermined or set period of time.
  • the body 602 may be preheated by application of thermal energy to the body 602 generally (e.g. , by placing the body 602 in an oven or furnace or other generalized thermal energy source) for a predetermined or set period of time.
  • the application of the base layer 612 may be performed by application of a material to a preheated body 602.
  • the body may be moved relative to an energy source, a thermal energy source, the tiles, or combinations thereof by an automated mount such as will be described in relation to FIG. 7.
  • an energy source, a thermal energy source, the tiles, or combinations thereof may be moved relative the body by one or more automated arms or motors as will be described in relation to FIG. 8.
  • the base layer 612 may be applied by electroplating, spray and fuse, laser cladding, gas metal arc welding, plasma transferred arc welding, thermal spraying, other suitable coating application processes, or combinations thereof.
  • a plurality of tiles 708 of superhard material may be secured to an exterior surface 704 and/or base layer 712.
  • Each of the plurality of tiles 708 may be similar or the same in dimensions or some of the tiles 708 may vary in size and/or shape, such as depicted in FIG. 7.
  • the plurality of tiles 708 may be positioned by relative movement between the body 702 and an energy source 714.
  • the mount 709 may be connected to an interior surface 706.
  • the mount 709 may connect to an interior surface 706 of the body 702.
  • the mount 709 may control the position of the body 702 relative to each of the tiles 708 as they are positioned against the base layer 712 and affixed thereto.
  • the tiles 708 may be affixed to the base layer 712 by welding. More specifically, each of the tiles 708 may be affixed or tacked to the base layer 712 by the application of an electric current from an energy source 714.
  • the energy source 714 may apply an electric current to a coating on each of the tiles 708 as described in relation to FIG. 1.
  • the relative movement between the body 702 and the energy source 714 may be achieved by automated movement of the body 702 (using, for example, the mount 709) and/or automated movement of the energy source 714.
  • the mount 709 may move the body 702 through a predetermined or set pattern of positions relative to the energy source 714 and each successive tile 708 may be positioned adjacent the base layer 712 to create a pattern of tiles according to the predetermined or set pattern of positions.
  • the energy source 714 or other electrical energy source may also be moved relative to the body 702 to produce or help produce the predetermined or set pattern of tiles 708.
  • the mount 709 may move the body 702 and/or energy source 714 within an inert environment, such as an enclosed chamber with a nitrogen atmosphere.
  • inert environment as used herein may refer to a non-reactive environment or atmosphere surrounding an area of the material being applied during the hardfacing process to reduce or prevent oxidation.
  • the inert environment may include the entire body 702 (i.e., within a nitrogen filled chamber).
  • the inert environment may include an inert envelope around the energy source, such as a gaseous envelope or physical housing around the probe 714.
  • the mount 709 may be included in a system with additional components such that the system may perform an embodiment of one or more methods described herein.
  • FIG. 8 depicts an embodiment of a system 819 for hardfacing a body 802 using an automated mount 809 and additional components.
  • the system 819 may include a computer number control ("CNC") machine or modified CNC machine.
  • a mount 809 may move the body 802 relative to an automated arm 817 and/or energy source 814 to position the plurality of tiles 808 and affix the plurality of tiles 808.
  • the tiles 808 may be positioned using the automated arm 817.
  • the automated arm 817 may move relative to the mount 809 and/or the mount may move relative to the automated arm 817, which may be stationary and/or not automated.
  • the automated arm 817 may include a plurality of tiles 808 which may be fed through the automated arm 817.
  • the tiles 808 may be positioned by the automated arm 817 adjacent the exterior surface 804 and/or the body 802.
  • the energy source 814 may secure the tiles 808 in place (e.g., by welding the tiles 808 to the exterior surface 804 of the body 802).
  • the automated arm 817 may move in an X-, Y-, and/or Z-direction relative to the mount 809 and/or may rotate relative to the mount 809 such that the automated arm 817 may position tiles 808 adjacent the exterior surface 804 and/or body 802 irrespective of the shape of the exterior surface 804 and/or the body 802.
  • the mount 809 may move the body 802 relative to the tiles 808 to position a first tile of the plurality of tiles 808 and the energy source 814 may affix a first tile of the plurality of tiles 808 before positioning a second tile of the plurality of tiles 808.
  • the energy source 814 may move in an X-, Y-, and/or Z-direction relative to the mount 809 and/or may rotate relative to the mount 809 such that the energy source 814 may secure tiles 808 adjacent the exterior surface 804 and/or the body 802 irrespective of the shape of the exterior surface 804 and/or the body 802.
  • the system 819 may include a thermal energy source 815.
  • Thermal energy source 815 may move in an X-, Y-, and/or Z-direction relative to the mount 809 and/or may rotate relative to the mount 809 such that the thermal energy source 815 may apply thermal energy to the tiles 808 adjacent the exterior surface 804 and/or the body 802 irrespective of the shape of the exterior surface 804 and/or the body 802.
  • the thermal energy source 815 may also apply a hardfacing material. The thermal energy source 815 will be described in greater detail in relation to FIG. 1 1.
  • the system 819 may include a hardfacing material source 823.
  • the hardfacing material source 823 may move in an X-, Y-, and/or Z-direction relative to the mount 809 and/or may rotate relative to the mount 809 such that the hardfacing material source 823 may provide hardfacing material to the exterior surface 804 and/or the body 802 irrespective of the shape of the exterior surface 804 and/or the body 802.
  • the hardfacing material source 823 will be described in greater detail in relation to FIG. 1 1.
  • the system 819 may include a housing 821 to control the environment around the body 802.
  • the housing 821 may contain an inert gas, such as nitrogen.
  • An inert gas may provide an inert environment to reduce oxidation during hardfacing.
  • the housing 821 may contain coating materials such as a hardfacing material or a base layer material during the hardfacing process.
  • the housing may provide an environment including indirect thermal energy (e.g., the housing may be an oven) such that the system 819 may preheat or heat treat the body and/or material applied thereto.
  • FIG. 9 depicts an embodiment of a method 901 for affixing one or more tiles on a surface of a body.
  • the method 901 may include positioning 934 a tile adjacent a surface of a body, affixing 936 the tile, and moving 938 the body, an energy source, and/or an automated arm according to a predetermined or set tile pattern.
  • the method 901 may then be repeated as necessary to affix one or more tiles to a body.
  • the tile may be the same as or similar to the tiles 108, 808 described in relation to FIGS. 1 and 8.
  • one or more of positioning 934, affixing 936, and moving 938 may be accomplished by an automated arm, automated energy source, automated mount, or combinations thereof, which may be the same as or similar to the automated arm 817, energy source 814, mount 809, or combinations thereof as described in relation to FIG. 8.
  • the automated arm 817 may position a tile 808 adjacent the body 802, the energy source 814 may affix (or tack) the tile 808 to the exterior surface 804 of the body 802, and the system 819 may then move the body 802, automated arm 817, and/or energy source 814 relative to one another according to a predetermined or set pattern.
  • FIG. 10 depicts an embodiment of a method 1001 for affixing a plurality of tiles to a surface of a body.
  • the method 1001 may include positioning 1040 a plurality of tiles adjacent to a surface of the body according to a predetermined or set tile pattern and affixing 1042 the plurality of tiles.
  • the method 1001 may include positioning 1040 substantially all of the plurality of tiles to be affixed to the body using one or more arms and/or a mount (such as described in relation to FIG. 8) before affixing 1042 any tile of the plurality of tiles.
  • the method 1001 may include may include positioning 1040 substantially all of plurality of the tiles to be affixed to the body using one or more automated arms before affixing 1042 more than one tile of the plurality of tiles simultaneously.
  • the method 1001 may include affixing two, three, four, five, six, or substantially all of the plurality of tiles at a time prior to affixing the tiles to the body.
  • the method 1001 may include positioning and fixing each of the tiles of the plurality of tiles sequentially using one or more automated arms and/or mount.
  • the method 1001 may include positioning more than one tile of the plurality of tiles at a time and then fixing them.
  • the method 1001 may include positioning two, three, four, five, six, or substantially all of the plurality of tiles at a time.
  • FIG. 1 1 depicts the application of a hardfacing material 1 1 10 to a body 1 102 and a plurality of tiles 1 108.
  • the hardfacing material 1 1 10 may at least partially fill the space between the tiles 1 108 and at least partially retain the tiles 1 108 in position relative to the body 1 102.
  • the hardfacing material 1 1 10 may be applied in a variety of manners. In an embodiment, the hardfacing material 1 1 10 may be applied concurrently with thermal energy.
  • the hardfacing material may be provided by a hardfacing material source 1 123. As shown in FIG.
  • the hardfacing material may be a powder 1 1 13 or particles of metal which may be delivered through the thermal energy source 1 1 15, (e.g., a torch) such that the thermal energy source 1 1 15 and the hardfacing material source 1 123 are the same. While a torch is depicted in FIG. 1 1 , it should be understood that the thermal energy source 1 1 15 may include a plasma torch, plasma-transferred-arc welding, an oxy-acetylene torch, a laser, infrared light, other directable thermal energy source, or combinations thereof. In another embodiment, the powder 1 1 13 or particles of metal may be delivered through a separate hardfacing material source 1 123.
  • the thermal energy source 1 1 15 e.g., a torch
  • the thermal energy source 1 1 15 may include a plasma torch, plasma-transferred-arc welding, an oxy-acetylene torch, a laser, infrared light, other directable thermal energy source, or combinations thereof.
  • the powder 1 1 13 or particles of metal may be delivered through a separate
  • a thermal energy source 1 1 15 may be used to direct both the powder 1 1 13 and thermal energy between the tiles 1 108.
  • the thermal energy from the thermal energy source 1 1 15 may fuse the powder 1 1 13 to the body 1 102, tiles 1 108, hardfacing material 1 1 10, or combinations thereof upon contact of the powder 11 13 to the body 1 102, tiles 1 108, hardfacing material 1 1 10, or combinations thereof.
  • the thermal energy from the thermal energy source 1 1 15 may also increase the temperature of the body 1 102, the tiles 1 108, the hardfacing material 1 1 10, and a base layer 1 1 12 (if used), or combinations thereof.
  • the increase in temperature of the tiles 1 108 and/or other components may increase chances of defects forming in the tiles 1 108, in the connection between the tiles 1 108 and the base layer 1 1 12, between the tiles 1 108 and the hardfacing material 1 1 10, or combinations thereof.
  • the tiles 1 108 may include TSP
  • the powder 1 1 13 may include tungsten carbide particles suspended in a low temperature Ni-Cr-Si-B matrix
  • the thermal energy source 1 1 15 may include an oxy- acetylene torch.
  • An oxy-acetylene torch may produce a flame that is approximately 3800 degrees Celsius.
  • the powder 1113 may fuse and form a continuous matrix at approximately 900 degrees Celsius.
  • the TSP of the tiles 1108 may begin to graphitize from a diamond crystal structure to a graphite structure at 1200 degrees Celsius.
  • Automated relative movement between the thermal energy source 1115 and the hardfacing material 1110 may allow for a precise quantity of thermal energy to be applied to the hardfacing material 1 110 while minimizing or reducing the application of thermal energy to the tiles 1 108.
  • manual control of the relative movement of the thermal energy source 1115 may impart any unintended movement of the operator's hand and/or inconsistent angles, duration, or proximity of application.
  • thermal energy source 1 115 may result in direction of the thermal energy source 1115 toward the tiles 1108, positioning of the thermal energy source 1115 too close to and/or too far from the hardfacing material 1110, and/or dwelling the thermal energy source 1115 over a particular location for too long and/or too short of a period of time.
  • the precise control of the positioning of the thermal energy source 1115 relative to the body 1102, the tiles 1108, the base layer 1112, or combinations thereof may be achieved by the automated movement of the thermal energy source 1115 relative to a mount similar to that described in the relation to FIGS. 7 and 8.
  • a mount may move the body 1102 through a predetermined or set pattern of positions such that the thermal energy source 1 115 or other thermal energy source may remain substantially stationary and thereby maintain a more consistent supply of energy and powder 1113 from the thermal energy source 1 115. Reducing variations in the supply of energy and powder 1113 may allow the more precise application of hardfacing material 1110 to the body 1102, the tiles 1108, the base layer 11 12, or combinations thereof.
  • a mount may move the body 1102 through the predetermined or set pattern of positions such that a layer of hardfacing material 1110 is applied laterally surrounding the tiles 1108 without directly applying thermal energy to the tiles 1108.
  • the body 1102 and/or the thermal energy source 1 115 may move through the predetermined or set pattern of rotations once to apply a first amount of the hardfacing material 11 10.
  • the body 1102 and/or the thermal energy source 11 15 may move through the predetermined or set pattern of positions more than once to apply more than the first amount of the hardfacing material 1 110 without applying thermal energy to the tiles 1108 for a continuous period.
  • moving the body 1102 and/or the thermal energy source 1115 through the predetermined or set pattern of positions twice may apply twice the hardfacing material 1110 at greater than 900 degrees Celsius while the tiles remain at a temperature below 1200 degrees Celsius.
  • the tiles 1108 may include material having a higher tolerance to temperature effects. For example, tungsten carbide may reach a temperature of 2200 degrees Celsius before experiencing adverse temperature effects.
  • the body 1102 may include a non-magnetic material, such as austenitic iron or steel, as described herein (e.g., the entire body may be non-magnetic).
  • the hardfacing materials used to hardface the body may include a non-magnetic material.
  • the material of the body 1102 may be non-magnetic due at least partially to a microstructure of the material that is stable at operating temperatures of a hardfaced stabilizer pad or other applications of a hardfaced body described herein.
  • the material of the body 1102 may experience changes in the microstructure upon heating of the body 1102 above a critical temperature (e.g., a recrystallization temperature, a eutectic temperature, etc.).
  • the body 1102 may remain at a temperature below 700 °C (1292 °F).
  • a desired amount of thermal energy may be imparted to the body and the materials in order to minimize excess heating of the body, allowing the body to remain at a temperature below 700 °C (1292 °F).
  • the body 1102 may include cold- worked austenite.
  • the austenite a face-centered cubic (“FCC") allotrope of iron, may be non-magnetic when in the FCC form.
  • the cold-working may increase the strength of the austenite to provide the strength for the stabilizer pad and/or other applications described herein.
  • the austenite may transform to the body-centered cubic ("BCC") allotrope of iron, ferrite, and become ferromagnetic.
  • BCC body-centered cubic
  • excess heating of the body 1 102 may induce a magnetic field in the body 1102.
  • excess heating of the body 1 102 may induce recrystallization of the material to a lower energy lattice and a resultant loss of the cold-working induced strength of the material.
  • direct heating of the body 1102 using a combustion- based thermal energy source 1115 may introduce impurities or additional elements into the body 1102.
  • a combustion- based thermal energy source 1115 e.g., an oxyacetylene torch
  • heating of the body 1102 using an oxyacetylene torch may introduce additional carbon to the austenite of the body 1102.
  • the introduction of additional carbon to the body 1102 may increase the carbon composition of the steel and reduce the toughness of the body 1102. Excess heating of the body 1 102 may make the body more brittle and therefore reduce the operational lifetime of the body 1102.
  • a predetermined or set pattern of positions may apply an equal amount of thermal energy to all parts of a surface of the hardfacing material 1110 and minimize heating of the underlying body.
  • a predetermined or set pattern may provide a direct application of thermal energy to all parts of the surface of the hardfacing material 1 110 once without crossing over another portion of the predetermined or set pattern.
  • a predetermined or set pattern may provide a direct application of thermal energy to one or more parts of the surface of the hardfacing material 1110.
  • a rate of movement, a proximity, an angle of the thermal energy source 1115, or combinations thereof relative to the hardfacing material 11 10 may vary, such that the total thermal energy imparted to the hardfacing material 1110 is substantially equal over an applied area of the hardfacing material 1110.
  • a rate of movement, a proximity, an angle of the thermal energy source 1 115, or combinations thereof relative to the hardfacing material 11 10 may vary within a predetermined or set pattern such that the entire hardfacing material 1110 is heated to a substantially equal temperature (i.e., the hardfacing material has varying thermal mass and/or thickness over an applied area). Example embodiments of predetermined or set patterns of positions will be described in relation to FIGS. 13 through 15.
  • FIG. 12 depicts another embodiment a hardfaced component 1200 made by an application of tiles 1208 and hardfacing material 1210 to an exterior surface 1204 of a body 1202.
  • the tiles 1208 and hardfacing material 1210 may be pre-formed in a hardfacing sheet 1216.
  • the hardfacing sheet 1216 may include the plurality of tiles 1208 embedded in the hardfacing material 1210 prior to the application of either the tiles 1208 or the hardfacing material 1210 to the exterior surface 1204 and/or the base layer 1212 if used.
  • the hardfacing sheet 1216 may include a flexible component (not shown in FIG. 12) to which the hardfacing material 1210 and the tiles 1208 are attached.
  • the flexible component may allow the hardfacing sheet 1216 to conform to and cover the shape of the exterior surface 1204 of the body 1202.
  • the hardfacing sheet 1216 may not include a flexible component and may be rigid.
  • the hardfacing sheet 1216 may be pre-formed to compliment and cover the shape of the exterior surface 1204 of the body 1202.
  • the hardfacing sheet 1216 may include a plurality of hardfacing sheets 1216 that, together, substantially conform to (or complement) and cover the exterior surface 1204 of the body 1202.
  • the tiles 1208 may be positioned within the hardfacing sheet 1216 and may then be secured in position relative to the body 1202 in a manner similar to or the same as described in relation to FIG. 7.
  • the tiles 1208 may be secured in position by passing an electrical current through the each of the tiles 1208 or through a coating thereon (as described in relation to FIG. 1).
  • the hardfacing material 1210 may include an electrically insulating material such that the electrical current applied to the tiles 1208 may be conducted through the tiles or coating and not dissipate into the hardfacing material 1210.
  • the hardfacing sheet 1216 may include tungsten carbide.
  • the tungsten carbide may be suspended in a matrix of binder material and/or a flexible component.
  • the hardfacing sheet 1216 may not include the tiles 1208 embedded in the hardfacing material 1210.
  • the tiles 1208 may be positioned and secured in a manner similar to and/or the same as described in relation to FIG. 7.
  • the hardfacing sheet 1216 may include complimentary apertures and/or pockets such that the hardfacing sheet 1216 may be applied to the body 1202 and tiles 1208 after the tiles are secured to the body.
  • the hardfacing material 1210 may include an electrically insulating material or an electrically conducting material, as the tiles are welded in position prior to the introduction of the hardfacing sheet 1216.
  • the hardfacing sheet 1216 may be fitted complimentarily around each of the plurality of tiles 1208 and to the exterior surface 1204 of the body 1202 and may be fused thereto through an application of thermal energy.
  • thermal energy and optionally hardfacing material as described in relation to FIG. 11
  • the application of thermal energy may be achieved through the automated movement of the thermal energy source and/or the body through a predetermined or set pattern of positions and/or movements relative to one another.
  • FIGS. 13 through 15 depict embodiments of predetermined or set patterns of positions and/or movements of the thermal energy source and the body relative to one another.
  • a predetermined or set pattern may include a predetermined or set array of positions, speed, dwell duration, thermal energy flux, or combinations thereof.
  • the pattern may be applied using a constant speed. In other embodiments, the pattern may be applied using a variable speed.
  • a first heating pattern 1318 is depicted in FIG. 13.
  • the tiles 1308 may become damaged when a tile temperature exceeds an upper temperature (for example 1200 degrees Celsius for a TSP).
  • the hardfacing material 1310 may melt and bind the TSP tiles at a transition temperature (for example a temperature exceeding 900 degrees Celsius for a Ni-Cr-Si-B binder material).
  • the heating pattern 1318 may be predetermined or set to promote or, in some embodiments, ensure, heating of the hardfacing material 1310 to a temperature exceeding the transition temperature without heating the tiles 1308 to a tile temperature exceeding the upper temperature.
  • the hardfacing temperature, the tile temperature, or other temperatures may be monitored by one or more thermometers before application of thermal energy, during application of thermal energy, after application of thermal energy, or combinations thereof.
  • a thermometer may monitor a source temperature of a thermal energy source.
  • a second thermometer may monitor the tile temperature of the tile 1308 nearest the thermal energy source.
  • a thermometer may monitor the hardfacing temperature of the hardfacing material 1310 at the application of thermal energy (i.e., a current point on the heating pattern 1318), ahead of the application of thermal energy (i.e., forward of a current point on the heating pattern 1318), behind the application of thermal energy (i.e., where the thermal energy has been applied on the heating pattern 1318), or other points on the hardfacing material 1310.
  • the one or more thermometers may be static during the application of thermal energy, or may be automated to move relative to the body 1302, tiles 1308, hardfacing material 1310, or combinations thereof during the application of thermal energy.
  • an array of thermometers may monitor a tile temperature of the two tiles 1308 nearest the application of thermal energy, a hardfacing temperature ahead of the application of thermal energy, a hardfacing temperature behind the application of thermal energy, a source temperature at the application of thermal energy (to detect fluctuations in the thermal energy applied) and an origin temperature at a start point of the heating pattern 1318 to monitor the rate of cooling of the hardfacing material 1310.
  • FIG. 13 schematically illustrates an embodiment of a predetermined or set heating pattern 1318 of positions and/or movements through which the body 1302 may be moved relative to a thermal energy source (not shown).
  • the point at which the thermal energy source may be directed is indicated by the predetermined or set heating pattern 1318 shown on the exterior surface 1304 of the body 1302.
  • a mount 1309 may be connected to an interior surface 1306 of the body 1302 and may move the body 1302.
  • the body 1302 may move with at least two degrees of freedom relative to a thermal energy source.
  • the body 1302 may move with at least three degrees of freedom relative to the thermal energy source.
  • the body 1302 may move with at least four degrees of freedom relative to the thermal energy source.
  • the body 1302 may move with at least five degrees of freedom relative to the thermal energy source.
  • the body 1302 may translate in an X-direction, a Y-direction, or a Z-direction; rotate about an X-axis, a Y-axis, or a Z-axis; or any combination thereof, relative to the thermal energy source.
  • the thermal energy source may move relative to the body 1302 and/or both the mount 1309 and the thermal energy source may move relative to each other.
  • the thermal energy source may translate in an X-, Y-, or Z- direction, rotate about an X-, Y-, or Z-axis, or any combination thereof relative to the body 1302.
  • the mount 1309 may take other forms than those shown herein.
  • the mount 1309 may move the body 1302 through a predetermined or set pattern of positions including a "snake" heating pattern 1318.
  • the predetermined or set pattern of positions may include simultaneously applying thermal energy and hardfacing material 1310 between the tiles 1308 in substantially parallel linear passes 1320 (e.g., applying powder 1113 via a thermal energy source 1115 as in FIG. 11).
  • the application of thermal energy to the hardfacing material 1310 without the application of additional hardfacing material such as in an embodiment using a hardfacing sheet (e.g., as hardfacing sheet 1216 depicted in FIG. 12) may fuse the hardfacing material 1310.
  • Each heating pattern 1318 may be made continuously by changing direction at either end of each linear pass 1320 to produce a heating pattern 1318 that may be continuous and including alternating directions with each linear pass 1320 in the heating pattern 1318.
  • the heating pattern 1318 may be partially discontinuous.
  • the body 1302 may be moved in a similar snake heating pattern 1318 at the same orientation to the body 1302 or at a different orientation to the body 1302.
  • Hardfacing material 1310 and/or thermal energy may be applied according to the heating pattern 1318 a second time at a 90-degree angle from the depicted heating pattern 1318 in FIG. 13.
  • the body 1302 may be rotated 90-degrees and the thermal energy source may be moved through a same heating pattern 1318 of predetermined or set positions.
  • the body 1302 and thermal energy source (not shown) may be moved relative to one another such that the thermal energy is applied according to the heating pattern 1318 rotated 90-degrees relative to a normal direction of the exterior surface 1304.
  • a 90-degree rotation may improve coverage of the application of thermal energy to the hardfacing material 1310.
  • an angular offset between each application of the heating pattern 1318 may be within a range having lower and upper values that include any of 5°, 10°, 15°, 25°, 35°, 45°, 55°, 65°, 70°, 75°, 80°, 85°, 90°, 95°, 100°, 105°, 1 10°, 1 15°, 125°, 135°, 145°, 155°, 165°, 170°, 175°, or any value therebetween.
  • the heating pattern 1318 may be applied at any appropriate angle to result in curing the hardfacing material 1310 and/or to substantially prevent damage to the tiles 1308.
  • the hardfacing may be applied in a single pass of the heating pattern 1318.
  • FIG. 14 schematically illustrates an embodiment of a predetermined or set heating pattern 1418 of positions and/or movements through a body 1402 and a thermal energy source may move relative to each other.
  • the path through which thermal energy may be applied is indicated by the predetermined or set heating pattern 1418 shown on the exterior surface 1404 of the body 1402.
  • a mount 1409 may be connected to an interior surface 1406 of the body 1402 and may move the body 1402.
  • the body 1402 may move with at least two degrees of freedom relative to a thermal energy source.
  • the body 1402 may move with at least three degrees of freedom relative to the thermal energy source.
  • the body 1402 may move with at least four degrees of freedom relative to the thermal energy source.
  • the body 1402 may move with at least five degrees of freedom relative to the thermal energy source.
  • the body 1402 may translate in an X-direction, a Y-direction, or a Z-direction; rotate about an X-axis, a Y-axis, or a Z-axis; or any combination thereof, relative to the thermal energy source.
  • the thermal energy source may move relative to the body 1402 and/or both the mount 1409 and the thermal energy source may move relative to each other.
  • the thermal energy source may translate in an X-, Y-, or Z- direction, rotate about an X-, Y-, or Z-axis, or any combination thereof relative to the body 1402.
  • the mount 1409 may take other forms than those shown herein.
  • the mount 1409 may move the body 1402 through a predetermined or set pattern of positions including a "stripe" heating pattern 1418.
  • the predetermined or set pattern of positions may include simultaneously applying thermal energy and/or hardfacing material 1410 between the tiles 1408 in substantially parallel linear passes 1420 (e.g., applying powder 1 1 13 via a thermal energy source 1 1 15 as in FIG. 1 1).
  • the application of thermal energy to the hardfacing material 1410 without the application of additional hardfacing material such as in an embodiment using a hardfacing sheet (e.g., as hardfacing sheet 1216 depicted in FIG. 12) may fuse the hardfacing material 1410.
  • Each linear pass 1420 may be made individually by temporarily removing the thermal energy from the body 1402 and/or hardfacing material 1410 when moving the body 1402 according to the dashed lines 1422 in the heating pattern 1418 shown in FIG. 14.
  • the thermal energy may be removed from the body 1402 by relative movement between the body 1402 and/or the thermal energy source in the Z-direction and/or turning off the thermal energy source.
  • the body may be moved according to the dashed lines 1422 in FIG. 14 when the thermal source is removed.
  • the heating pattern 1418 including substantially parallel linear passes 1420 may reduce a dwell time of the thermal energy source near a given region on the body 1402 and/or hardfacing material 1410.
  • the body 1402 and/or thermal energy source may be moved relative to one another in a similar stripe heating pattern 1418 at the same orientation to the body 1402 or at a different orientation to the body 1402.
  • the heating pattern 1418 may be applied a second time at approximately a 90- degree angle from the depicted pattern 1418 in FIG. 14.
  • a 90-degree rotation may improve coverage of the application of thermal energy to the hardfacing material 1410.
  • the heating pattern 1418 may be applied at a 45-degree angle from a previous application.
  • an angular offset between each application of the heating pattern 1418 may be within a range having lower and upper values that include any of 5°, 10°, 15°, 25°, 35°, 45°, 55°, 65°, 70°, 75°, 80°, 85°, 90°, 95°, 100°, 105°, 110°, 115°, 125°, 135°, 145°, 155°, 165°, 170°, 175°, or any value therebetween.
  • the heating pattern 1418 may be applied at any appropriate angle to result in substantially even heating of the hardfacing material 1410 and to substantially prevent overheating of the tiles 1408.
  • the hardfacing may be applied in a single pass of the heating pattern 1418.
  • FIG. 15 schematically illustrates an embodiment of a predetermined or set heating pattern 1518 of positions and/or movements through which the body 1502 may move relative to a thermal energy source.
  • the point at which the thermal energy source may be directed is indicated by the predetermined or set heating pattern 1518 shown on the exterior surface 1504 of the body 1502.
  • the mount 1509 may be connected to an interior surface 1506 of the body 1502 and may move the body 1502.
  • the body 1502 may move with at least two degrees of freedom relative to a thermal energy source.
  • the body 1502 may move with at least three degrees of freedom relative to the thermal energy source.
  • the body 1502 may move with at least four degrees of freedom relative to the thermal energy source.
  • the body 1502 may move with at least five degrees of freedom relative to the thermal energy source.
  • the body 1502 may translate in an X-direction, a Y-direction, or a Z-direction; rotate about an X-axis, a Y-axis, or a Z-axis; or any combination thereof, relative to the thermal energy source.
  • a mount 1509 may move the body 1502 and/or thermal energy source may be moved relative to one another through a predetermined or set pattern of positions including a "spiral" heating pattern 1518.
  • the predetermined or set pattern of positions may include simultaneously applying thermal energy and hardfacing material 1510 between the tiles 1508 (e.g., applying powder 1113 via a thermal energy source 1115 as in FIG. 11).
  • the application of thermal energy to the hardfacing material 1510 without the application of additional hardfacing material such as in an embodiment using a hardfacing sheet (e.g., as hardfacing sheet 1216 depicted in FIG. 1212) may fuse the hardfacing material 1510.
  • the heating pattern 1518 may extend via a non- linear portion 1524 to a substantially opposite side of the exterior surface 1504 before applying another substantially linear pass 1520.
  • a spiral pattern may be applied in either direction (i.e., inward or outward).
  • the body 1502 and/or thermal energy source may be moved relative to one another in a similar spiral heating pattern 1518 at the same orientation to the body 1502 or at a different orientation to the body 1502.
  • the heating pattern 1518 or a pattern similar thereto may be applied a second time at approximately a 90-degree angle from the depicted heating pattern 1518 in FIG. 15.
  • a 90-degree rotation may improve coverage of the application of thermal energy to the hardfacing material 1510.
  • the heating pattern 1518 or a pattern similar thereto may be applied at a 45-degree angle from a previous application.
  • the heating pattern 1518 or a pattern similar thereto may be applied at any appropriate angle to result in substantially even heating of the hardfacing material 1510 and to substantially prevent overheating of the tiles 1508.
  • a spiral heating pattern 1518 as depicted in FIG. 15 or a pattern similar thereto may substantially cover the entire surface of the body 1502 and/or hardfacing material 1510 without subsequent application of the heating pattern 1518 at an angle to that depicted in FIG. 15.
  • FIGS. 13 through 15 depict embodiments of predetermined or set patterns that may be used to guide the movement of a thermal energy source and/or a body relative to one another, any appropriate pattern may be used depending on the locations of the tiles of superhard material secured to the body.
  • the initial application of hardfacing material 1610 to the exterior surface 1604 of a body 1602 (and base later 1612, if present) may result in an uneven surface of the hardfacing material 1610.
  • the initial application of hardfacing material 1610 to the exterior surface 1604 (and base later 1612, if present) may also result in an application of hardfacing material 1610 over top of the tiles 1608 due to overspray during application.
  • the hardfacing material 1610 may be smoothed and leveled with the tiles 1608 by the application of an overlying layer to build up an outside surface 111 as depicted in FIG. 1.
  • FIG. 17 illustrates additional hardfacing material applied to the hardfacing material 1610 and tiles 1608 shown in FIG. 16.
  • the additional application may result in an overlying layer of hardfacing material 1710 that completely covers tiles 1708.
  • the overlying layer of hardfacing material 1710 may be created by application of hardfacing material according to any of the methods described herein or combinations thereof.
  • the overlying layer may include a hardfacing material that is the same as the hardfacing material 1710 applied previously.
  • the overlying layer may also include a hardfacing material with a different composition such that a gradient in properties is created across a thickness of the hardfacing material 1710.
  • a hardfacing material used to build up the overlying layer may include a copper-alloy.
  • a gradient may include increasing or decreasing hardness of the hardfacing material as the gradient approaches the body 1702 (or base layer 1712, if used).
  • a gradient may include increasing or decreasing toughness of the hardfacing material 1710 as the gradient approaches the body 1702 (or base layer 1712, if used).
  • the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof may be subjected to a heat treatment.
  • the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof may be heat treated according to any appropriate heat treatment.
  • the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof may be placed in a preheated oven at 600 degree Celsius for 4 hours. After 4 hours exposure to the 600 degree Celsius oven, the oven may be turned off.
  • the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof may be allowed to cool within the enclosed and still hot oven for and additional period of time.
  • the assembly may be allowed to cool gradually for up to 4, 6, or 8 hours.
  • Gradually cooling the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof may reduce strain within the hardfacing material 1710, tiles 1708, base layer 1712, or combinations thereof; and/or within interfaces between the hardfacing material 1710 and the tiles 1708, between the hardfacing material 1710 and the base layer 1712, and/or between the tiles 1708 and the base layer 1712.
  • the hardfacing material 1810 may be ground down to leave a predetermined thickness of hardfacing material 1810 that may form a coherent outside surface 1811 with the tiles 1808 covering the body 1802 (and/or base layer 1812, if used).
  • the body 1802 may be hardfaced within the system 819 described in connection with FIG .8.
  • the system 819 may include an oven (not shown) for heat treating the body 1702, base layer 1712, tiles 1708, hardfacing material 1710, or combinations thereof.
  • the automated control of a body relative to an energy source to secure tiles thereon and/or relative to a directable thermal energy source capable of applying and/or fusing hardfacing material in an inert environment may result in a finished hardfaced component such as the stabilizer pad 100 in FIG. 1 that includes less defects and less internal strain than a manually produced piece in less time.
  • a hardfaced component manufactured in accordance with the present disclosure may have an increased wear resistance, increased operational lifetime, decreased risk of delamination, a decreased risk of cracking during use, or combinations thereof.
  • a stabilizer may use the combination of tiles and hardfacing as described herein on blades, and as such, the methods for producing such hardfaced stabilizers may be similar to those described above. That is, a tubular stabilizer may be placed in a system for hardfacing using an automated mount and additional components, including a CNC machine or modified CNC machine as described with reference to FIG. 8.
  • Such a system includes a mount adapted to hold a tubular body such as a tubular stabilizer, and also includes other features and components as described with reference to FIG. 8.
  • a tubular body such as a tubular stabilizer
  • any of the above embodiments may be used to hardface a tubular stabilizer.
  • the products and methods described herein may also be used on any other suitable tools, such as drill bits, hole openers, reamers, or the like.
  • the products and methods described herein may also be used on any other downhole components, such as in hardbanding for tubulars or other components or the like.
  • any directions or reference frames in the preceding description are merely relative directions or movements.
  • any references to “up” and “down” or “above” and “below” or “interior” and “exterior” are merely descriptive of the relative position or movement of the related elements. It should be understood that “interior” and “exterior” are relative directions.

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Abstract

Dans des modes de réalisation, la présente invention concerne des appareils, des systèmes et des procédés pour l'application automatisé d'un revêtement dur sur une surface. L'application automatique d'un revêtement dur sur une surface peut comprendre la fixation de tuiles d'un matériau extra-dur sur une surface, l'application d'un matériau de revêtement dur autour des tuiles et la fusion du matériau de revêtement dur à l'aide d'une source d'énergie thermique. La source d'énergie thermique et l'ensemble constitué par la surface, le matériau de revêtement dur et les tuiles peuvent être déplacés automatiquement l'un par rapport à l'autre selon un diagramme.
PCT/US2015/045460 2014-08-19 2015-08-17 Application automatisée d'un revêtement dur pour des applications d'outils de fond de trou WO2016028662A1 (fr)

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US20210046566A1 (en) * 2019-08-16 2021-02-18 Cutting & Wear Resistant Developments Limited Apparatus and method for hard facing a substrate
US10954727B1 (en) * 2017-12-21 2021-03-23 Nabors Drilling Technologies Usa, Inc. Dual-wear pad for downhole drilling housings
CN112730121A (zh) * 2020-12-24 2021-04-30 江苏徐工工程机械研究院有限公司 销轴加工和质量检测装置及方法
US11364705B2 (en) * 2017-10-17 2022-06-21 Exxonmobil Upstream Research Company Diamond-like-carbon based friction reducing tapes

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EP1036913A1 (fr) * 1999-03-18 2000-09-20 Camco International (UK) Limited Méthode pour appliquer une couche protectrice d'usure à la surface d'un outil à aléser
US6196338B1 (en) * 1998-01-23 2001-03-06 Smith International, Inc. Hardfacing rock bit cones for erosion protection
US20110073233A1 (en) * 2009-09-30 2011-03-31 Baker Hughes Incorporated Method of Applying Hardfacing Sheet
US20120193148A1 (en) * 2011-01-28 2012-08-02 Baker Hughes Incorporated Non-magnetic drill string member with non-magnetic hardfacing and method of making the same
US8450637B2 (en) * 2008-10-23 2013-05-28 Baker Hughes Incorporated Apparatus for automated application of hardfacing material to drill bits

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US6196338B1 (en) * 1998-01-23 2001-03-06 Smith International, Inc. Hardfacing rock bit cones for erosion protection
EP1036913A1 (fr) * 1999-03-18 2000-09-20 Camco International (UK) Limited Méthode pour appliquer une couche protectrice d'usure à la surface d'un outil à aléser
US8450637B2 (en) * 2008-10-23 2013-05-28 Baker Hughes Incorporated Apparatus for automated application of hardfacing material to drill bits
US20110073233A1 (en) * 2009-09-30 2011-03-31 Baker Hughes Incorporated Method of Applying Hardfacing Sheet
US20120193148A1 (en) * 2011-01-28 2012-08-02 Baker Hughes Incorporated Non-magnetic drill string member with non-magnetic hardfacing and method of making the same

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11364705B2 (en) * 2017-10-17 2022-06-21 Exxonmobil Upstream Research Company Diamond-like-carbon based friction reducing tapes
US10954727B1 (en) * 2017-12-21 2021-03-23 Nabors Drilling Technologies Usa, Inc. Dual-wear pad for downhole drilling housings
US20210046566A1 (en) * 2019-08-16 2021-02-18 Cutting & Wear Resistant Developments Limited Apparatus and method for hard facing a substrate
CN112730121A (zh) * 2020-12-24 2021-04-30 江苏徐工工程机械研究院有限公司 销轴加工和质量检测装置及方法
CN112730121B (zh) * 2020-12-24 2024-04-02 江苏徐工工程机械研究院有限公司 销轴加工和质量检测装置及方法

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