WO2017087781A1

WO2017087781A1 - Wear-resistant drilling tools and systems and methods for making same

Info

Publication number: WO2017087781A1
Application number: PCT/US2016/062735
Authority: WO
Inventors: Christopher L. Drenth; Michael D. Rupp; Cody A. Pearce
Original assignee: Bly Ip Inc.
Priority date: 2015-11-18
Filing date: 2016-11-18
Publication date: 2017-05-26

Abstract

A wear-resistant drilling tool having an infiltrated body and a plurality of button elements. The infiltrated body includes a matrix and a binder that secures hard particulate material and diamond particles of the matrix together. The infiltrated matrix is formed around the plurality of button elements to secure the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to a distal face of the infiltrated body. Alternatively, rather than providing a plurality of button elements separate from the infiltrated body, the infiltrated body can define a distal face and a plurality of projections that project from the distal face.

Description

WEAR-RESISTANT DRILLING TOOLS AND SYSTEMS

AND METHODS FOR MAKING SAME

CROSS-REFERENCE TO RELATED PATENT APPLICATION

[001] This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 62/257,021, filed November 18, 2015, which application is hereby incorporated by reference herein in its entirety.

FIELD

[002] The disclosed invention relates to wear-resistant drilling tools, and, more particularly, to wear-resistant drilling tools having infiltrated bodies that secure button elements or projections in a desired position relative to a distal face of the infiltrated body.

BACKGROUND

[003] Conventionally, percussive button bits are used to quickly penetrate a variety of formations. These bits typically have buttons that are press-fit into openings formed within the face of the bit. Upon insertion of the buttons, a conical or hemispherical surface of the buttons projects from the bit face. Unfortunately, there are significant manufacturing and quality issues associated with these bits. In particular, the buttons often do not fit properly within the openings of the bit face, and it is difficult to adjust the shapes and sizes of the buttons and/or openings to ensure a sufficiently tight fit. Moreover, there is often a limited supply or inventory of buttons of various sizes; thus, it is also difficult to locate other buttons that are of a more appropriate size for a given drill bit. When the buttons are not properly secured within the openings of the bit face, the buttons are likely to become dislodged during drilling operations, necessitating the replacement of the button and rendering the drilling process inefficient.

[004] More recently, there have been some attempts to apply various coatings to the bit crown to strengthen the attachment of buttons within the openings of the bit. However, these techniques have been excessively costly and have only limited applicability. Additionally, they are associated with a risk of button degradation due to welding heat. Furthermore, these methods do not correct the manufacturing and quality issues associated with buttons that cannot be sufficiently press-fit into openings within the bit face. [005] Thus, there is a need for wear-resistant drilling tools and methods that address one or more of the deficiencies of known percussive button bits.

SUMMARY

[006] Described herein, in various aspects, is a wear-resistant drilling tool having an infiltrated body and a plurality of button elements. The infiltrated body can include a matrix and a binder. The matrix can include a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material. The binder can secure the hard particulate material and the abrasive particles together. The infiltrated body can define a distal face. The infiltrated matrix can be formed around the plurality of button elements to secure the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the infiltrated body.

[007] Also described is a method of forming a wear-resistant drilling tool. The method can include preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material. The method can also include shaping the matrix into a desired shape around a plurality of button elements. The method can further include infiltrating the matrix with a binder material. The binder material can secure the hard particulate material and the abrasive particles of the matrix together. The infiltrated matrix can define a distal face of the drilling tool, and the infiltrated matrix can secure the plurality of button elements in a desired position in which a portion of each button body of the plurality of button elements projects relative to the distal face of the drilling tool.

[008] Further described herein is an infiltrated wear-resistant drilling tool that includes an infiltrated body. The infiltrated body can have a matrix and a binder. The matrix can include a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material. The binder can secure the hard particulate material and the abrasive particles together. The infiltrated body can define a distal face and a plurality of projections that project from the distal face. As disclosed herein, the projections can effectively serve as button elements that are formed by the infiltrated body.

[009] Still further described herein is a method of forming a wear-resistant drilling tool. The method can include preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material. The method can also include shaping the matrix into a desired shape. The method can further include infiltrating the matrix with a binder material. The binder material can secure the hard particulate material and the abrasive particles of the matrix together. The infiltrated matrix can define a distal face and a plurality of projections that project from the distal face.

[0010] Still further described herein is a wear-resistant drilling tool having a body blank, a plurality of button elements, a matrix, and a binder. The body blank can have a distal end defining a plurality of pockets. Each button element can be at least partially received within a respective pocket of the body blank such that a portion of the button element projects relative to the distal end of the body blank. The matrix can be positioned within the plurality of pockets of the body blank and surround the button element within each body blank. The matrix can comprise a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material. The binder can be positioned within the plurality of pockets of the body blank and surround the button element within each body blank. The binder can secure the hard particulate material and the abrasive particles of the matrix together and secure the button element within each pocket of the body blank to surrounding portions of the body blank.

DESCRIPTION OF THE DRAWINGS

[0011] Figures 1A-1D depict various views of an exemplary wear-resistant drill bit as disclosed herein. Figure 1A depicts a perspective view of the drill bit. Figure IB depicts a side view of the drill bit. Figure 1C is a distal end view of the drill bit. Figure ID is a cross-sectional view of the drill bit, taken at line X-X of Figure 1C.

[0012] Figures 2A-2D are front perspective views of exemplary button elements as disclosed herein. Figure 2A depicts an exemplary hemispherical button element. Figure 2B depicts an exemplary parabolic (semi-ballistic) button element. Figure 2C depicts an exemplary conical button element. Figure 2D depicts an exemplary ballistic button element.

[0013] Figure 3 A is a transparent perspective view of an exemplary wear-resistant drill bit as disclosed herein. Figures 3B-3F depict the elements of an exemplary mold assembly that can be used to produce the drill bit of Figure 3A. Figure 3B is a perspective view of the mold assembly. Figure 3C is a perspective view of a face mold element of the mold assembly of Figure 3B. Figure 3D is a perspective view of a body mold element of the mold assembly of Figure 3B. Figure 3E is a perspective view of an interior mold element of the mold assembly of Figure 3B. Figure 3F is a perspective view of an exemplary funnel element of the mold assembly of Figure 3B.

[0014] Figures 4A and 4B are images of exemplary all-cast drill bits having projections as disclosed herein.

[0015] Figure 5 is a distal end view of an exemplary drill bit having a plurality of button elements as disclosed herein.

[0016] Figure 6A is a partially cutaway perspective view of an exemplary drill bit as disclosed herein. Figure 6B is an enlarged sectional view showing a portion of a crown of the drill bit of Figure 6 A.

[0017] Figures 7A-7B are side views of exemplary drill bits as disclosed herein. As shown, the drill bits can have ribs and/or cutting edges defined by the skirt/shank of the drill bits.

[0018] Figure 8A is a front elevational view of an exemplary drilling tool having an infiltrated crown that is provided separately from, and configured for mechanical attachment to, a shank. Figure 8B is an isolated perspective view of the infiltrated crown of Figure 8 A. Figure 8C is an exploded side perspective view of the drilling tool of Figure 8 A.

[0019] Figure 9A is a front elevational view of an exemplary drilling tool having an infiltrated crown that is provided separately from, and configured for mechanical attachment to, a shank. Figure 9B is an isolated perspective view of the infiltrated crown of Figure 9A. Figure 9C is an exploded side perspective view of the drilling tool of Figure 9A.

DETAILED DESCRIPTION

[0020] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. [0021] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0022] As used herein the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. For example, use of the term "a channel" can refer to one or more of such channels.

[0023] All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

[0024] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0025] As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0026] The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list.

[0027] As used herein, the term "proximal" refers to a direction toward the surface of a formation (where a drill rig can be located), whereas the term "distal" refers to a direction toward the bottom of a drill hole, moving away from the surface of the formation. When the terms "proximal" and "distal" are used to describe system components, it is expected that during normal use of those components, the "proximal" components will be positioned proximally (closer to the surface of the formation) relative to the "distal" components and the "distal" components will be positioned distally (closer to the bottom of a drill hole) relative to the "proximal" components.

[0028] As used herein, the term "[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. Where two or more metals are listed in this manner, the weight percentage of the listed metals in combination is greater than the weight percentage of any other component of the alloy.

[0029] As used herein, the term "tungsten carbide" means any material composition that contains chemical compounds of tungsten and carbon in any stoichiometric or non- stoichiometric ratio or proportion, such as, for example, WC, W₂C, and combinations of WC and W₂C. Tungsten carbide includes any morphological form of this material, for example, cast tungsten carbide, sintered tungsten carbide, monocrystalline tungsten carbide, and macrocrystalline tungsten carbide.

[0030] As used herein, the term "wear-resistant" refers to a drilling tool that is not designed to erode or degrade to expose cutting material imbedded or otherwise positioned within the drilling tool. Thus, wear-resistant tools are distinguishable from— and operate in a fundamentally different way than— impregnated drilling tools that are designed to wear away to continuously expose cutting media within the drilling tools.

[0031] The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus and associated methods can be placed into practice by modifying the illustrated apparatus and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry.

[0032] Disclosed herein, in various aspects and with reference to Figures 1 A-9C is a wear- resistant drilling tool 10, which, in exemplary aspects, can be a drill bit. Optionally, the drill bit can be a percussive drill bit, such as a button drill bit, a blade drill bit, or a down-the-hole (DTH) hammer bit. In exemplary aspects, the drill bit can be a button drill bit comprising carbide and polycrystalline diamond (PCD) buttons, such as, for example and without limitation, a rotary drag bit, a bi-cone bit, or a tri-cone bit. Although depicted as a drill bit in the Figures, it is contemplated that other wear-resistant drilling tools, such as hole reamers, back reamers, hole openers, and drill string stabilizers, can be formed in the manner disclosed herein.

[0033] In one aspect, the wear-resistant drilling tool 10 can comprise an infiltrated body 12 comprising a matrix 14 and a binder (not shown). In this aspect, the matrix 14 can comprise a hard particulate material and a plurality of abrasive particles 16 dispersed throughout the hard particulate material. It is contemplated that the binder can secure the hard particulate material and the abrasive particles together. As shown in Figure 1 A and ID, the infiltrated body 12 can define a distal face 18. In exemplary aspects, the distal face 18 can serve as a cutting face as further disclosed herein. In exemplary aspects, the plurality of abrasive particles 16 can comprise a plurality of diamond particles. However, it is contemplated that any conventional abrasive cutting media can be used.

[0034] It is contemplated that the wear-resistant drilling tools 10 disclosed herein can be configured to provide abrasive wear resistance to most, if not all, of the bodies of the drilling tools while still retaining the ductility and toughness needed for connection to a drill string. It is further contemplated that the wear-resistant drilling tools 10 disclosed herein can provide these benefits at similar production costs to conventional wear-resistant drilling tools.

[0035] In exemplary aspects, the wear-resistant drilling tools 10 disclosed herein can provide an improvement in wear resistance over current drilling tools, which typically use only thru- hardened alloy steel bodies and can be carburized for wear resistance and/or have costly surface coatings that are applied with welding or laser-welding techniques.

[0036] In further exemplary aspects, it is contemplated that the disclosed wear-resistant drilling tools 10 can overcome the significant cost and inventory issues associated with current percussive bit technology. In particular, in current percussive bits, button pockets are drilled into the bodies, and the buttons are retained with only a mechanical press-fit, which requires very tight tolerances for both the button pockets and the buttons. As the drills used to form the button pockets wear down, the button pockets become progressively smaller in diameter. As a result, it is common practice for bit manufacturers and drilling operators to stock three sizes of each button type to fit a range of drilled pockets, which is costly. It is contemplated that the drilling tools and manufacturing methods disclosed herein can produce a significant reduction (e.g., as high as a 2/3 reduction) in button inventory, thereby making the production of percussive drilling tools far more affordable and eliminating the need for some of the space previously allocated to button storage.

Drilling Tools Having Button Elements

[0037] In another aspect, the wear-resistant drilling tool 10 can comprise a plurality of button elements 50. In this aspect, it is contemplated that each button element 50 can have the shape of any conventional button that is used in button bits as are known in the art. In exemplary aspects, it is contemplated that the plurality of button elements 50 can optionally comprise tungsten carbide.

[0038] In exemplary aspects, the infiltrated matrix 14 of the wear-resistant drilling tool 10 can be formed around the plurality of button elements 50 to secure the plurality of button elements in a desired position. In these aspects, the desired position can correspond to a position in which a portion of each button element 50 of the plurality of button elements projects (in a distal direction) relative to the distal face 18 of the infiltrated body. It is contemplated that the binder of the infiltrated body can be chemically bonded to the plurality of button elements. It is contemplated that the chemical bonding between the binder of the infiltrated body and the plurality of button elements can provide improved button retention in comparison to

conventional button drilling tools (e.g., button bits). In exemplary aspects, it is contemplated that the chemical bonding between the binder of the infiltrated body and the plurality of button elements can generally be similar to the chemical bonding in existing carbide bits. However, it is further contemplated that the thermal stresses associated with the chemical bonding can be substantially different. In particular, because the bit body comprises powder instead of a solid piece of steel, there is no thermal mismatch between the bit body and the button

elements. Indeed, the entire bit can be bonded with the same material, whereas existing button bits require brazing between the steel and the buttons. Moreover, the disclosed bits can be heated and cooled uniformly at the same rate. The disclosed bit bodies can comprise carbides, which have a thermal expansion coefficient of one-third to one-half that of conventional steel bodies, thereby greatly reducing the amount of stress on the joint between the bit body and the button elements (in comparison to current braze joints). [0039] In further exemplary aspects, each button element 50 of the plurality of button elements can have a body portion 52 that is chemically bonded to the binder of the infiltrated body and a distal end portion 54 that projects relative to the distal face of the infiltrated body. Optionally, in these aspects, the distal end portion of at least one button element can have a variable diameter that decreases moving away from the body portion. For example, and with reference to Figures 2A-2D, it is contemplated that the distal end portion of at least one button element can have a hemispherical shape, a substantially hemispherical shape, a conical shape, or a substantially conical shape. Exemplary button element shapes are depicted in Figures 2A-2D, including a hemispherical button shape (Figure 2A), a parabolic button shape (Figure 2B), a conical button shape (Figure 2C), and a ballistic button shape (Figure 2D). In use, it is contemplated that the hemispherical button shape can optionally be optimized for hard ground conditions. It is further contemplated that the parabolic button shape can be optimized for fast penetration in medium ground conditions. It is still further contemplated that the conical and ballistic button shapes can be optimized for fast penetration in all non-abrasive ground types while providing a relatively smaller contact area.

[0040] Optionally, as disclosed herein, the wear-resistant drilling tool can be a full-face drill bit, such as, for example and without limitation, a percussive drill bit, a rotary/tri-cone drill bit, a reverse circulation (RC) drill bit, or a sonic drill bit. In exemplary aspects, the drill bit can have a longitudinal axis 15 and comprise a shank 20 and a full face crown 30. In these aspects, the full face crown can have a cutting face 18 and an outer surface 34. It is contemplated that the full face crown 30 and the shank 20 can cooperate to define an interior space 25 about the longitudinal axis. In exemplary aspects, the full face crown 30 can define a plurality of bores 36 extending from the cutting face to the interior space. In further exemplary aspects, the full face crown 30 can completely circumferentially enclose the interior space 25. In still further exemplary aspects, the full face crown does not comprise a waterway extending radially between the outer surface of the full face crown and the interior space. Optionally, in one aspect, the full face crown can comprise at least one channel 38 that extends radially inwardly toward the longitudinal axis 15 of the drill bit 10.

[0041] In exemplary aspects, the full face crown 30 and the shank 20 can be chemically bonded or fused together. In further exemplary aspects, the full face crown 30 and the shank 20 can be integrally formed (e.g., infiltrated) as one piece. Alternatively, in other exemplary aspects and as depicted in Figures 8A-9C, the infiltrated body 12 can be an infiltrated crown 130 that is provided separately from, and configured for mechanical attachment to, a shank 120.

Optionally, in these aspects, the infiltrated crown 130 can be configured for threaded

engagement with a threaded distal end of the shank 120. For example, as shown in Figures 8A- 8C, it is contemplated that the infiltrated crown 130 can have a proximal stem 140 that is configured for receipt within an interior portion 125 of the shank 120. In exemplary aspects, the proximal stem 140 can have a reduced diameter relative to a distal portion 135 of the infiltrated crown 130. It is further contemplated that the proximal stem 140 can have a threaded outer surface that is configured for complementary engagement with a threaded inner surface of the shank 120 that defines the interior portion 125 of the shank. Alternatively, as shown in Figures 9A-9C, it is contemplated that a proximal portion 137 of the infiltrated crown 130 can have a threaded inner surface that defines an interior portion 139 of the infiltrated crown and is configured for threaded engagement with a threaded outer surface of a distal portion 127 of the shank 120 (such that the distal portion of the shank is received within the interior portion of the infiltrated crown). Although threaded engagement has been described above, it is contemplated that other types of mechanical engagement can be used to mechanically secure the infiltrated crown 130 to the shank 120. For example, it is contemplated that the proximal stem 140 (or other proximal portion) of the infiltrated crown 130 can be shaped to frictionally engage an inner surface of the shank 120. As another example, it is contemplated that the infiltrated crown 130 can be mechanically secured to the shank 120 using at least one fastener, such as a bolt, screw, projection, and the like, which can be coupled to the infiltrated crown 130 (or the shank 120) and be configured for engagement or receipt within a complementary opening or receptacle of the other of the shank 120 (or the crown 130). Regardless of the method of mechanical attachment between the infiltrated crown 130 and the shank 120, it is contemplated that the crown 130 and the shank 120 can cooperate to define an interior space 25 and bores 36 as further described herein. Although the detachable and selective connection of the crown 130 and shank 120 is disclosed above with respect to a full-face drill bit, it is contemplated that such a construction can be applied to other drilling tools, including reamers and other drill bits.

[0042] Methods of forming a wear-resistant drilling tool having a plurality of button elements are also disclosed. In one aspect, a method of forming the wear-resistant drilling tool can comprise preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material. In another aspect, the method can comprise shaping the matrix into a desired shape around a plurality of button bodies. In a further aspect, the method can comprise infiltrating the matrix with a binder material. In this aspect, the binder material can secure the hard particulate material and the abrasive particles of the matrix together. It is contemplated that the infiltrated matrix can define a distal face of the drilling tool. It is further contemplated that the infiltrated matrix can secure the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the drilling tool.

[0043] Optionally, shaping the matrix can comprise placing the matrix within a mold assembly 70. In exemplary aspects, it is contemplated that the elements of the mold assembly 70 can optionally comprise graphite. Optionally, in exemplary aspects, and as shown in Figures 3 A-3F, the mold assembly 70 can comprise a face mold element 72 that defines a plurality of openings 74 that are configured to receive respective button elements 50. The face mold element can define a recessed portion that is in communication with the openings 74 and configured to define the shape of the distal face of the drilling tool. The face mold element 72 can further comprise a spindle 76 that is positioned centrally within the recessed portion and that extends axially away from the openings 74.

[0044] The mold assembly 70 can further comprise a body mold element 80 having a proximal end portion 84 and a distal end portion 86, with the distal end portion being configured for engagement with the face mold element 72. As shown in Figure 3D, the body mold element 80 can comprise an opening 82 that extends between the proximal and distal end portions 84, 86 and is positioned in communication with the recessed portion of the face mold element 72. The opening 82 can be shaped to define the outer surface of the crown (and, optionally, the shank) of the drilling tool. When the infiltrated body is provided as an infiltrated crown that is separate from the shank of the drilling tool, the opening 82 can be shaped to define the outer surface of the crown, including a proximal stem or other proximal portions of the crown. Optionally, the proximal end portion 84 of the body mold element 80 can have a recessed portion that defines a ledge 85 extending circumferentially around the opening 82.

[0045] As shown in Figure 3E, the mold assembly 70 can still further comprise an interior mold element 90 having a projection 96 that extends within the opening 82 of the body mold element 80 to define the shape of the interior space 25 of the drilling tool. The interior mold element 90 can further comprise a flange portion 92 that is configured to engage the ledge 85 within the recessed portion of the body mold element 80. The flange portion 92 can define at least one opening 94 (optionally, a plurality of openings 94) that are positioned in

communication with the opening 82 of the body mold element 80.

[0046] As shown in Figure 3F, the mold assembly 70 can still further comprise a funnel 100 that is configured to engage the proximal end portion 84 of the body mold element 80. The funnel 100 can have an opening 102 that is positioned in communication with the openings 94 of the flange portion 92 of the interior mold element 90. As assembled, the elements of the mold assembly 70 can be aligned relative to a longitudinal axis 71 of the mold assembly.

[0047] In use, the plurality of button elements (e.g., carbide button elements) can be positioned within the openings 74 of the face mold element 72. Subsequently, the other elements of the mold assembly 70 can be assembled as depicted in Figure 3B and described above. The material of the drilling tool 10 (e.g., metal powder) can be delivered through the opening 102 of the funnel 100 and then through the openings 94 of the flange portion 92 of the interior mold element 90 and, ultimately, into the opening 82 of the body mold element 80. Optionally, vibration can be applied using conventional means to assist with delivery of the material into the opening 82 of the body mold element 80. Once the body mold element 80 is full, a binder material/infiltrant (e.g., a silver- or copper-based infiltrant) can be delivered through the openings 94 of the flange portion 92 of the interior mold element 90 and then through the opening 82 of the body mold element 80. After delivery of the binder material/infiltrant, at least a portion of the mold assembly, containing the button elements, the metal powder, and the binder material/infiltrant, can be placed within a furnace. The furnace can be operated such that the binder material/infiltrant is given sufficient time to melt and infiltrate the drilling tool. After sufficient time in the furnace, the components of the mold assembly can be ground off using conventional methods to separate the drilling tool.

[0048] Optionally, in exemplary aspects, the components of the mold assembly can be reusable. Alternatively, in other exemplary aspects, the components of the mold assembly can be disposable (configured for one-time use). [0049] Optionally, in exemplary aspects, when the infiltrated body 12 serves as an infiltrated crown, it is contemplated that the method of forming the wear-resistant drilling tool can comprise mechanically attaching the infiltrated body to (optionally, threading the infiltrated body onto or into) a shank, such as, for example and without limitation, a steel shank having a threaded distal end as further described herein.

Drilling Tools Having Projections Defined by an Infiltrated Body

[0050] Rather than including button elements 50 that project from the distal face of the drilling tool, it is contemplated that the drilling tool (e.g., a drill bit as disclosed herein) can instead include projections 60 that are formed from the same material as the remainder of the drilling tool and infiltrated concurrently with the remainder of the drilling tool (as one piece). In exemplary aspects, an infiltrated wear-resistant drilling tool 10 can comprise an infiltrated body comprising a matrix and a binder. In these aspects, the matrix can comprise a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material. The binder can secure the hard particulate material and the abrasive particles together. In exemplary aspects, the infiltrated body can define a distal face and a plurality of projections 60 that project from the distal face.

[0051] In exemplary aspects, at least one projection of the plurality of projections 60 has a variable diameter that decreases moving away from the distal face of the infiltrated body. For example, at least one projection of the plurality of projections can have a hemispherical shape, a substantially hemispherical shape, a conical shape, or a substantially conical shape.

[0052] In further exemplary aspects, the plurality of abrasive particles of the matrix can comprise a plurality of diamond particles. In still further exemplary aspects, the plurality of abrasive particles of the matrix can comprise tungsten carbide. Optionally, in these aspects, the matrix can have a concentration of tungsten carbide that decreases moving proximally away from the distal face of the infiltrated body.

[0053] In exemplary aspects, the infiltrated drilling tool can have a crown 30 and a shank 20 that are chemically bonded or fused together. In further exemplary aspects, it is contemplated that the crown 30 (e.g., full face crown) and the shank 20 can be integrally formed (e.g., infiltrated) as one piece. Alternatively, in other exemplary aspects and as depicted in Figures 8A-9C and as further disclosed herein, the infiltrated body can be an infiltrated crown 130 that defines the projections 60 and is provided separately from, and configured for mechanical attachment to, a shank 120. Optionally, in these aspects, the infiltrated crown 130 can be configured for threaded engagement with a threaded distal end of the shank 120. For example, as shown in Figures 8A-8C, it is contemplated that the infiltrated crown 130 can have a proximal stem 140 that is configured for receipt within an interior portion 125 of the shank 120. In exemplary aspects, the proximal stem 140 can have a reduced diameter relative to a distal portion 135 of the infiltrated crown 130. It is further contemplated that the proximal stem 140 can have a threaded outer surface that is configured for complementary engagement with a threaded inner surface of the shank 120 that defines the interior portion 125 of the shank. Alternatively, as shown in Figures 9A-9C, it is contemplated that a proximal portion 137 of the infiltrated crown 130 can have a threaded inner surface that defines an interior portion 139 of the infiltrated crown and is configured for threaded engagement with a threaded outer surface of a distal portion 127 of the shank 120 (such that the distal portion of the shank is received within the interior portion of the infiltrated crown). Although threaded engagement has been described above, it is contemplated that other types of mechanical engagement can be used to mechanically secure the infiltrated crown 130 to the shank 120. For example, it is contemplated that the proximal stem 140 (or other proximal portion) of the infiltrated crown 130 can be shaped to frictionally engage an inner surface of the shank 120. As another example, it is contemplated that the infiltrated crown 130 can be mechanically secured to the shank 120 using at least one fastener, such as a bolt, screw, projection, and the like, which can be coupled to the infiltrated crown 130 (or the shank 120) and be configured for engagement or receipt within a complementary opening or receptacle of the other of the shank 120 (or the crown 130). Regardless of the method of mechanical attachment between the infiltrated crown 130 and the shank 120, it is contemplated that the crown 130 and the shank 120 can cooperate to define an interior space 25 and bores 36 as further described herein. Although the detachable and selective connection of the crown 130 and shank 120 is disclosed above with respect to a full-face drill bit, it is contemplated that such a construction can be applied to other drilling tools, including reamers and other drill bits.

[0054] Methods of forming a wear-resistant drilling tool having projections as disclosed herein are also disclosed. In one aspect, a method of forming the wear-resistant drilling tool can comprise preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material. In another aspect, the method can comprise shaping the matrix into a desired shape. In an additional aspect, the method can comprise infiltrating the matrix with a binder material. In this aspect, the binder material can secure the hard particulate material and the abrasive particles of the matrix together. As further disclosed herein, the infiltrated matrix can define a distal face and a plurality of projections that project from the distal face.

[0055] In further aspects, shaping the matrix can optionally comprise placing the matrix within a mold assembly. Optionally, in exemplary aspects, a mold assembly 70 as disclosed herein for use with drilling tools having button elements can be used to form drilling tools having projections defined by an infiltrated body. In some optional aspects, instead of placing button elements within the openings 74 of the face mold element 72 (as is the case with drilling tools having button elements), the openings of the face mold element can be filled with a matrix as disclosed herein. In these aspects, the process of forming the drilling tool can thereafter correspond to the same process followed to form the drilling tools having button elements. In additional optional aspects, it is contemplated that the process of forming the drilling tool can be a two-stage process, with the first stage including formation of the projections and the second stage including formation of the remainder of the tool. In these aspects, when the mold assembly 70 is used, the first stage can comprise delivering a matrix comprising abrasive material as disclosed herein to the openings 74 of the face mold element 72. In the second stage, the remainder of the drilling tool can be formed according to the same general process disclosed herein with respect to the formation of drilling tools having button elements. Optionally, if a two-stage process is used, it is contemplated that the face mold element 72 can be modified to define the shape of only the projections, whereas the face mold element used to form drilling tools having button elements (in a one-stage process) can optionally define features of the body of the drilling tool.

[0056] Optionally, in exemplary aspects, when the infiltrated body serves as an infiltrated crown, it is contemplated that the method of forming the wear-resistant drilling tool can comprise mechanically attaching the infiltrated body to (optionally, threading the infiltrated body onto or into) a shank, such as, for example and without limitation, a steel shank having a threaded distal end as further disclosed herein.

[0057] Optionally, in still further exemplary aspects, it is contemplated that the infiltrated body can include both button elements 50 and projections 60 as disclosed herein. In these aspects, during formation of the drilling tool, selected openings 74 of the face mold element 72 can receive button elements 50 while other openings of the face mold element can be filled with a matrix as disclosed herein.

Alternative Methods of Forming Drilling Tool Projections

[0058] In further optional aspects, instead of a button element or a consistent matrix composition forming projections from a drilling tool, it is contemplated that projections can be formed using a relatively small button element (e.g., a carbide button element) that is surrounded on its perimeter by a thin matrix layer comprising abrasive material (e.g., diamond particles) as needed to provide the projection with a desired shape (for example, corresponding to the shapes of the openings 74 in the face mold element 72). During drilling, it is contemplated that the button element can be configured to receive shock loading while the matrix layer comprising the abrasive particles can provide wear resistance.

[0059] In still further optional aspects, it is contemplated that only a portion of the body of the drilling tool can be formed using a casting process. In these aspects, it is contemplated that oversized button pockets can be formed in (e.g., drilled into) a conventional body blank (e.g., a steel body blank). It is further contemplated that the steel body blank can serve as a mold for at least a portion of the crown of the drilling tool. For example, it is contemplated that cutting elements (e.g., button elements, diamond cutters, combination carbide and diamond layer cutters) can be positioned within the oversized button pockets defined in the body blank. Following positioning of the button elements within the oversized button pockets, a matrix material and a binder material (infiltrant) as disclosed herein can be delivered to the area in between the button elements and surrounding portions of the body blank. After delivery of the matrix material and the binder material, the body blank and material within the oversized button pockets can be positioned within a furnace (e.g., an induction furnace) as disclosed herein until the button elements are secured into place. In use, it is contemplated that this process can reduce the cost of drilling tools by reducing the amount of matrix powders and binders required to form the tools. Instead, the drilling tools would have a hybrid crown composition of steel, matrix, binder, and cutting elements. It is further contemplated that this process can reduce the tolerances conventionally required when machining holes in a steel body blank that are complementary to the diameters of cutting elements in a brazing process. It is still further contemplated that these methods can achieve the desired chemical bonding, reduction in button inventory, and perfect fit of button elements while also further reducing the cost of the drilling tool.

Exemplary Configurations

[0060] In exemplary aspects, the drill bits disclosed herein can be full-face bits. In these aspects, it is contemplated that the full face drill bits disclosed herein can be plug and/or non- coring bits. In still further exemplary aspects, it is contemplated that the drill bits disclosed herein can be concave-faced drill bits. In still further exemplary aspects, it is contemplated that the drill bits disclosed herein can be non-concave faced drill bits.

[0061] It is further contemplated that the interior space 25 of the disclosed drilling tools can be configured to receive water or other drilling fluid during use of the drill bit 10. In one aspect, the water or other drilling fluid can be supplied to the interior space 25 at a desired pressure.

[0062] In exemplary aspects, it is contemplated that the plurality of bores 36 can be configured to direct water (or other drilling fluid) directly (or substantially directly) to the distal (cutting) face 18 from the interior space 25. It is further contemplated that the direct supply of pressurized water (or other drilling fluid) to the cutting face 18 can increase flow velocity across the cutting face, thereby permitting more rapid removal of cuttings and significantly increasing the convective cooling of the cutting face. It is further contemplated that the plurality of bores 36 can reduce the contact area of the cutting face 18 relative to conventional drill bits, thereby improving the penetration rate of the drill bit 10. It is still further contemplated that the plurality of bores 36 can permit novel distribution of water (or other drilling fluid) relative to the cutting face 18, thereby improving the wear resistance of the drill bit 10. It is still further contemplated that the plurality of bores 36 can provide flexibility in the distribution of water (or other drilling fluid) such that the center port of conventional drill bits is unnecessary (and can be eliminated from the drill bit). Optionally, in some aspects, it is contemplated that the cutting face 18 can have a convex profile. In other aspects, it is contemplated that the cutting face 18 can optionally have a concave profile.

[0063] In exemplary aspects, the plurality of bores 36 can optionally be equally (or substantially equally) distributed about the cutting face 18. Optionally, in some aspects, the plurality of bores 36 can be randomly spaced from a center point of the drill bit 10. In other aspects, the plurality of bores can optionally be uniformly (or substantially uniformly) spaced from the center point of the drill bit 10. In these aspects, it is contemplated that at least two concentric rows of bores can be provided, with the bores in each respective row being uniformly (or substantially uniformly) spaced from the center point of the drill bit 10. More generally, it is contemplated that the plurality of bores 36 can be provided in any selected configuration. It is further contemplated that the plurality of bores 36 can be distributed so as to optimize the wear characteristics of the drill bit 10 for a particular application.

[0064] It is contemplated that the each bore 36 of the plurality of bores can be provided in a selected shape. In exemplary aspects, the plurality of bores 36 can have a cylindrical shape (with a circular cross-sectional profile) or a substantially cylindrical shape (with a substantially circular cross-sectional profile). However, it is contemplated that the plurality of bores 36 can have any shape, including, for example and without limitation, a conical or substantially conical (tapered) shape (with a circular or substantially circular cross-sectional profile), a shape having a rectangular or substantially rectangular cross-sectional profile, a shape having a square or substantially square cross-sectional profile, an S-shape, and the like.

[0065] In exemplary aspects, it is contemplated that the full face crown can have an outer diameter that is greater than an outer diameter of the shank 20 such that the full face crown projects radially outwardly relative to the shank. Optionally, in exemplary aspects, the plurality of channels 38 can be equally or substantially equally circumferentially spaced about the outer surface 34 of the full face crown 30. In one aspect, it is contemplated that the plurality of channels 38 can optionally be equally or substantially equally sized.

[0066] Optionally, in further exemplary aspects, it is contemplated that an inner surface of the shank 20 can define at least one flute (or extending parallel or substantially parallel to the longitudinal axis 15 of the bit 10). In these aspects, each flute of the at least one flute can optionally correspond to a rounded grooves extending radially from the inner surface of the shank 20 toward an outer surface of the shank. It is contemplated that the at least one flute can optionally be positioned in fluid communication with at least one bore 36 of the full face crown 30.

[0067] Exemplary drilling tool configurations are depicted in Figures 5 and 7A-7B. As shown in Figure 5, it is contemplated that the plurality of button elements or projections of the drilling tool can comprise face button elements/projections 50a positioned proximate a center portion of the cutting face and gauge button elements/projections 50b that are positioned radially outwardly from the face button elements/projections.

[0068] Optionally, in exemplary aspects, and as shown in Figure 5, the full face crown 30 can comprise one or more axial slots (chipways) 39 that are defined in the side portions of the full face crown and configured to permit delivery of cuttings from the cutting face 18 to the annulus between the outer diameter of the drill bit and the drill hole. In these aspects, each chipway 39 can be positioned in communication with the cutting face 18 and extend axially along a portion of the side of the full face crown 30.

[0069] Optionally, as shown in Figures 7A-7B, it is contemplated that an outer surface of the shank 20 can define a plurality of axial ribs 40 that project radially outwardly from adjoining portions of the outer surface of the shank. It is further contemplated that outer surface of the shank 20 can define cutting edges 42 and/or other reverse/retraction cutting features, such as those disclosed in U.S. Patent Application Publication No. 2014/0367171, filed September 24, 2013, which is incorporated herein by reference in its entirety.

[0070] In exemplary aspects, and with reference to Figures 7A-7B, it is contemplated that the disclosed cast drilling tools can provide complete geometric freedom with respect to the shape and/or placement of chipways 39, ribs 40, cutting edges 42 and other reverse/retraction cutting features, which are typically very costly because they are milled into oversized steel blanks. Optionally, it is further contemplated that manufacturing processes used to produce the disclosed cast drilling tools can permit addition of anti-wear or cutting performance materials to the reverse/retraction cutting features. For example, it is contemplated that tungsten carbide, diamond, and the like can be selectively added to the specific locations of these features as part of the casting process.

Exemplary Materials

[0071] The binder materials disclosed herein can include, for example, cobalt-based, iron- based, nickel-based, silver-based, iron and nickel-based, cobalt and nickel-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, molybdenum based, and titanium-based alloys. The alloying elements can include, but are not limited to, one or more of the following elements—manganese (Mn), nickel (Ni), silver (Ag), tin (Sn), zinc (Zn), silicon (Si), molybdenum (Mo), tungsten (W), boron (B) and phosphorous (P). The binder material can also be selected from commercially pure elements such as cobalt, aluminum, silver, copper, magnesium, titanium, iron, and nickel. By way of example and not limitation, the binder composite material can 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.

[0072] The abrasive particles of the matrix compositions disclosed herein can comprise diamond, synthetic diamond, metal or semi-metal carbides, nitrides, oxides, or borides. For example, and without limitation, the abrasive particles can comprise diamond or ceramic materials such as carbides, nitrides, oxides, and borides (including boron carbide (B₄C)) and combinations of them, such as carbonitrides. More specifically, the abrasive particles can comprise carbides and borides made from elements such as W, Ti, Mo, Nb, V, Hf, Ta, Cr, Zr, Al, and Si. By way of example and without limitation, materials that may be used to form abrasive particles include tungsten carbide (WC, W₂C), titanium carbide (TiC), tantalum carbide (TaC), titanium diboride (TiB₂), chromium carbides, titanium nitride (TiN), vanadium carbide (VC), aluminium oxide (A1₂0₃), aluminium nitride (A1N), boron nitride (BN), and silicon carbide (SiC). Furthermore, combinations of different abrasive particles may be used to tailor the physical properties and characteristics of the matrix material. The abrasive particles may be formed using techniques known to those of ordinary skill in the art. Most suitable materials for abrasive particles are commercially available and the formation of the remainder is within the ability of one of ordinary skill in the art.

[0073] In one example, and not meant to be limiting, the hard particulate material of the matrix can comprise a tungsten-based alloy. In a further example, and not meant to be limiting, the hard particulate material of the matrix can comprise a tungsten carbide-based alloy. However, it is contemplate that other conventional hard particulate materials can be used.

[0074] In exemplary aspects, it is contemplated that the drilling tools disclosed herein can be formed using the matrix and binder compositions disclosed in U.S. Patent Application No.

14/710,997, filed May 13, 2015, which is incorporated herein by reference in its entirety.

Exemplary Aspects

[0075] In view of the described devices, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the "particular" aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0076] Aspect 1 : A wear-resistant drilling tool, comprising: an infiltrated body comprising a matrix and a binder, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material, wherein the binder secures the hard particulate material and the abrasive particles together, and wherein the infiltrated body defines a distal face; and a plurality of button elements, wherein the infiltrated matrix is formed around the plurality of button elements to secure the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the infiltrated body.

[0077] Aspect 2: The wear-resistant drilling tool of aspect 1, wherein the binder of the infiltrated body is chemically bonded to the plurality of button elements.

[0078] Aspect 3 : The wear-resistant drilling tool of aspect 2, wherein each button element of the plurality of button elements has a body portion that is chemically bonded to the binder of the infiltrated body and a distal end portion that projects relative to the distal face of the infiltrated body, and wherein the distal end portion of at least one button element has a variable diameter that decreases moving away from the body portion.

[0079] Aspect 4: The wear-resistant drilling tool of aspect 3, wherein the distal end portion of at least one button element has a substantially hemispherical shape.

[0080] Aspect 5: The wear-resistant drilling tool of aspect 3, wherein the distal end portion of at least one button element has a substantially conical shape.

[0081] Aspect 6: The wear-resistant drilling tool of any one of aspects 1-3, wherein the plurality of button elements comprise tungsten carbide.

[0082] Aspect 7: The wear-resistant drilling tool of any one of aspects 1-3, wherein the plurality of abrasive particles comprises a plurality of diamond particles.

[0083] Aspect 8: The wear-resistant drilling tool of any one of the preceding aspects, wherein the wear-resistant drilling tool comprises a drill bit. [0084] Aspect 9: The wear-resistant drilling tool of aspect 8, wherein the drill bit is a full- face drill bit, the drill bit having a longitudinal axis and comprising: a shank; a full face crown having a cutting face and an outer surface, the full face crown and the shank cooperating to define an interior space about the longitudinal axis, wherein the full face crown defines a plurality of bores extending from the cutting face to the interior space, and wherein the full face crown completely circumferentially encloses the interior space.

[0085] Aspect 10: The wear-resistant drilling tool of aspect 9, wherein the full face crown does not comprise a waterway extending radially between the outer surface of the full face crown and the interior space.

[0086] Aspect 11 : The wear-resistant drilling tool of aspect 9 or aspect 10, wherein the full face crown comprises at least one channel that extends radially inwardly toward the longitudinal axis of the drill bit.

[0087] Aspect 12: The wear-resistant drilling tool of aspect 8, wherein the infiltrated body is an infiltrated crown that is mechanically attached to a shank to form the drill bit.

[0088] Aspect 13 : A method of forming a wear-resistant drilling tool, the method

comprising: preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material; shaping the matrix into a desired shape around a plurality of button elements; and infiltrating the matrix with a binder material, wherein the binder material secures the hard particulate material and the abrasive particles of the matrix together, wherein the infiltrated matrix defines a distal face of the drilling tool, and wherein the infiltrated matrix secures the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the drilling tool.

[0089] Aspect 14: The method of aspect 13, wherein shaping the matrix comprises placing the matrix within a mold.

[0090] Aspect 15: The method of aspect 13 or aspect 14, wherein the wear-resistant drilling tool is a drill bit, and wherein the method further comprises mechanically attaching the infiltrated matrix to a shank to form the drill bit.

[0091] Aspect 16: An infiltrated wear-resistant drilling tool, comprising: an infiltrated body comprising a matrix and a binder, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material, wherein the binder secures the hard particulate material and the abrasive particles together, and wherein the infiltrated body defines a distal face and a plurality of projections that project from the distal face.

[0092] Aspect 17: The wear-resistant drilling tool of aspect 16, wherein at least one projection of the plurality of projections has a variable diameter that decreases moving away from the distal face of the infiltrated body.

[0093] Aspect 18: The wear-resistant drilling tool of aspect 16 or aspect 17, wherein the at least one projection of the plurality of projections has a substantially hemispherical shape.

[0094] Aspect 19: The wear-resistant drilling tool of aspect 16 or aspect 17, wherein the at least one projection of the plurality of projections has a substantially conical shape.

[0095] Aspect 20: The wear-resistant drilling tool of aspect 16 or aspect 17, wherein the plurality of abrasive particles of the matrix comprises a plurality of diamond particles.

[0096] Aspect 21 : The wear-resistant drilling tool of aspect 16 or aspect 17, wherein the plurality of abrasive particles of the matrix comprise tungsten carbide.

[0097] Aspect 22: The wear-resistant drilling tool of aspect 21, wherein the matrix has a concentration of tungsten carbide that decreases moving proximally away from the distal face of the infiltrated body.

[0098] Aspect 23 : The wear-resistant drilling tool of any one of aspects 16-22, wherein the wear-resistant drilling tool comprises a drill bit.

[0099] Aspect 24: The wear-resistant drilling tool of aspect 23, wherein the drill bit is a full- face drill bit, the drill bit having a longitudinal axis and comprising: a shank; a full face crown having a cutting face and an outer surface, the cutting face being defined by the distal face of the infiltrated body, the full face crown and the shank cooperating to define an interior space about the longitudinal axis, wherein the full face crown defines a plurality of bores extending from the cutting face to the interior space, and wherein the full face crown completely circumferentially encloses the interior space. [00100] Aspect 25: The wear-resistant drilling tool of aspect 24, wherein the full face crown does not comprise a waterway extending radially between the outer surface of the full face crown and the interior space.

[00101] Aspect 26: The wear-resistant drilling tool of aspect 24 or aspect 25, wherein the full face crown comprises at least one channel that extends radially inwardly toward the longitudinal axis of the drill bit.

[00102] Aspect 27: The wear-resistant drilling tool of aspect 23, wherein the infiltrated body is an infiltrated crown that is mechanically attached to a shank to form the drill bit.

[00103] Aspect 28: A method of forming a wear-resistant drilling tool, the method

comprising: preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material; shaping the matrix into a desired shape; and infiltrating the matrix with a binder material, wherein the binder material secures the hard particulate material and the abrasive particles of the matrix together, wherein the infiltrated matrix defines a distal face and a plurality of projections that project from the distal face.

[00104] Aspect 29: The method of aspect 28, wherein shaping the matrix comprises placing the matrix within a mold.

[00105] Aspect 30: The method of aspect 28 or aspect 29, wherein the wear-resistant drilling tool is a drill bit, and wherein the method further comprises mechanically attaching the infiltrated matrix to a shank to form the drill bit.

[00106] Aspect 31 : A wear-resistant drilling tool, comprising: a body blank having a distal end defining a plurality of pockets; a plurality of button elements, each button element at least partially received within a respective pocket of the body blank such that a portion of the button element projects relative to the distal end of the body blank; a matrix positioned within the plurality of pockets of the body blank and surrounding the button element within each body blank, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material; and a binder positioned within the plurality of pockets of the body blank and surrounding the button element within each body blank, wherein the binder secures the hard particulate material and the abrasive particles of the matrix together and secures the button element within each pocket of the body blank to surrounding portions of the body blank.

[00107] All publications and patent applications mentioned in the specification are indicative of the level of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[00108] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

What is claimed is:

1. A wear-resistant drilling tool, comprising: an infiltrated body comprising a matrix and a binder, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material, wherein the binder secures the hard particulate material and the abrasive particles together, and wherein the infiltrated body defines a distal face; and a plurality of button elements, wherein the infiltrated matrix is formed around the plurality of button elements to secure the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the infiltrated body.

2. The wear-resistant drilling tool of claim 1, wherein the binder of the infiltrated body is chemically bonded to the plurality of button elements.

3. The wear-resistant drilling tool of claim 2, wherein each button element of the plurality of button elements has a body portion that is chemically bonded to the binder of the infiltrated body and a distal end portion that projects relative to the distal face of the infiltrated body, and wherein the distal end portion of at least one button element has a variable diameter that decreases moving away from the body portion.

4. The wear-resistant drilling tool of claim 3, wherein the distal end portion of at least one button element has a substantially hemispherical shape.

5. The wear-resistant drilling tool of claim 3, wherein the distal end portion of at least one button element has a substantially conical shape.

6. The wear-resistant drilling tool of claim 3, wherein the plurality of button elements comprise tungsten carbide.

7. The wear-resistant drilling tool of claim 3, wherein the plurality of abrasive particles comprises a plurality of diamond particles.

8. The wear-resistant drilling tool of claim 1, wherein the wear-resistant drilling tool comprises a drill bit.

9. The wear-resistant drilling tool of claim 8, wherein the drill bit is a full-face drill bit, the drill bit having a longitudinal axis and comprising: a shank; a full face crown having a cutting face and an outer surface, the full face crown and the shank cooperating to define an interior space about the longitudinal axis, wherein the full face crown defines a plurality of bores extending from the cutting face to the interior space, and wherein the full face crown completely circumferentially encloses the interior space.

10. The wear-resistant drilling tool of claim 9, wherein the full face crown does not comprise a waterway extending radially between the outer surface of the full face crown and the interior space.

11. The wear-resistant drilling tool of claim 10, wherein the full face crown comprises at least one channel that extends radially inwardly toward the longitudinal axis of the drill bit.

12. The wear-resistant drilling tool of claim 8, wherein the infiltrated body is an infiltrated crown that is mechanically attached to a shank to form the drill bit.

13. A method of forming a wear-resistant drilling tool, the method comprising: preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material; shaping the matrix into a desired shape around a plurality of button elements; and infiltrating the matrix with a binder material, wherein the binder material secures the hard particulate material and the abrasive particles of the matrix together, wherein the infiltrated matrix defines a distal face of the drilling tool, and wherein the infiltrated matrix secures the plurality of button elements in a desired position in which a portion of each button element of the plurality of button elements projects relative to the distal face of the drilling tool.

14. The method of claim 13, wherein shaping the matrix comprises placing the matrix within a mold.

15. The method of claim 13, wherein the wear-resistant drilling tool is a drill bit, and wherein the method further comprises mechanically attaching the infiltrated matrix to a shank to form the drill bit.

16. An infiltrated wear-resistant drilling tool, comprising: an infiltrated body comprising a matrix and a binder, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material, wherein the binder secures the hard particulate material and the abrasive particles together, and wherein the infiltrated body defines a distal face and a plurality of projections that project from the distal face.

17. The wear-resistant drilling tool of claim 16, wherein at least one projection of the plurality of projections has a variable diameter that decreases moving away from the distal face of the infiltrated body.

18. The wear-resistant drilling tool of claim 17, wherein the at least one projection of the plurality of projections has a substantially hemispherical shape.

19. The wear-resistant drilling tool of claim 16, wherein the at least one projection of the plurality of projections has a substantially conical shape.

20. The wear-resistant drilling tool of claim 17, wherein the plurality of abrasive particles of the matrix comprises a plurality of diamond particles.

21. The wear-resistant drilling tool of claim 17, wherein the plurality of abrasive particles of the matrix comprise tungsten carbide.

22. The wear-resistant drilling tool of claim 21, wherein the matrix has a concentration of tungsten carbide that decreases moving proximally away from the distal face of the infiltrated body.

23. The wear-resistant drilling tool of claim 16, wherein the wear-resistant drilling tool comprises a drill bit.

24. The wear-resistant drilling tool of claim 23, wherein the drill bit is a full-face drill bit, the drill bit having a longitudinal axis and comprising: a shank; a full face crown having a cutting face and an outer surface, the cutting face being defined by the distal face of the infiltrated body, the full face crown and the shank cooperating to define an interior space about the longitudinal axis, wherein the full face crown defines a plurality of bores extending from the cutting face to the interior space, and wherein the full face crown completely circumferentially encloses the interior space.

25. The wear-resistant drilling tool of claim 24, wherein the full face crown does not comprise a waterway extending radially between the outer surface of the full face crown and the interior space.

26. The wear-resistant drilling tool of claim 25, wherein the full face crown comprises at least one channel that extends radially inwardly toward the longitudinal axis of the drill bit.

27. The wear-resistant drilling tool of claim 23, wherein the infiltrated body is an infiltrated crown that is mechanically attached to a shank to form the drill bit.

28. A method of forming a wear-resistant drilling tool, the method comprising: preparing a matrix by dispersing a plurality of abrasive particles throughout a hard particulate material; shaping the matrix into a desired shape; and infiltrating the matrix with a binder material, wherein the binder material secures the hard particulate material and the abrasive particles of the matrix together, wherein the infiltrated matrix defines a distal face and a plurality of projections that project from the distal face.

29. The method of claim 28, wherein shaping the matrix comprises placing the matrix within a mold.

30. The method of claim 28, wherein the wear-resistant drilling tool is a drill bit, and wherein the method further comprises mechanically attaching the infiltrated matrix to a shank to form the drill bit.

31. A wear-resistant drilling tool, comprising: a body blank having a distal end defining a plurality of pockets; a plurality of button elements, each button element at least partially received within a respective pocket of the body blank such that a portion of the button element projects relative to the distal end of the body blank; a matrix positioned within the plurality of pockets of the body blank and surrounding the button element within each body blank, the matrix comprising a hard particulate material and a plurality of abrasive particles dispersed throughout the hard particulate material; and a binder positioned within the plurality of pockets of the body blank and surrounding the button element within each body blank, wherein the binder secures the hard particulate material and the abrasive particles of the matrix together and secures the button element within each pocket of the body blank to surrounding portions of the body blank.