US20150330154A1 - Fully infiltrated rotary drill bit - Google Patents
Fully infiltrated rotary drill bit Download PDFInfo
- Publication number
- US20150330154A1 US20150330154A1 US14/710,997 US201514710997A US2015330154A1 US 20150330154 A1 US20150330154 A1 US 20150330154A1 US 201514710997 A US201514710997 A US 201514710997A US 2015330154 A1 US2015330154 A1 US 2015330154A1
- Authority
- US
- United States
- Prior art keywords
- particle
- drill bit
- rotary drill
- matrix
- binder material
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
- 239000000463 material Substances 0.000 claims abstract description 89
- 239000011159 matrix material Substances 0.000 claims abstract description 80
- 239000011230 binding agent Substances 0.000 claims abstract description 49
- 239000002245 particle Substances 0.000 claims abstract description 47
- 239000002131 composite material Substances 0.000 claims abstract description 46
- 239000000203 mixture Substances 0.000 claims abstract description 38
- 238000002844 melting Methods 0.000 claims abstract description 24
- 230000008018 melting Effects 0.000 claims abstract description 24
- 229910045601 alloy Inorganic materials 0.000 claims description 33
- 239000000956 alloy Substances 0.000 claims description 33
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 17
- 229910052759 nickel Inorganic materials 0.000 claims description 15
- 238000005520 cutting process Methods 0.000 claims description 13
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 239000010949 copper Substances 0.000 claims description 10
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 9
- 229910052802 copper Inorganic materials 0.000 claims description 9
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 229910052721 tungsten Inorganic materials 0.000 claims description 8
- 229910017052 cobalt Inorganic materials 0.000 claims description 7
- 239000010941 cobalt Substances 0.000 claims description 7
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 7
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 239000010937 tungsten Substances 0.000 claims description 7
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 6
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 5
- 229910003460 diamond Inorganic materials 0.000 claims description 5
- 239000010432 diamond Substances 0.000 claims description 5
- 239000000696 magnetic material Substances 0.000 claims description 5
- 229910052719 titanium Inorganic materials 0.000 claims description 5
- 239000010936 titanium Substances 0.000 claims description 5
- 229910052725 zinc Inorganic materials 0.000 claims description 5
- 239000011701 zinc Substances 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- 150000001247 metal acetylides Chemical class 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052749 magnesium Inorganic materials 0.000 claims description 3
- 239000011777 magnesium Substances 0.000 claims description 3
- 150000002739 metals Chemical class 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- 150000004767 nitrides Chemical class 0.000 claims description 3
- 229910000531 Co alloy Inorganic materials 0.000 claims 2
- 229910000640 Fe alloy Inorganic materials 0.000 claims 1
- 229910000831 Steel Inorganic materials 0.000 description 9
- 238000000034 method Methods 0.000 description 9
- 239000010959 steel Substances 0.000 description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- 238000005553 drilling Methods 0.000 description 5
- 229910002804 graphite Inorganic materials 0.000 description 5
- 239000010439 graphite Substances 0.000 description 5
- 230000008595 infiltration Effects 0.000 description 5
- 238000001764 infiltration Methods 0.000 description 5
- 239000000843 powder Substances 0.000 description 4
- -1 tungsten carbides Chemical class 0.000 description 4
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- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 description 2
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 2
- 229910033181 TiB2 Inorganic materials 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910003468 tantalcarbide Inorganic materials 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- PIGFYZPCRLYGLF-UHFFFAOYSA-N Aluminum nitride Chemical compound [Al]#N PIGFYZPCRLYGLF-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 229910000760 Hardened steel Inorganic materials 0.000 description 1
- 229910000617 Mangalloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
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- 229910052796 boron Inorganic materials 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
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- 239000000919 ceramic Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
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- 238000001816 cooling Methods 0.000 description 1
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- 229910052735 hafnium Inorganic materials 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
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- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 230000000877 morphologic effect Effects 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
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- 229910052720 vanadium Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
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
- 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
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/42—Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/48—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of core type
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/62—Drill bits characterised by parts, e.g. cutting elements, which are detachable or adjustable
Definitions
- This invention relates to a rotary drill bit. More specifically, this invention relates to a fully infiltrated rotary drill bit.
- Rotary drill bits are commonly used for subterranean drilling of bore holes or wells. Many types of drills and associated methods have been employed for such drilling.
- a common type of drilling employs a rotary drill bit affixed to the end of a drill string.
- Rotary drill bits typically include a plurality of cutting elements secured to a face region of a bit body.
- the drill string includes tubular pipe and equipment segments that couple the drill bit located at the bottom of the borehole to other drilling equipment at the surface.
- a rotary table or top drive may be used for rotating the drill string and the drill bit within the borehole.
- the shank of the drill bit may be coupled directly to the drive shaft of a down-hole motor, which then may be used to rotate the drill bit.
- Rotary drill bits generally have either a disk shape or a substantially cylindrical shape, particularly on the cutting end that houses the cutting elements.
- the cutting elements each have a cutting surface that is generally made from a hard, super-abrasive material, such as polycrystalline diamond, often in the form of a substantially circular end surface of the element, and are often referred to as “polycrystalline diamond compact” (PDC) cutters.
- PDC polycrystalline diamond compact
- Many forms of such bits are possible; however, the cutting elements are often fabricated separately from the bit body and then fixed into pockets formed in its outer surface.
- the cutting elements may be fixed in any suitable manner, such as, for example, by use of a bonding material, including various adhesives or, more typically, various braze alloys.
- the bit body is secured to a hardened steel shank having an American Petroleum Institute (API) thread connection for attaching the drill bit to the drill string.
- API American Petroleum Institute
- the cutting elements and their cutting surfaces are placed in contact with the earth formation to be drilled. As the bit is rotated, the cutting elements progressively shear away the surface of the underlying formation to form the borehole.
- bit body of a rotary drill bit may be formed from steel; however, such bit bodies experience abrasive wear, the rate of which can vary significantly as a function of the drilling environment. In order to reduce the wear and extend their life, bit bodies have also been made from particle-matrix composite materials.
- Particle-matrix composite bit bodies have been fabricated in graphite molds with machined cavities. Additional fine features may be added to the cavity of the graphite mold by hand-held tools. Inserts or cores made from sand, clay or other materials may also be used to obtain the desired configuration of some features of the bit body. Where necessary, preform elements or displacements (which may be made from any suitable material, including ceramic components, graphite components, or resin-coated sand compact components) may be positioned within the mold and used to define various features, including internal passages, cutting element pockets, junk slots, and other external topographic or internal features of the bit body.
- the cavity of the graphite mold is filled with hard particulate carbide material (such as tungsten carbides, titanium carbides, tantalum carbides, etc.).
- hard particulate carbide material such as tungsten carbides, titanium carbides, tantalum carbides, etc.
- the preformed steel blank is then positioned in the mold at the appropriate location and orientation, which typically is at least partially submerged in the particulate carbide material within the mold.
- the mold then may be vibrated or the particles otherwise packed to increase the packing density of the carbide powder and produce the powder form.
- a matrix material such as a copper-based alloy, is melted and introduced to the carbide powder so as to cause infiltration of the powder form by the molten matrix material.
- the mold and bit body are allowed to cool to solidify the matrix material and bond the steel blank to the particle-matrix composite material forming a crown.
- the mold and any displacements are removed from the bit body. Destruction of the graphite mold typically is required to remove the bit body.
- Thread forms may be machined on an exposed surface of the steel blank to provide a threaded connection between the bit body and the steel shank.
- bit bodies that include particle-matrix composite materials offer significant advantages over all-steel bit bodies in terms of abrasion and erosion-resistance, the lower strength and toughness of such bit bodies limit their use in certain applications. Improvement of the particle-matrix composite to increase the toughness, strength or other properties would increase the applications where such bit bodies may be used.
- the invention relates to a rotary drill bit comprising a bit body that comprises at least one particle-matrix composite material and a binder material.
- each of the at least one particle-matrix composite material has a particle material composition, which also has a particle material melting temperature.
- the binder material has a binder material composition that differs from the particle material composition.
- the binder material composition has a binder material melting temperature that is lower than the particle material melting temperature.
- At least one of the particle-matrix material composition and the binder material composition can be comprised of a matrix material and a plurality of hard particles dispersed throughout the matrix materials.
- the binder material When formed, the binder material is infiltrated within and substantially encapsulates particle-matrix composite material to form a substantially uniform particle grain microstructure.
- the particle-matrix composite material is substantially non-melted in the formation process of the drill bit.
- FIG. 1 is a schematic partial cross-sectional view of an exemplary embodiment of a rotary drill bit disclosed herein.
- FIG. 2 is a schematic partial cross-sectional view of a second exemplary embodiment of a rotary drill bit disclosed herein.
- a particle-matrix composite material can include two or more such particle-matrix composite material unless the context indicates otherwise.
- 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.
- 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.
- [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.
- material composition means the chemical composition and microstructure of a material. In other words, materials having the same chemical composition but a different microstructure are considered to have different material compositions.
- 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, W 2 C, and combinations of WC and W 2 C.
- Tungsten carbide includes any morphological form of this material, for example, cast tungsten carbide, sintered tungsten carbide, monocrystalline tungsten carbide, and macrocrystalline tungsten carbide.
- FIG. 1 An exemplary embodiment of an earth-boring rotary drill bit 10 having a bit body 20 is illustrated in FIG. 1 .
- the bit body 20 has a distal cutting region 22 configured to engage a subterranean earth formation and a proximal treaded region 24 configured to be selectively coupled to a drill sting.
- the proximal treaded region defines an open internal cavity 26 extending along a longitudinal axis of the bit body.
- a helical thread 28 which is configured to matingly engage and attach to the drill string, can be formed on an interior wall surface of the open internal cavity.
- the bit body is fully infiltrated and, as such, will not be required to be conventionally secured to an underlying support shank.
- the bit body 20 comprises at least one particle-matrix composite material that is infiltrated by a binder material so that the at least one particle-matrix composite material is fully infiltrated by and is substantially encapsulated by the binder material to form a substantially uniform particle grain microstructure.
- each particle-matrix composite material has a particle material composition that has a particle material melting temperature.
- the binder material has a binder material composition that has a binder material melting temperature that is lower than the particle material melting temperature. Further, the particle material composition and the binder material composition are different material compositions.
- At least one of the particle-matrix material composition and the binder material composition is comprised of a matrix material and a plurality of hard particles dispersed throughout the matrix materials.
- the plurality of hard particles can be dispersed substantially randomly throughout the matrix material.
- each particle-matrix composite material is substantially comprised of the matrix material having the plurality of hard particles dispersed throughout.
- the binder material can comprises a second particle-matrix composite material.
- the second particle-matrix composite material is substantially comprised of a matrix material having a plurality of hard particles dispersed throughout.
- the binder material can comprises non-magnetic materials and/or wear resistant materials.
- the matrix material in the particle-matrix composition material can comprise non-magnetic materials and/or wear resistant materials.
- the formed drill bit would be entirely formed from non-magnetic materials and/or wear resistant materials.
- the matrix material of the binder composite material may include, for example, cobalt-based, iron-based, nickel-based, iron and nickel-based, cobalt and nickel-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, 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), tin (Sn) zinc (In), silicon (Si), molybdenum (Mo), tungsten (W), boron (B) and phosphorous (P).
- the matrix material of the binder composite material can also be selected from commercially pure elements such as cobalt, aluminum, copper, magnesium, titanium, iron, and nickel.
- the matrix material of the binder composite material may include carbon steel, alloy steel, stainless steel, tool steel, Hadfield manganese steel, nickel or cobalt superalloy material, and low thermal expansion iron or nickel based alloys.
- the hard particles can comprise the hard particles can comprise diamond, or metal or semi-metal carbides, nitrides, oxides, or borides.
- the hard particles can comprise diamond or ceramic materials such as carbides, nitrides, oxides, and borides (including boron carbide (B 4 C)) and combinations of them, such as carbonitrides.
- the hard particles can comprise carbides and borides made from elements such as W, Ti, Mo, Nb, V, Hf, Ta, Cr, Zr, Al, and Si.
- materials that may be used to form hard particles include tungsten carbide (WC, W 2 C), titanium carbide (TiC), tantalum carbide (TaC), titanium diboride (TiB 2 ), chromium carbides, titanium nitride (TiN), vanadium carbide (VC), aluminium oxide (Al 2 O 3 ), aluminium nitride (AlN), boron nitride (BN), and silicon carbide (SiC).
- combinations of different hard particles may be used to tailor the physical properties and characteristics of the particle-matrix composite material.
- the hard particles may be formed using techniques known to those of ordinary skill in the art. Most suitable materials for hard particles are commercially available and the formation of the remainder is within the ability of one of ordinary skill in the art.
- the matrix of the particle-matrix composite composition can comprise a tungsten-based alloy and the matrix of the binder material composition can be selected from a group comprising a copper based alloy, a zinc based alloy, and a nickel based alloy.
- the matrix of the particle-matrix composite composition can comprise a tungsten carbide-based alloy and the matrix of the binder material composition can be selected from a group comprising a copper based alloy, a zinc based alloy, and a nickel based alloy.
- tungsten and or tungsten carbide is desirable for use because of its higher hardness, which allows the use of smaller particles due to its high melting point, and suitability for use in an infiltration process because of the generally shorter times at high temperature prior to solidification and cooling of the matrix materials (in contrast with other methods of making a particle-matrix composite materials such as various powder metallurgy processes, such as sintering, that typically employ much longer times at high temperatures).
- the binder material has a binder material composition that has a binder material melting temperature that is lower than the particle material melting temperature
- the at least one particle-matrix composite material is in an unmelted state in the formed substantially uniform particle grain microstructure of the drill bit.
- the difference between the binder material melting temperature and the particle material melting temperature is greater than 500° F., preferably greater than 1000° F., and more preferred being greater than 1,500° F.
- the at least one particle-matrix composite material can comprise a plurality of particle-matrix composite materials.
- each particle-matrix composite material can be disposed in a layer positioned transverse to a longitudinal axis of the bit body. This layered approach allows for a fully infiltrated bit body using a common binder material that can have separate desired mechanical properties for the respective layers.
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- Engineering & Computer Science (AREA)
- Geology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- Mechanical Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Earth Drilling (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
- Drilling Tools (AREA)
Abstract
Description
- This application claims priority to U.S. Provisional Application No. 61/992,654 filed May 13, 2014, which is herein incorporated by reference in its entirety.
- This invention relates to a rotary drill bit. More specifically, this invention relates to a fully infiltrated rotary drill bit.
- Rotary drill bits are commonly used for subterranean drilling of bore holes or wells. Many types of drills and associated methods have been employed for such drilling. A common type of drilling employs a rotary drill bit affixed to the end of a drill string. Rotary drill bits typically include a plurality of cutting elements secured to a face region of a bit body. The drill string includes tubular pipe and equipment segments that couple the drill bit located at the bottom of the borehole to other drilling equipment at the surface. A rotary table or top drive may be used for rotating the drill string and the drill bit within the borehole. Alternatively, the shank of the drill bit may be coupled directly to the drive shaft of a down-hole motor, which then may be used to rotate the drill bit.
- Rotary drill bits generally have either a disk shape or a substantially cylindrical shape, particularly on the cutting end that houses the cutting elements. The cutting elements each have a cutting surface that is generally made from a hard, super-abrasive material, such as polycrystalline diamond, often in the form of a substantially circular end surface of the element, and are often referred to as “polycrystalline diamond compact” (PDC) cutters. Many forms of such bits are possible; however, the cutting elements are often fabricated separately from the bit body and then fixed into pockets formed in its outer surface. The cutting elements may be fixed in any suitable manner, such as, for example, by use of a bonding material, including various adhesives or, more typically, various braze alloys. The bit body is secured to a hardened steel shank having an American Petroleum Institute (API) thread connection for attaching the drill bit to the drill string. In use, the cutting elements and their cutting surfaces are placed in contact with the earth formation to be drilled. As the bit is rotated, the cutting elements progressively shear away the surface of the underlying formation to form the borehole.
- The bit body of a rotary drill bit may be formed from steel; however, such bit bodies experience abrasive wear, the rate of which can vary significantly as a function of the drilling environment. In order to reduce the wear and extend their life, bit bodies have also been made from particle-matrix composite materials.
- Particle-matrix composite bit bodies have been fabricated in graphite molds with machined cavities. Additional fine features may be added to the cavity of the graphite mold by hand-held tools. Inserts or cores made from sand, clay or other materials may also be used to obtain the desired configuration of some features of the bit body. Where necessary, preform elements or displacements (which may be made from any suitable material, including ceramic components, graphite components, or resin-coated sand compact components) may be positioned within the mold and used to define various features, including internal passages, cutting element pockets, junk slots, and other external topographic or internal features of the bit body. The cavity of the graphite mold is filled with hard particulate carbide material (such as tungsten carbides, titanium carbides, tantalum carbides, etc.). The preformed steel blank is then positioned in the mold at the appropriate location and orientation, which typically is at least partially submerged in the particulate carbide material within the mold.
- The mold then may be vibrated or the particles otherwise packed to increase the packing density of the carbide powder and produce the powder form. A matrix material, such as a copper-based alloy, is melted and introduced to the carbide powder so as to cause infiltration of the powder form by the molten matrix material. The mold and bit body are allowed to cool to solidify the matrix material and bond the steel blank to the particle-matrix composite material forming a crown. The mold and any displacements are removed from the bit body. Destruction of the graphite mold typically is required to remove the bit body.
- After the bit body has been removed from the mold, the bit body is conventionally secured to the steel shank. Thread forms may be machined on an exposed surface of the steel blank to provide a threaded connection between the bit body and the steel shank.
- While steel blanks afford a generally acceptable means of connecting the steel shank and the bit body, shifting of the blank in the mold during infiltration can occur resulting in misalignment of the blank with respect to the bit body, thereby causing the bit body to be unusable, or requiring additional machining or other rework of the bit body. Further, introduction of the blank as an additional component requires that it be degreased or otherwise cleaned prior to infiltration to ensure a metallurgical bond between the blank and the metal matrix. Still further, depending on the material used for the blank, interaction between the blank and matrix material may lead to the formation of phases at the interface between them that can result in crack formation and propagation during use of the bit.
- While bit bodies that include particle-matrix composite materials offer significant advantages over all-steel bit bodies in terms of abrasion and erosion-resistance, the lower strength and toughness of such bit bodies limit their use in certain applications. Improvement of the particle-matrix composite to increase the toughness, strength or other properties would increase the applications where such bit bodies may be used.
- The invention relates to a rotary drill bit comprising a bit body that comprises at least one particle-matrix composite material and a binder material. In one aspect, each of the at least one particle-matrix composite material has a particle material composition, which also has a particle material melting temperature. In another aspect, the binder material has a binder material composition that differs from the particle material composition. In this aspect, the binder material composition has a binder material melting temperature that is lower than the particle material melting temperature.
- In a further aspect, at least one of the particle-matrix material composition and the binder material composition can be comprised of a matrix material and a plurality of hard particles dispersed throughout the matrix materials.
- When formed, the binder material is infiltrated within and substantially encapsulates particle-matrix composite material to form a substantially uniform particle grain microstructure. In this aspect, it is contemplated that the particle-matrix composite material is substantially non-melted in the formation process of the drill bit.
- These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:
-
FIG. 1 is a schematic partial cross-sectional view of an exemplary embodiment of a rotary drill bit disclosed herein. -
FIG. 2 is a schematic partial cross-sectional view of a second exemplary embodiment of a rotary drill bit disclosed herein. - The illustrations presented herein, are not meant to be actual views of any particular material, apparatus, system, or method, but are merely idealized representations of that which is disclosed herein. Additionally, elements common between figures may retain the same numerical designation.
- The present invention can be understood more readily by reference to the following detailed description, examples, drawing, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
- The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.
- As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a particle-matrix composite material” can include two or more such particle-matrix composite material unless the context indicates otherwise.
- 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.
- 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.
- 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.
- As used herein, the term “material composition” means the chemical composition and microstructure of a material. In other words, materials having the same chemical composition but a different microstructure are considered to have different material compositions.
- 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.
- An exemplary embodiment of an earth-boring
rotary drill bit 10 having abit body 20 is illustrated inFIG. 1 . Thebit body 20 has adistal cutting region 22 configured to engage a subterranean earth formation and a proximaltreaded region 24 configured to be selectively coupled to a drill sting. In one aspect, the proximal treaded region defines an openinternal cavity 26 extending along a longitudinal axis of the bit body. It is further contemplated that ahelical thread 28, which is configured to matingly engage and attach to the drill string, can be formed on an interior wall surface of the open internal cavity. As contemplated in the invention, the bit body is fully infiltrated and, as such, will not be required to be conventionally secured to an underlying support shank. - In another aspect, the
bit body 20 comprises at least one particle-matrix composite material that is infiltrated by a binder material so that the at least one particle-matrix composite material is fully infiltrated by and is substantially encapsulated by the binder material to form a substantially uniform particle grain microstructure. In one aspect, each particle-matrix composite material has a particle material composition that has a particle material melting temperature. In another aspect, the binder material has a binder material composition that has a binder material melting temperature that is lower than the particle material melting temperature. Further, the particle material composition and the binder material composition are different material compositions. - It is contemplated that at least one of the particle-matrix material composition and the binder material composition is comprised of a matrix material and a plurality of hard particles dispersed throughout the matrix materials. The plurality of hard particles can be dispersed substantially randomly throughout the matrix material. In another aspect, each particle-matrix composite material is substantially comprised of the matrix material having the plurality of hard particles dispersed throughout.
- In a further aspect, the binder material can comprises a second particle-matrix composite material. In this aspect, the second particle-matrix composite material is substantially comprised of a matrix material having a plurality of hard particles dispersed throughout. In a further aspect, the binder material can comprises non-magnetic materials and/or wear resistant materials. Similarly, the matrix material in the particle-matrix composition material can comprise non-magnetic materials and/or wear resistant materials. In one aspect, it is contemplated that the formed drill bit would be entirely formed from non-magnetic materials and/or wear resistant materials.
- The matrix material of the binder composite material may include, for example, cobalt-based, iron-based, nickel-based, iron and nickel-based, cobalt and nickel-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, 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), tin (Sn) zinc (In), silicon (Si), molybdenum (Mo), tungsten (W), boron (B) and phosphorous (P). The matrix material of the binder composite material can also be selected from commercially pure elements such as cobalt, aluminum, copper, magnesium, titanium, iron, and nickel. By way of example and not limitation, the matrix material of the binder composite material may include carbon steel, alloy steel, stainless steel, tool steel, Hadfield manganese steel, nickel or cobalt superalloy material, and low thermal expansion iron or nickel based alloys.
- The hard particles can comprise the hard particles can comprise diamond, or metal or semi-metal carbides, nitrides, oxides, or borides. For example, and without limitation, the hard 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 hard 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 hard 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 (Al2O3), aluminium nitride (AlN), boron nitride (BN), and silicon carbide (SiC). Furthermore, combinations of different hard particles may be used to tailor the physical properties and characteristics of the particle-matrix composite material. The hard particles may be formed using techniques known to those of ordinary skill in the art. Most suitable materials for hard particles are commercially available and the formation of the remainder is within the ability of one of ordinary skill in the art.
- In one example, and not meant to be limiting, the matrix of the particle-matrix composite composition can comprise a tungsten-based alloy and the matrix of the binder material composition can be selected from a group comprising a copper based alloy, a zinc based alloy, and a nickel based alloy. In a further example, and not meant to be limiting, the matrix of the particle-matrix composite composition can comprise a tungsten carbide-based alloy and the matrix of the binder material composition can be selected from a group comprising a copper based alloy, a zinc based alloy, and a nickel based alloy. The use of tungsten and or tungsten carbide is desirable for use because of its higher hardness, which allows the use of smaller particles due to its high melting point, and suitability for use in an infiltration process because of the generally shorter times at high temperature prior to solidification and cooling of the matrix materials (in contrast with other methods of making a particle-matrix composite materials such as various powder metallurgy processes, such as sintering, that typically employ much longer times at high temperatures).
- Because the binder material has a binder material composition that has a binder material melting temperature that is lower than the particle material melting temperature, the at least one particle-matrix composite material is in an unmelted state in the formed substantially uniform particle grain microstructure of the drill bit. When formed, it is desired that the particle-matrix composite material is substantially encapsulated by the infiltrated binder material. Further, to accomplish the desired infiltration without melting of the particle-matrix composite composition, the difference between the binder material melting temperature and the particle material melting temperature is greater than 500° F., preferably greater than 1000° F., and more preferred being greater than 1,500° F.
- In a further aspect, and as shown in
FIG. 2 , it is further contemplated that the at least one particle-matrix composite material can comprise a plurality of particle-matrix composite materials. In this aspect, each particle-matrix composite material can be disposed in a layer positioned transverse to a longitudinal axis of the bit body. This layered approach allows for a fully infiltrated bit body using a common binder material that can have separate desired mechanical properties for the respective layers. - Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
Claims (25)
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US14/710,997 US20150330154A1 (en) | 2014-05-13 | 2015-05-13 | Fully infiltrated rotary drill bit |
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US201461992654P | 2014-05-13 | 2014-05-13 | |
US14/710,997 US20150330154A1 (en) | 2014-05-13 | 2015-05-13 | Fully infiltrated rotary drill bit |
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EP (1) | EP3143236A1 (en) |
CN (1) | CN106471207A (en) |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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KR20190067823A (en) * | 2016-10-28 | 2019-06-17 | 세인트-고바인 아브라시브즈 인크. | Core drill bit and molding method |
US10378286B2 (en) * | 2015-04-30 | 2019-08-13 | Schlumberger Technology Corporation | System and methodology for drilling |
CN110291052A (en) * | 2016-12-02 | 2019-09-27 | 圣戈班磨料磨具股份有限公司 | Coring bit component |
CN110394902A (en) * | 2018-04-25 | 2019-11-01 | 圣戈班磨料磨具有限公司 | Hollow drill bit and its manufacturing method |
Families Citing this family (1)
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CN109159307A (en) * | 2018-08-31 | 2019-01-08 | 古治勇 | The hot-forming included chip space glass perforating drill of one kind and its production technology |
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US7776256B2 (en) * | 2005-11-10 | 2010-08-17 | Baker Huges Incorporated | Earth-boring rotary drill bits and methods of manufacturing earth-boring rotary drill bits having particle-matrix composite bit bodies |
US8517125B2 (en) * | 2007-05-18 | 2013-08-27 | Smith International, Inc. | Impregnated material with variable erosion properties for rock drilling |
US20100193254A1 (en) * | 2009-01-30 | 2010-08-05 | Halliburton Energy Services, Inc. | Matrix Drill Bit with Dual Surface Compositions and Methods of Manufacture |
US8079428B2 (en) * | 2009-07-02 | 2011-12-20 | Baker Hughes Incorporated | Hardfacing materials including PCD particles, welding rods and earth-boring tools including such materials, and methods of forming and using same |
US9421671B2 (en) * | 2011-02-09 | 2016-08-23 | Longyear Tm, Inc. | Infiltrated diamond wear resistant bodies and tools |
-
2015
- 2015-05-13 EP EP15793275.7A patent/EP3143236A1/en not_active Withdrawn
- 2015-05-13 CN CN201580024457.9A patent/CN106471207A/en active Pending
- 2015-05-13 PE PE2016002188A patent/PE20170018A1/en not_active Application Discontinuation
- 2015-05-13 AU AU2015259190A patent/AU2015259190A1/en not_active Abandoned
- 2015-05-13 US US14/710,997 patent/US20150330154A1/en not_active Abandoned
- 2015-05-13 WO PCT/US2015/030535 patent/WO2015175641A1/en active Application Filing
- 2015-05-13 CA CA2948825A patent/CA2948825A1/en not_active Abandoned
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2016
- 2016-11-14 CL CL2016002889A patent/CL2016002889A1/en unknown
Patent Citations (1)
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US20030010532A1 (en) * | 2001-07-11 | 2003-01-16 | Kristiansen Steffen S. | Drill bit having adjustable total flow area |
Cited By (9)
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US10378286B2 (en) * | 2015-04-30 | 2019-08-13 | Schlumberger Technology Corporation | System and methodology for drilling |
US11008813B2 (en) * | 2015-04-30 | 2021-05-18 | Schlumberger Technology Corporation | System and methodology for drilling |
KR20190067823A (en) * | 2016-10-28 | 2019-06-17 | 세인트-고바인 아브라시브즈 인크. | Core drill bit and molding method |
CN110072822A (en) * | 2016-10-28 | 2019-07-30 | 圣戈班磨料磨具股份有限公司 | Coring bit and forming method |
EP3532440A4 (en) * | 2016-10-28 | 2020-06-24 | Saint-Gobain Abrasives, Inc. | Core drill bit and methods of forming |
US10723041B2 (en) * | 2016-10-28 | 2020-07-28 | Saint-Gobain Abrasives, Inc./Saint-Gobain Abrasifs | Core drill bit |
KR102240527B1 (en) | 2016-10-28 | 2021-04-19 | 세인트-고바인 아브라시브즈 인크. | Core Drill Bit and Forming Method |
CN110291052A (en) * | 2016-12-02 | 2019-09-27 | 圣戈班磨料磨具股份有限公司 | Coring bit component |
CN110394902A (en) * | 2018-04-25 | 2019-11-01 | 圣戈班磨料磨具有限公司 | Hollow drill bit and its manufacturing method |
Also Published As
Publication number | Publication date |
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PE20170018A1 (en) | 2017-03-04 |
CL2016002889A1 (en) | 2017-05-05 |
WO2015175641A1 (en) | 2015-11-19 |
EP3143236A1 (en) | 2017-03-22 |
AU2015259190A1 (en) | 2016-11-17 |
CA2948825A1 (en) | 2015-11-19 |
CN106471207A (en) | 2017-03-01 |
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