WO2008042329B1 - Particle matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials - Google Patents

Particle matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials

Info

Publication number
WO2008042329B1
WO2008042329B1 PCT/US2007/021071 US2007021071W WO2008042329B1 WO 2008042329 B1 WO2008042329 B1 WO 2008042329B1 US 2007021071 W US2007021071 W US 2007021071W WO 2008042329 B1 WO2008042329 B1 WO 2008042329B1
Authority
WO
WIPO (PCT)
Prior art keywords
bit body
tungsten carbide
exterior surface
bit
resistant material
Prior art date
Application number
PCT/US2007/021071
Other languages
French (fr)
Other versions
WO2008042329A1 (en
Inventor
James L Overstreet
Original Assignee
Baker Hughes Inc
James L Overstreet
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 Baker Hughes Inc, James L Overstreet filed Critical Baker Hughes Inc
Priority to CA2667079A priority Critical patent/CA2667079C/en
Priority to EP07839096A priority patent/EP2084305A1/en
Publication of WO2008042329A1 publication Critical patent/WO2008042329A1/en
Publication of WO2008042329B1 publication Critical patent/WO2008042329B1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
    • C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Abstract

A rotary drill bit includes a bit body substantially formed of a particle-matrix composite material having an exterior surface and an abrasive wear-resistant material disposed on at least a portion of the exterior surface of the bit body. Methods for applying an abrasive wear-resistant material to a surface of a drill bit are also provided.

Claims

AMENDED CLAIMS received by the International Bureau on 07 April 2008
1. A rotary drill bit for drilling at least one subterranean formation, the rotary drill bit comprising: a bit body substantially formed of a non-infiltrated particle-matrix composite material and having an exterior surface; and an abrasive wear-resistant material disposed on at least a portion of the exterior surface of the bit body.
2. The rotary drill bit of claim I5 wherein the abrasive wear-resistant material disposed on the at least a portion of the exterior surface of the bit body comprises pre- application materials in the following ratios: a matrix material, the matrix material comprising between about 2 parts and about 5 parts of 10 parts by weight of the pre-application materials, the matrix material comprising at least 75% nickel by weight and having a melting point of less than about 14600C; a plurality of -10 ASTM mesh sintered tungsten carbide pellets substantially randomly dispersed throughout the matrix material, the plurality of sintered tungsten carbide pellets comprising between about 3 parts and about 5.5 parts by weight of the pre- application materials, each sintered tungsten carbide pellet comprising a plurality of tungsten carbide particles bonded together with a binder alloy, the binder alloy having a melting point greater than about 12000C; and a plurality of -18 ASTM mesh cast tungsten carbide granules substantially randomly dispersed throughout the matrix material, the plurality of cast tungsten carbide granules comprising less than about 3.5 parts by weight of the pre-application materials; and the pre-application materials are selectively suitable for disposition on the exterior surface of the bit body at a temperature above the melting point of the matrix material and below the melting point of the cast tungsten carbide granules and the sintered tungsten carbide pellets.
40
3. The rotary drill bit of claim 2, wherein the plurality of -10 ASTM mesh sintered tungsten carbide pellets comprises a plurality of -60/+80 ASTM mesh sintered tungsten carbide pellets, and wherein the plurality of -18 ASTM mesh cast tungsten carbide granules comprises a plurality of -100/+270 ASTM mesh cast tungsten carbide granules.
4. The rotary drill bit of claim 2, wherein the plurality of -10 ASTM mesh sintered tungsten carbide pellets comprises a plurality of -60/+80 ASTM mesh sintered tungsten carbide pellets and a plurality of -120/+270 ASTM mesh sintered tungsten carbide pellets, the plurality of -60/+80 ASTM mesh sintered tungsten carbide pellets comprising between about 30% and about 35% by weight of the abrasive wear-resistant material, the plurality of -120/+270 ASTM mesh sintered tungsten carbide pellets comprising between about 10% and about 20% by weight of the abrasive wear-resistant material.
5. The rotary drill bit according to anyone of claims 1 through 4, further comprising: a shank attached directly to the bit body, the shank comprising a portion configured to attach the shank to a drill string, and wherein the bit body substantially formed of the non-infiltrated particle-matrix composite material comprises a plurality of hard particles randomly dispersed throughout a matrix material, the hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt- and nickel-based alloys, iron- and nickel-based alloys, iron- and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys.
41
6. The rotary drill bit of claim 5, wherein the wear-resistant material is disposed in at least one recess extending into the bit body from the exterior surface, an exposed surfaces of the wear-resistant material being substantially level with the exterior surface of the bit body adjacent the wear-resistant material, taken in a direction generally perpendicular to the exterior surface of the bit body adjacent the wear-resistant material.
7. The rotary drill bit of claim 6, wherein the bit body further comprises a plurality ofblad.es, and wherein the at least one recess extends into a formation-engaging surface of the blade and extends along an edge defined by the intersection between two surfaces comprising a portion of the exterior surface of the bit body.
8. The rotary drill bit according to claim 6 or claim 7, wherein the bit body is configured to carry a plurality of cutting elements, and the material composition of the particle matrix composite material varies within the bit body.
9. The rotary drill bit of claim 8, wherein the material composition of the particle matrix composite material varies substantially continuously throughout the bit body.
10. The rotary drill bit according to claim 1 or claim 2, further comprising: at least one cutting element secured to the bit body along an interface; and a brazing alloy disposed between the bit body and the at least one cutting element at the interface, the brazing alloy securing the at least one cutting element to the bit body, at least a continuous portion of the wear-resistant material being bonded to an exterior surface of the bit body and a surface of the at least one cutting element and extending over the interface between the bit body and the at least one cutting element and covering at least a portion of the brazing alloy.
11. The rotary drill bit of claim 10, wherein the bit body comprises a pocket in the exterior surface of the bit body, at least a portion of the at least one cutting element being disposed within the pocket, the interface extending along adjacent surfaces of the bit
42 body and the at least one cutting element, and wherein the bit body further comprises at least one recess formed in the exterior surface of the bit body adjacent the interface, at least a portion of the abrasive wear-resistant material being disposed within the at least one recess.
12. The rotary drill bit according to claim 10 or claim 11, wherein the at least one cutting element comprises a cutting element body and a polycrystalline diamond compact table secured to an end of the cutting element body.
13. A method for applying an abrasive wear-resistant material to a surface of a drill bit, the method comprising: providing a drill bit comprising a bit body formed of a non-infiltrated particle-matrix composite material having an exterior surface; mixing a plurality of -10 ASTM mesh sintered tungsten carbide pellets and a plurality of -18 ASTM mesh cast tungsten carbide granules in a matrix material to provide a pre-application abrasive wear-resistant material, the matrix material comprising at least 75% nickel by weight, the matrix material having a melting point of less than about 14550C3 each sintered tungsten carbide pellet comprising a plurality of tungsten carbide particles bonded together with a binder alloy, the binder alloy having a melting point greater than about 12000C, the matrix material comprising between about 20% and about 60% by weight of the pre-application abrasive wear-resistant material, the plurality of sintered tungsten carbide pellets comprising between about 30% and about 55% by weight of the pre-application abrasive wear-resistant material, the plurality of cast tungsten carbide granules comprising less than about 35% by weight of the pre-application abrasive wear-resistant material; heating the matrix material, comprising heating at least a portion of the pre-application abrasive wear-resistant material to a temperature above the melting point of the matrix; applying the molten matrix material, at least some of the sintered tungsten carbide pellets, and at least some of the cast tungsten carbide granules to at least a portion of the exterior surface of the bit body; and solidifying the molten matrix material.
14. The method of claim 13, wherein heating the matrix material comprises one of heating the matrix material with an electrical arc, heating the matrix material with a plasma-transferred arc and burning acetylene in substantially pure oxygen to heat the matrix material.
15. The method of claim 13, wherein providing a drill bit formed of a non- infiltrated particle-matrix composite material further comprises forming the bit body having the non-infiltrated particle-matrix composite material comprising: providing a powder mixture comprising: a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr; and a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt- and nickel-based alloys, iron- and nickel-based alloys, iron- and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys; and a binder material; pressing the powder mixture with substantially isostatic pressure to form a green body substantially composed of a particle matrix composite material; and sintering the green body to provide a fully sintered bit body substantially composed of a particle matrix composite material having a desired final density.
16. The method of claim 15, wherein sintering the green body to provide a fully sintered bit body comprises: partially sintering the green body to provide a brown body;
44 machining at least one feature in a surface of the brown body; and sintering the brown body to provide the fully sintered bit body.
17. The method of claim 15, wherein sintering the green body to provide the fully sintered bit body comprises linearly shrinking the green body by between about 10% and about 20%.
18. The method of claim 15 , further comprising: providing a shank configured for attachment to a drill string; attaching the shank directly to the fully sintered bit body by at least one of welding, brazing, and soldering an interface between the fully sintered bit body and the shank; and attaching a plurality of cutting elements to a surface of the fully sintered bit body.
19. The method of claim 13, wherein providing a drill bit formed of a non- infiltrated particle-matrix composite material includes providing a drill bit comprising: a bit body having an exterior surface and a pocket therein, the pocket being configured to receive a portion of a cutting element, the method further comprising: positioning a portion of a cutting element within the pocket in the exterior surface of the bit body; melting a brazing alloy; applying molten brazing alloy to an interface between the cutting element and the exterior surface of the bit body; solidifying the molten brazing alloy; and applying the abrasive wear-resistant material to the exterior surface of the bit body, at least a continuous portion of the abrasive wear-resistant material being bonded to a surface of the cutting element and a portion of the exterior surface of the bit body and extending over an interface between the cutting element and the exterior surface of the bit body and covering the brazing alloy.
45
20. The method of claim 19, further comprising forming at least one recess in the exterior surface of the bit body adjacent the pocket that is configured to receive the cutting element, and wherein applying the abrasive wear-resistant material further comprises applying the abrasive wear-resistant material to the exterior surface of the bit body within the at least one recess.
21. The method of claim 13, further comprising providing at least one recess extending into an exterior surface of the bit body of a drill bit; applying the pre-application abrasive wear-resistant material to the at least one recess; heating the pre-application abrasive wear-resistant material to melt the matrix material; and causing a surface of the molten matrix material to be substantially level with the exterior surface of the bit body adjacent the wear-resistant material in a direction taken generally perpendicular to the exterior surface of the bit body adjacent the wear-resistant material.
46
PCT/US2007/021071 2006-09-29 2007-09-28 Particle matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials WO2008042329A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA2667079A CA2667079C (en) 2006-09-29 2007-09-28 Particle-matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials
EP07839096A EP2084305A1 (en) 2006-09-29 2007-09-28 Particle matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US84815406P 2006-09-29 2006-09-29
US60/848,154 2006-09-29
US11/823,800 US8002052B2 (en) 2005-09-09 2007-06-27 Particle-matrix composite drill bits with hardfacing
US11/823,800 2007-06-27

Publications (2)

Publication Number Publication Date
WO2008042329A1 WO2008042329A1 (en) 2008-04-10
WO2008042329B1 true WO2008042329B1 (en) 2008-06-12

Family

ID=38955201

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2007/021071 WO2008042329A1 (en) 2006-09-29 2007-09-28 Particle matrix composite drill bits with hardfacing and methods of manufacturing and repairing such drill bits using hardfacing materials

Country Status (5)

Country Link
US (1) US8002052B2 (en)
EP (1) EP2084305A1 (en)
CA (1) CA2667079C (en)
RU (1) RU2457281C2 (en)
WO (1) WO2008042329A1 (en)

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US20080029310A1 (en) 2008-02-07
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US8002052B2 (en) 2011-08-23

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