US20200047253A1 - Methods Of Fabricating Ceramic Or Intermetallic Parts - Google Patents
Methods Of Fabricating Ceramic Or Intermetallic Parts Download PDFInfo
- Publication number
- US20200047253A1 US20200047253A1 US16/656,999 US201916656999A US2020047253A1 US 20200047253 A1 US20200047253 A1 US 20200047253A1 US 201916656999 A US201916656999 A US 201916656999A US 2020047253 A1 US2020047253 A1 US 2020047253A1
- Authority
- US
- United States
- Prior art keywords
- intermetallic
- ceramic
- workpiece
- workpieces
- 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.)
- Pending
Links
- 239000000919 ceramic Substances 0.000 title claims abstract description 109
- 238000000034 method Methods 0.000 title claims abstract description 71
- 238000004519 manufacturing process Methods 0.000 claims abstract description 46
- 230000008569 process Effects 0.000 claims abstract description 34
- 238000009792 diffusion process Methods 0.000 claims abstract description 27
- 239000000654 additive Substances 0.000 claims abstract description 26
- 230000000996 additive effect Effects 0.000 claims abstract description 26
- 239000000463 material Substances 0.000 claims description 79
- 239000011230 binding agent Substances 0.000 claims description 57
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 40
- 229910052751 metal Inorganic materials 0.000 claims description 39
- 239000002184 metal Substances 0.000 claims description 38
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 30
- 239000002131 composite material Substances 0.000 claims description 28
- 239000000956 alloy Substances 0.000 claims description 23
- 229910052721 tungsten Inorganic materials 0.000 claims description 23
- 239000010937 tungsten Substances 0.000 claims description 23
- 229910045601 alloy Inorganic materials 0.000 claims description 22
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 21
- 238000006243 chemical reaction Methods 0.000 claims description 21
- 229910052796 boron Inorganic materials 0.000 claims description 18
- 229910052759 nickel Inorganic materials 0.000 claims description 18
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 18
- 229910052710 silicon Inorganic materials 0.000 claims description 17
- 239000010703 silicon Substances 0.000 claims description 17
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 16
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 16
- 239000011651 chromium Substances 0.000 claims description 16
- 238000001764 infiltration Methods 0.000 claims description 16
- 230000008595 infiltration Effects 0.000 claims description 16
- 229910052742 iron Inorganic materials 0.000 claims description 16
- 239000010936 titanium Substances 0.000 claims description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 15
- 229910052782 aluminium Inorganic materials 0.000 claims description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 15
- 229910052804 chromium Inorganic materials 0.000 claims description 15
- 229910052750 molybdenum Inorganic materials 0.000 claims description 15
- 239000011733 molybdenum Substances 0.000 claims description 15
- 229910052758 niobium Inorganic materials 0.000 claims description 15
- 239000010955 niobium Substances 0.000 claims description 15
- 229910052719 titanium Inorganic materials 0.000 claims description 15
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 14
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 14
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 14
- 239000010941 cobalt Substances 0.000 claims description 14
- 229910017052 cobalt Inorganic materials 0.000 claims description 14
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 14
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 14
- 229910052715 tantalum Inorganic materials 0.000 claims description 14
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 13
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 13
- 150000004767 nitrides Chemical class 0.000 claims description 13
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 13
- 229910052720 vanadium Inorganic materials 0.000 claims description 13
- 229910052726 zirconium Inorganic materials 0.000 claims description 13
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 12
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 12
- 229910052735 hafnium Inorganic materials 0.000 claims description 12
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 12
- 229910052763 palladium Inorganic materials 0.000 claims description 11
- 229910021332 silicide Inorganic materials 0.000 claims description 11
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 10
- 229910052702 rhenium Inorganic materials 0.000 claims description 10
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims description 10
- 229910052707 ruthenium Inorganic materials 0.000 claims description 10
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 claims description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 9
- 229910052802 copper Inorganic materials 0.000 claims description 9
- 239000010949 copper Substances 0.000 claims description 9
- 229910002804 graphite Inorganic materials 0.000 claims description 9
- 239000010439 graphite Substances 0.000 claims description 9
- 229910052738 indium Inorganic materials 0.000 claims description 9
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims description 9
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 9
- 229910052718 tin Inorganic materials 0.000 claims description 9
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 8
- 229910052762 osmium Inorganic materials 0.000 claims description 8
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 claims description 8
- 229910052760 oxygen Inorganic materials 0.000 claims description 8
- 239000001301 oxygen Substances 0.000 claims description 8
- 238000007639 printing Methods 0.000 claims description 8
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- 239000011701 zinc Substances 0.000 claims description 8
- 229910052741 iridium Inorganic materials 0.000 claims description 7
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims description 7
- 238000005121 nitriding Methods 0.000 claims description 7
- 229910052757 nitrogen Inorganic materials 0.000 claims description 7
- 239000011135 tin Substances 0.000 claims description 7
- 229910021529 ammonia Inorganic materials 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- 239000003610 charcoal Substances 0.000 claims description 6
- 150000003839 salts Chemical class 0.000 claims description 6
- 229910052709 silver Inorganic materials 0.000 claims description 6
- 239000004332 silver Substances 0.000 claims description 6
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 5
- 238000000151 deposition Methods 0.000 claims description 5
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052737 gold Inorganic materials 0.000 claims description 5
- 239000010931 gold Substances 0.000 claims description 5
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims description 5
- 239000011133 lead Substances 0.000 claims description 5
- 230000000149 penetrating effect Effects 0.000 claims description 4
- 239000012779 reinforcing material Substances 0.000 claims description 4
- 230000000873 masking effect Effects 0.000 claims description 2
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims 1
- 238000005553 drilling Methods 0.000 description 28
- -1 that is to say Substances 0.000 description 18
- 239000002245 particle Substances 0.000 description 17
- 230000002787 reinforcement Effects 0.000 description 17
- 230000003014 reinforcing effect Effects 0.000 description 16
- 239000000203 mixture Substances 0.000 description 14
- 229910000765 intermetallic Inorganic materials 0.000 description 13
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 11
- 238000002844 melting Methods 0.000 description 10
- 230000008018 melting Effects 0.000 description 10
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 10
- 238000005520 cutting process Methods 0.000 description 9
- 239000012530 fluid Substances 0.000 description 9
- 230000008901 benefit Effects 0.000 description 8
- 229910052706 scandium Inorganic materials 0.000 description 8
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 8
- 229910000601 superalloy Inorganic materials 0.000 description 8
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 7
- 229910052684 Cerium Inorganic materials 0.000 description 7
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 7
- 229910052791 calcium Inorganic materials 0.000 description 7
- 239000011575 calcium Substances 0.000 description 7
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 7
- 238000006073 displacement reaction Methods 0.000 description 7
- 229910052744 lithium Inorganic materials 0.000 description 7
- 229910052749 magnesium Inorganic materials 0.000 description 7
- 239000011777 magnesium Substances 0.000 description 7
- 239000011156 metal matrix composite Substances 0.000 description 7
- 229910052727 yttrium Inorganic materials 0.000 description 7
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 7
- 229910052691 Erbium Inorganic materials 0.000 description 6
- 229910052777 Praseodymium Inorganic materials 0.000 description 6
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 6
- 230000003628 erosive effect Effects 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 229910052746 lanthanum Inorganic materials 0.000 description 6
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 6
- 150000002739 metals Chemical class 0.000 description 6
- 239000003921 oil Substances 0.000 description 6
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 6
- 229910052779 Neodymium Inorganic materials 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 5
- 229910052771 Terbium Inorganic materials 0.000 description 5
- 229910052769 Ytterbium Inorganic materials 0.000 description 5
- 238000000149 argon plasma sintering Methods 0.000 description 5
- 229910052788 barium Inorganic materials 0.000 description 5
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 5
- 229910052790 beryllium Inorganic materials 0.000 description 5
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 5
- 229910052697 platinum Inorganic materials 0.000 description 5
- 229910052703 rhodium Inorganic materials 0.000 description 5
- 239000010948 rhodium Substances 0.000 description 5
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 229910052712 strontium Inorganic materials 0.000 description 5
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 5
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 5
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 5
- 229910052688 Gadolinium Inorganic materials 0.000 description 4
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 4
- 229910052689 Holmium Inorganic materials 0.000 description 4
- 229910052765 Lutetium Inorganic materials 0.000 description 4
- 229910018487 Ni—Cr Inorganic materials 0.000 description 4
- 229910052772 Samarium Inorganic materials 0.000 description 4
- 229910052775 Thulium Inorganic materials 0.000 description 4
- 239000010953 base metal Substances 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- 239000010432 diamond Substances 0.000 description 4
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 4
- 229910052733 gallium Inorganic materials 0.000 description 4
- KJZYNXUDTRRSPN-UHFFFAOYSA-N holmium atom Chemical compound [Ho] KJZYNXUDTRRSPN-UHFFFAOYSA-N 0.000 description 4
- OHSVLFRHMCKCQY-UHFFFAOYSA-N lutetium atom Chemical compound [Lu] OHSVLFRHMCKCQY-UHFFFAOYSA-N 0.000 description 4
- 150000001247 metal acetylides Chemical class 0.000 description 4
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 4
- 229910052714 tellurium Inorganic materials 0.000 description 4
- PORWMNRCUJJQNO-UHFFFAOYSA-N tellurium atom Chemical compound [Te] PORWMNRCUJJQNO-UHFFFAOYSA-N 0.000 description 4
- 229910001151 AlNi Inorganic materials 0.000 description 3
- 229910052693 Europium Inorganic materials 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 3
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 229910052787 antimony Inorganic materials 0.000 description 3
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 3
- 229910052797 bismuth Inorganic materials 0.000 description 3
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 3
- 229910052793 cadmium Inorganic materials 0.000 description 3
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 3
- 229910052792 caesium Inorganic materials 0.000 description 3
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 239000011153 ceramic matrix composite Substances 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 238000010894 electron beam technology Methods 0.000 description 3
- OGPBJKLSAFTDLK-UHFFFAOYSA-N europium atom Chemical compound [Eu] OGPBJKLSAFTDLK-UHFFFAOYSA-N 0.000 description 3
- 229910052732 germanium Inorganic materials 0.000 description 3
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 description 3
- 230000000670 limiting effect Effects 0.000 description 3
- 229910001338 liquidmetal Inorganic materials 0.000 description 3
- 230000004807 localization Effects 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000001465 metallisation Methods 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 239000011591 potassium Substances 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 229910052701 rubidium Inorganic materials 0.000 description 3
- IGLNJRXAVVLDKE-UHFFFAOYSA-N rubidium atom Chemical compound [Rb] IGLNJRXAVVLDKE-UHFFFAOYSA-N 0.000 description 3
- 238000000110 selective laser sintering Methods 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 239000003381 stabilizer Substances 0.000 description 3
- 238000005728 strengthening Methods 0.000 description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical group [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 3
- 238000010146 3D printing Methods 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 2
- 229910052692 Dysprosium Inorganic materials 0.000 description 2
- SHLSZXHICXGDQD-UHFFFAOYSA-N [Fe].[Ni].[Mn].[Sn].[Cu] Chemical compound [Fe].[Ni].[Mn].[Sn].[Cu] SHLSZXHICXGDQD-UHFFFAOYSA-N 0.000 description 2
- XHNWSECJVGHCEX-UHFFFAOYSA-N [Ni].[Mn].[Sn].[Cu] Chemical compound [Ni].[Mn].[Sn].[Cu] XHNWSECJVGHCEX-UHFFFAOYSA-N 0.000 description 2
- HEWIALZDOKKCSI-UHFFFAOYSA-N [Ni].[Zn].[Mn].[Cu] Chemical compound [Ni].[Zn].[Mn].[Cu] HEWIALZDOKKCSI-UHFFFAOYSA-N 0.000 description 2
- GZWXHPJXQLOTPB-UHFFFAOYSA-N [Si].[Ni].[Cr] Chemical compound [Si].[Ni].[Cr] GZWXHPJXQLOTPB-UHFFFAOYSA-N 0.000 description 2
- 238000005255 carburizing Methods 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- 229910000599 Cr alloy Inorganic materials 0.000 description 1
- 229910019918 CrB2 Inorganic materials 0.000 description 1
- 229910000570 Cupronickel Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910019802 NbC Inorganic materials 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- 229910000943 NiAl Inorganic materials 0.000 description 1
- 229910000624 NiAl3 Inorganic materials 0.000 description 1
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910010038 TiAl Inorganic materials 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- 229910034327 TiC Inorganic materials 0.000 description 1
- 229910052770 Uranium Inorganic materials 0.000 description 1
- 208000034699 Vitreous floaters Diseases 0.000 description 1
- OFQKOEFRYIYLHP-UHFFFAOYSA-N [Au].[Hf] Chemical compound [Au].[Hf] OFQKOEFRYIYLHP-UHFFFAOYSA-N 0.000 description 1
- JMPCSVLFBYHHHL-UHFFFAOYSA-N [B].[Co].[Ni].[Mn] Chemical compound [B].[Co].[Ni].[Mn] JMPCSVLFBYHHHL-UHFFFAOYSA-N 0.000 description 1
- SSFOHMYAXTWKFB-UHFFFAOYSA-N [B].[W].[Ni].[Cr].[Si].[Co] Chemical compound [B].[W].[Ni].[Cr].[Si].[Co] SSFOHMYAXTWKFB-UHFFFAOYSA-N 0.000 description 1
- FMBQNXLZYKGUIA-UHFFFAOYSA-N [Cd].[Zn].[Cu].[Ag] Chemical compound [Cd].[Zn].[Cu].[Ag] FMBQNXLZYKGUIA-UHFFFAOYSA-N 0.000 description 1
- PQIJHIWFHSVPMH-UHFFFAOYSA-N [Cu].[Ag].[Sn] Chemical compound [Cu].[Ag].[Sn] PQIJHIWFHSVPMH-UHFFFAOYSA-N 0.000 description 1
- RIRXDDRGHVUXNJ-UHFFFAOYSA-N [Cu].[P] Chemical compound [Cu].[P] RIRXDDRGHVUXNJ-UHFFFAOYSA-N 0.000 description 1
- ZNCOYTQIIOTLKT-UHFFFAOYSA-N [Fe].[B].[Cr].[Si].[Ni] Chemical compound [Fe].[B].[Cr].[Si].[Ni] ZNCOYTQIIOTLKT-UHFFFAOYSA-N 0.000 description 1
- IZBSGLYEQXJERA-UHFFFAOYSA-N [In].[Ni].[Cu] Chemical compound [In].[Ni].[Cu] IZBSGLYEQXJERA-UHFFFAOYSA-N 0.000 description 1
- RQCJDSANJOCRMV-UHFFFAOYSA-N [Mn].[Ag] Chemical compound [Mn].[Ag] RQCJDSANJOCRMV-UHFFFAOYSA-N 0.000 description 1
- SWRLHCAIEJHDDS-UHFFFAOYSA-N [Mn].[Cu].[Zn] Chemical compound [Mn].[Cu].[Zn] SWRLHCAIEJHDDS-UHFFFAOYSA-N 0.000 description 1
- PRSVGTLZWHPRBM-UHFFFAOYSA-N [Mn].[Si].[Ni].[Cr] Chemical compound [Mn].[Si].[Ni].[Cr] PRSVGTLZWHPRBM-UHFFFAOYSA-N 0.000 description 1
- ZBTDWLVGWJNPQM-UHFFFAOYSA-N [Ni].[Cu].[Au] Chemical compound [Ni].[Cu].[Au] ZBTDWLVGWJNPQM-UHFFFAOYSA-N 0.000 description 1
- DUQYSTURAMVZKS-UHFFFAOYSA-N [Si].[B].[Ni] Chemical compound [Si].[B].[Ni] DUQYSTURAMVZKS-UHFFFAOYSA-N 0.000 description 1
- OZYPSHAMSANXCY-UHFFFAOYSA-N [W].[Ni].[Cr].[Si].[Co] Chemical compound [W].[Ni].[Cr].[Si].[Co] OZYPSHAMSANXCY-UHFFFAOYSA-N 0.000 description 1
- PEDRMCVBZKSOHT-UHFFFAOYSA-N [Zn].[Ag].[Ni].[Cu] Chemical compound [Zn].[Ag].[Ni].[Cu] PEDRMCVBZKSOHT-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- DMFGNRRURHSENX-UHFFFAOYSA-N beryllium copper Chemical compound [Be].[Cu] DMFGNRRURHSENX-UHFFFAOYSA-N 0.000 description 1
- ZMDCATBGKUUZHF-UHFFFAOYSA-N beryllium nickel Chemical compound [Be].[Ni] ZMDCATBGKUUZHF-UHFFFAOYSA-N 0.000 description 1
- ZXLMKCYEDRYHQK-UHFFFAOYSA-N beryllium titanium Chemical compound [Be].[Ti] ZXLMKCYEDRYHQK-UHFFFAOYSA-N 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 238000004814 ceramic processing Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000000788 chromium alloy Substances 0.000 description 1
- XRBURMNBUVEAKD-UHFFFAOYSA-N chromium copper nickel Chemical compound [Cr].[Ni].[Cu] XRBURMNBUVEAKD-UHFFFAOYSA-N 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- UTICYDQJEHVLJZ-UHFFFAOYSA-N copper manganese nickel Chemical compound [Mn].[Ni].[Cu] UTICYDQJEHVLJZ-UHFFFAOYSA-N 0.000 description 1
- YOCUPQPZWBBYIX-UHFFFAOYSA-N copper nickel Chemical compound [Ni].[Cu] YOCUPQPZWBBYIX-UHFFFAOYSA-N 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- QIYFTTFTJMLKAQ-UHFFFAOYSA-N gold manganese Chemical compound [Mn].[Au] QIYFTTFTJMLKAQ-UHFFFAOYSA-N 0.000 description 1
- MSNOMDLPLDYDME-UHFFFAOYSA-N gold nickel Chemical compound [Ni].[Au] MSNOMDLPLDYDME-UHFFFAOYSA-N 0.000 description 1
- NDNKRACDDKGFIP-UHFFFAOYSA-N gold niobium Chemical compound [Nb].[Nb].[Nb].[Au] NDNKRACDDKGFIP-UHFFFAOYSA-N 0.000 description 1
- AKRLAIBIFFOGMI-UHFFFAOYSA-N gold scandium Chemical compound [Sc].[Au].[Au].[Au].[Au] AKRLAIBIFFOGMI-UHFFFAOYSA-N 0.000 description 1
- RZDQHXVLPYMFLM-UHFFFAOYSA-N gold tantalum Chemical compound [Ta].[Ta].[Ta].[Au] RZDQHXVLPYMFLM-UHFFFAOYSA-N 0.000 description 1
- WMXKNDIJGCNPEH-UHFFFAOYSA-N gold thulium Chemical compound [Tm].[Au] WMXKNDIJGCNPEH-UHFFFAOYSA-N 0.000 description 1
- ZNKMCMOJCDFGFT-UHFFFAOYSA-N gold titanium Chemical compound [Ti].[Au] ZNKMCMOJCDFGFT-UHFFFAOYSA-N 0.000 description 1
- BMOFLINJXRPQCY-UHFFFAOYSA-N gold vanadium Chemical compound [V].[Au] BMOFLINJXRPQCY-UHFFFAOYSA-N 0.000 description 1
- YPANPSDPZOVDOM-UHFFFAOYSA-N gold zirconium Chemical compound [Zr].[Au] YPANPSDPZOVDOM-UHFFFAOYSA-N 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229910001293 incoloy Inorganic materials 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- ZAUUZASCMSWKGX-UHFFFAOYSA-N manganese nickel Chemical compound [Mn].[Ni] ZAUUZASCMSWKGX-UHFFFAOYSA-N 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
- ZLANVVMKMCTKMT-UHFFFAOYSA-N methanidylidynevanadium(1+) Chemical class [V+]#[C-] ZLANVVMKMCTKMT-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229910001175 oxide dispersion-strengthened alloy Inorganic materials 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000010587 phase diagram Methods 0.000 description 1
- OFNHPGDEEMZPFG-UHFFFAOYSA-N phosphanylidynenickel Chemical compound [P].[Ni] OFNHPGDEEMZPFG-UHFFFAOYSA-N 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000011160 polymer matrix composite Substances 0.000 description 1
- 229920013657 polymer matrix composite Polymers 0.000 description 1
- 238000004881 precipitation hardening Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- MZFIXCCGFYSQSS-UHFFFAOYSA-N silver titanium Chemical compound [Ti].[Ag] MZFIXCCGFYSQSS-UHFFFAOYSA-N 0.000 description 1
- VYNIYUVRASGDDE-UHFFFAOYSA-N silver zirconium Chemical compound [Zr].[Ag] VYNIYUVRASGDDE-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 229910001258 titanium gold Inorganic materials 0.000 description 1
- DNYWZCXLKNTFFI-UHFFFAOYSA-N uranium Chemical compound [U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U][U] DNYWZCXLKNTFFI-UHFFFAOYSA-N 0.000 description 1
- 229910001247 waspaloy Inorganic materials 0.000 description 1
Images
Classifications
-
- B22F3/1055—
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/62—Treatment of workpieces or articles after build-up by chemical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1143—Making porous workpieces or articles involving an oxidation, reduction or reaction step
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F3/26—Impregnating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0022—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors
- C04B38/0025—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors starting from inorganic materials only, e.g. metal foam; Lanxide type products
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4523—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied from the molten state ; Thermal spraying, e.g. plasma spraying
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/88—Metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/047—Making non-ferrous alloys by powder metallurgy comprising intermetallic compounds
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0475—Impregnated alloys
-
- C22C1/0491—
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/06—Solid state diffusion of only metal elements or silicon into metallic material surfaces using gases
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/60—After-treatment
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/10—Oxidising
- C23C8/12—Oxidising using elemental oxygen or ozone
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/10—Oxidising
- C23C8/16—Oxidising using oxygen-containing compounds, e.g. water, carbon dioxide
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/20—Carburising
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/24—Nitriding
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/40—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using liquids, e.g. salt baths, liquid suspensions
- C23C8/42—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using liquids, e.g. salt baths, liquid suspensions only one element being applied
- C23C8/48—Nitriding
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/60—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using solids, e.g. powders, pastes
- C23C8/62—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using solids, e.g. powders, pastes only one element being applied
- C23C8/64—Carburising
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/60—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using solids, e.g. powders, pastes
- C23C8/62—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using solids, e.g. powders, pastes only one element being applied
- C23C8/68—Boronising
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/80—After-treatment
-
- 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
- E21B10/42—Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/241—Chemical after-treatment on the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/002—Drill-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
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0005—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with at least one oxide and at least one of carbides, nitrides, borides or silicides as the main non-metallic constituents
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
-
- Y02P10/295—
Definitions
- Additive manufacturing can provide certain advantages over traditional manufacturing processes.
- additive manufacturing e.g., 3D printing
- one of the most significant advantages of additive manufacturing is the design flexibility and the ability to create forms and features not feasible any other way. Similar advantages of additive manufacturing are applicable to other industries.
- Additive manufacturing systems such as direct metal laser sintering or electron-beam melting, are currently available for fabricating or “printing” metal components. Printing ceramic materials via additive manufacturing, however, poses significant challenges.
- ceramic materials are bonded together using water or a binding agent, such as a polymer or a metal.
- the bonded structure is then fired using conventional ceramic processing steps to convert the bonded structure to a ceramic.
- it is difficult to bond or melt ceramic particles to build up an additive manufactured structure due to the high melting temperature of the ceramic particles.
- ceramics particles are brittle and therefore sensitive to thermal stresses common to additive manufacturing as each successive layer is melted or sintered and cooled to build up the desired structure or part.
- FIG. 1 is a schematic flowchart of an exemplary method of fabricating a part.
- FIG. 2 is a perspective view of an exemplary drill bit that may be at least partially fabricated in accordance with the principles of the present disclosure.
- FIG. 3 is a cross-sectional view of the drill bit of FIG. 2 .
- FIG. 4 is a cross-sectional side view of an exemplary mold assembly for use in forming the drill bit of FIG. 2 .
- FIG. 5 is a cross-sectional side view of the drill bit of FIG. 2 as comprising a hard composite portion and one or more localized ceramic or intermetallic workpieces.
- FIG. 6 is a cross-sectional side view of the drill bit of FIG. 2 as comprising a hard composite portion and a ceramic or intermetallic workpiece.
- FIG. 7 is a cross-sectional view of the drill bit of FIG. 2 as comprising a hard composite portion and multiple ceramic or intermetallic workpieces.
- FIG. 8 is a schematic drawing showing one example of a drilling assembly suitable for use in conjunction with the drill bits of the present disclosure.
- the present disclosure relates to part manufacturing and, more particularly, to fabricating ceramic or intermetallic parts using additive manufacturing.
- Embodiments described herein provide processes or methods that allow ceramic or intermetallic materials to be fabricated using additive manufacturing techniques.
- the presently disclosed methods may be used, for example, to print a three-dimensional porous metallic workpiece via an additive manufacturing process.
- the porous metallic workpiece is subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.
- Burnout of binding agents typically included in a ceramic is not necessary since the resulting ceramic or intermetallic structure is initially produced as a metallic structure or workpiece, after which a suitable diffusion-based process transforms the metallic workpiece in situ to a ceramic or intermetallic.
- a part may be manufactured by printing and carburizing a tungsten structure resulting in a tungsten carbide structure, such as a drill bit or a drill bit component, which may subsequently be infiltrated to form a tungsten carbide metal-matrix composite. It will be appreciated that many different shapes and structures are possible beyond those common to particle production methods, foam production methods, and resulting structures of packed powder.
- Such tools and parts include, but are not limited to, oilfield drill bits or cutting tools (e.g., fixed-angle drill bits, roller-cone drill bits, coring drill bits, bi-center drill bits, impregnated drill bits, reamers, stabilizers, hole openers, cutters), non-retrievable drilling components, aluminum drill bit bodies associated with casing drilling of wellbores, drill-string stabilizers, cones for roller-cone drill bits, models for forging dies used to fabricate support arms for roller-cone drill bits, arms for fixed reamers, arms for expandable reamers, internal components associated with expandable reamers, sleeves attached to an uphole end of a rotary drill bit, rotary steering tools, logging-while-drilling tools, measurement-while-drilling tools, side-wall coring tools, fishing spears, washover tools, rotors, stators and
- the term “part” refers to any tool, part, component, or structure that may benefit from being manufactured as a ceramic or intermetallic, either in its entirety or in part. It should be noted that the shape, configuration, design, or size of the part fabricated using the principles or methods described herein is only limited by the selected additive manufacturing process used to fabricate the desired part. For instance, a ceramic or intermetallic part produced by additive manufacturing and the principles disclosed herein may take a variety of forms, such as a completed part, a porous network that is subsequently infiltrated or filled in to form a metal-matrix or ceramic-matrix composite, or various components or reinforcement formats that may be used to reinforce a composite material.
- Ceramic or intermetallic material formed by additive manufacturing examples include powders, mesoscale structures, and building-block components to be used in creating larger structures.
- suitable composite materials include sites, and the like.
- Such ceramic or intermetallic components may be used to reinforce metals, alloys, or metal-matrix composites such that the parts become suitable replacements for oxide dispersion-strengthened alloys.
- the production of ceramic-matrix composites using such ceramic or intermetallic components may produce additional strengthening in a porous network of mesoscale structures that is not achievable by the conventional fiber-reinforcement method.
- the principles disclosed herein can also be employed to create ceramic parts where an open porous structure is required such as a filter, a screen, a catalyst, and the like.
- Intermetallics are generally classified in two groups: stoichiometric and non-stoichiometric.
- Stoichiometric intermetallics such as Al 3 Ni
- Non-stoichiometric intermetallics such as AlNi
- Non-stoichiometric intermetallics occur over a range of compositions and are generally more ductile than stoichiometric intermetallics.
- non-stoichiometric intermetallics provide intermediate properties between those of ceramics and stoichiometric intermetallics and those of pure metals and solid-solution alloys.
- stoichiometric intermetallic structures provide enhanced stiffness and strength, similar to ceramics, whereas non-stoichiometric intermetallic structures provide intermediate reinforcing properties (e.g., still stiffer than matrix materials, that is to say, binder or alloy materials, but with some ductility compared to ceramic and stoichiometric intermetallic materials).
- the method 10 may include printing a three-dimensional porous metallic workpiece using an additive manufacturing process, as at 12 .
- the additive manufacturing process may include, but is not limited to, laser sintering (LS) [e.g., selective laser sintering (SLS), direct metal laser sintering (DMLS)], laser melting (LM) [e.g., selective laser melting (SLM), lasercusing], electron-beam melting (EBM), laser metal deposition [e.g., direct metal deposition (DMD), laser engineered net shaping (LENS), directed light fabrication (DLF), direct laser deposition (DLD), direct laser fabrication (DLF), laser rapid forming (LRF), laser melting deposition (LMD)], any combination thereof, and the like.
- LS laser sintering
- SLS selective laser sintering
- DMLS direct metal laser sintering
- LM selective laser melting
- EBM electron-beam melting
- laser metal deposition e.g., direct metal deposition (DMD), laser engineered net shaping (LENS), directed light fabrication (DLF), direct laser deposition (DLD), direct laser fabrication (DLF), laser rapid
- the metallic workpiece may be made out of any base metal or base metal alloy that can form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to appropriate conditions.
- Carbides may be formed by using aluminum, boron, calcium, cerium, chromium, erbium, iron, hafnium, lanthanum, lithium, magnesium, manganese, molybdenum, niobium, praseodymium, scandium, silicon, tantalum, titanium, vanadium, tungsten, yttrium, ytterbium, and zirconium.
- Nitrides may be formed by using aluminum, boron, calcium, cerium, cobalt, chromium, iron, gallium, hafnium, indium, lithium, magnesium, manganese, molybdenum, niobium, nickel, scandium, silicon, tantalum, titanium, vanadium, tungsten, yttrium, and zirconium.
- Borides may be formed by using aluminum, barium, beryllium, calcium, cerium, cobalt, chromium, dysprosium, erbium, europium, iron, gadolinium, hafnium, holmium, lanthanum, lithium, lutetium, magnesium, manganese, molybdenum, niobium, neodymium, nickel, osmium, palladium, praseodymium, platinum, rhenium, rhodium, ruthenium, scandium, samarium, strontium, tantalum, terbium, titanium, thulium, vanadium, tungsten, yttrium, ytterbium, and zirconium.
- Oxides may be formed by using aluminum, barium, beryllium, bismuth, calcium, cadmium, cerium, cobalt, chromium, cesium, copper, erbium, iron, gallium, germanium, hafnium, indium, potassium, lanthanum, lithium, magnesium, manganese, molybdenum, sodium, niobium, neodymium, nickel, lead, praseodymium, rubidium, antimony, scandium, silicon, tin, strontium, tantalum, terbium, tellurium, titanium, vanadium, tungsten, yttrium, zinc, and zirconium.
- Silicides may be formed by using barium, boron, calcium, cerium, cobalt, chromium, dysprosium, erbium, iron, gadolinium, hafnium, holmium, iridium, lanthanum, lithium, lutetium, magnesium, manganese, molybdenum, niobium, neodymium, nickel, osmium, palladium, praseodymium, platinum, rhenium, rhodium, ruthenium, scandium, samarium, strontium, tantalum, terbium, tellurium, titanium, thulium, vanadium, tungsten, yttrium, ytterbium, and zirconium.
- Intermetallics may be formed by using at least two metallic elements that form intermetallic compounds.
- elements that form refractory aluminum-based intermetallics include cobalt, chromium, copper, iron, hafnium, iridium, manganese, molybdenum, niobium, nickel, palladium, platinum, rhenium, ruthenium, scandium, tantalum, titanium, vanadium, tungsten, and zirconium.
- refractory intermetallic systems include silver-titanium, silver-zirconium, gold-hafnium, gold-manganese, gold-niobium, gold-scandium, gold-tantalum, gold-titanium, gold-thulium, gold-vanadium, gold-zirconium, beryllium-copper, beryllium-iron, beryllium-niobium, beryllium-nickel, beryllium-palladium, beryllium-titanium, beryllium-vanadium, beryllium-tungsten, beryllium-zirconium, any combination thereof, and the like.
- This skilled in the art will readily appreciate that the principles of the present disclosure can apply to several other potential intermetallics not listed herein, without departing from the scope of the disclosure.
- Suitable base metals that may be used to form the metallic workpiece and subsequently form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic include, but are not limited to, any element from any of the foregoing lists.
- Suitable base metal alloys that may be used to form the metallic workpiece and subsequently form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic include, but are not limited to, any alloy wherein the most prevalent element, when measured by weight, is from one of the foregoing lists.
- the porous metallic workpiece may then be subjected to a diffusion-based process to convert at least a portion of the metallic workpiece to a ceramic or intermetallic workpiece, as at 14.
- Suitable diffusion-based processes include, but are not limited to, carburizing, nitriding, bonding, and oxidizing, all of which may convert the metallic workpiece into a desired ceramic or intermetallic composition.
- a reaction atmosphere comprising any capable media that may result in the production of a ceramic (e.g., an oxide, a carbide, a boride, a nitride, a silicide) or an intermetallic material (e.g., AlNi, TiAl).
- Suitable media includes, but is not limited to, methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, vaporized metal (i.e., gas), molten metal, or any combination thereof.
- the porosity of the metallic workpiece may allow the media of the reaction atmosphere to access some or all of the internals of the metallic workpiece and thereby react with and diffuse into all desired regions thereof.
- the metallic workpiece may be printed such that the porosity is relatively low in select regions or throughout all of the metallic workpiece. Such embodiments may result in a ceramic or intermetallic part that may be more ductile (e.g., still metallic) at its core or in selected regions.
- the media of the reaction atmosphere may be unable to access and react with the center of the metallic workpiece, thereby resulting in a part that is more ductile at its core.
- portions of the metallic workpiece may be masked off such that the media of the reaction atmosphere is unable to access the masked-off portions and a ceramic or intermetallic material will, therefore, not result at those regions.
- the diffusion-based process may be terminated prematurely such that the media of the reaction atmosphere is unable to completely react with all portions of the metallic workpiece, thereby also potentially resulting in a ductile core, such as is done in case-hardening applications.
- a gradient of materials e.g., alloys, intermetallics, and ceramics
- a gradient of materials may result from the process, thereby producing a functional gradient of properties.
- a Ni core may remain with a NiAl intermediate layer and a NiAl 3 outer layer.
- the diffusion-based process may be conducted at an elevated temperature within a furnace, for example.
- the furnace used to conduct the diffusion-based process may comprise a continuous or batch furnace capable of operating with the desired media of the reaction atmosphere. Suitable furnaces include, but are not limited to, a belt furnace, a vacuum furnace, a muffle furnace, a retort furnace, any combination thereof, and the like.
- the diffusion-based process may incorporate the use of a liquid-metal bath. More particularly, the liquid-metal bath may be useful in reacting constituents together to create the ceramic or intermetallic part.
- the metallic workpiece may be immersed in a liquid-metal bath to create the ceramic or intermetallic part.
- the nickel-based workpiece may be immersed in an aluminum bath to produce an intermetallic, such as AlNi 3 , AlNi, Al 3 Ni 2 , or Al 3 Ni.
- this process may be carried to completion to completely transform the Ni to an intermetallic composition, or it may be carried to an intermediate stage that may produce one of these intermetallic phases throughout the part or a functional gradient of phases (and properties), depending on the time and temperature cycle of the diffusion-based process.
- the method 10 may prove advantageous in fabricating parts from several commonly used ceramic or intermetallic material systems.
- Tungsten carbide for example, is commonly used in the oil and gas industry to fabricate hard and erosion-resistant parts.
- WC parts may be fabricated using the method 10 .
- a porous tungsten metallic workpiece may first be printed using additive manufacturing to a desired size and shape, as at 12.
- the porous tungsten metallic workpiece may comprise a plurality of mesoscale reinforcement components.
- the printed tungsten metallic workpiece may then be carburized via the above-described diffusion-based processes to provide a WC part, as at 14.
- Other material systems that may be produced using the method 10 include, but are not limited to, Al 2 O 3 , AlN, BN, B 4 C, CrB 2 , Cr 2 C 3 , NbC, SiC, Si 3 N 4 , TiB 2 , TiC, TiN, Ti(C,N), VC, MgO, Y 2 O 3 , or any carbide, oxide, boride, nitride, silicide or any intermetallic compound in which at least one metallic component of the resulting intermetallic or ceramic is capable of being printed using additive manufacturing.
- the method 10 may optionally and further include infiltrating the ceramic or intermetallic workpiece with a binder material to produce a composite, as at 16.
- Example composites include metal-matrix, ceramic-matrix, and polymer-matrix composites.
- a metal-matrix composite (MMC) is generally made from a reinforcement material that is infiltrated with a binder or infiltration or matrix material.
- the ceramic or intermetallic workpiece may comprise the reinforcement material
- the binder material may include, but is not limited to, copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, any mixture thereof, any alloy thereof, and any combination thereof.
- the infiltration process may include placing the ceramic or intermetallic workpiece and the binder material into a furnace.
- the ceramic or intermetallic workpiece and the binder material may be deposited in a container or a mold prior to being introduced into the furnace.
- the binder material will liquefy and proceed to infiltrate the porous network of the ceramic or intermetallic workpiece.
- the resulting composite may then be removed from the furnace and cooled at a controlled rate.
- the resulting composite may be a sealed or solid composite part or tool.
- FIG. 2 illustrated is a perspective view of an exemplary drill bit 100 that may be fabricated, at least in part, in accordance with the principles of the present disclosure. More particularly, one or more portions of the drill bit 100 may be fabricated using the method 10 of FIG. 1 . It will be appreciated, however, that discussion of the drill bit 100 may equally apply to any of the parts mentioned or described herein that may be used in the oil and gas industry or any other industry, without departing from the scope of the disclosure.
- the drill bit 100 may include or otherwise define a plurality of cutter blades 102 arranged along the circumference of a bit head 104 .
- the bit head 104 is connected to a shank 106 to form a bit body 108 .
- the shank 106 may be connected to the bit head 104 by welding, such as using laser arc welding that results in the formation of a weld 110 around a weld groove 112 .
- the shank 106 may further include or otherwise be connected to a threaded pin 114 , such as an American Petroleum Institute (API) drill pipe thread.
- API American Petroleum Institute
- the drill bit 100 includes five cutter blades 102 , in which multiple recesses or pockets 116 are formed.
- Cutting elements 118 may be fixedly installed within each recess 116 . This can be done, for example, by brazing each cutting element 118 into a corresponding recess 116 . As the drill bit 100 is rotated in use, the cutting elements 118 engage the rock and underlying earthen materials, to dig, scrape or grind away the material of the formation being penetrated.
- drilling fluid or “mud” can be pumped downhole through a drill string (not shown) coupled to the drill bit 100 at the threaded pin 114 .
- the drilling fluid circulates through and out of the drill bit 100 at one or more nozzles 120 positioned in nozzle openings 122 defined in the bit head 104 .
- Junk slots 124 are formed between each adjacent pair of cutter blades 102 . Cuttings, downhole debris, formation fluids, drilling fluid, etc., may pass through the junk slots 124 and circulate back to the well surface within an annulus formed between exterior portions of the drill string and the inner wall of the wellbore being drilled.
- FIG. 3 is a cross-sectional side view of the drill bit 100 of FIG. 2 . Similar numerals from FIG. 2 that are used in FIG. 3 refer to similar components that are not described again.
- the shank 106 may be securely attached to a metal blank (or mandrel) 202 at the weld 110 and the metal blank 202 extends into the bit body 108 .
- the shank 106 and the metal blank 202 are generally cylindrical structures that define corresponding fluid cavities 204 a and 204 b , respectively, in fluid communication with each other.
- the fluid cavity 204 b of the metal blank 202 may further extend longitudinally into the bit body 108 .
- At least one flow passageway 206 may extend from the fluid cavity 204 b to exterior portions of the bit body 108 .
- the nozzle openings 122 may be defined at the ends of the flow passageways 206 at the exterior portions of the bit body 108 .
- the pockets 116 are formed in the bit body 108 and are shaped or otherwise configured to receive the cutting elements 118 ( FIG. 2 ).
- the bit body 108 may comprise a hard composite portion 208 and, in accordance with the teachings of the present disclosure, all or any portion of the hard composite portion 208 may be fabricated in accordance with the method of FIG. 1 .
- FIG. 4 is a cross-sectional side view of a mold assembly 300 that may be used to form the drill bit 100 of FIGS. 2 and 3 . While the mold assembly 300 is shown and discussed as being used to help fabricate the drill bit 100 , those skilled in the art will readily appreciate that the mold assembly 300 and its several variations described herein may be used to help fabricate any of the downhole tools or parts mentioned above, without departing from the scope of the disclosure.
- the mold assembly 300 may include several components such as a mold 302 , a gauge ring 304 , and a funnel 306 .
- the funnel 306 may be operatively coupled to the mold 302 via the gauge ring 304 , such as by corresponding threaded engagements, as illustrated.
- the gauge ring 304 may be omitted from the mold assembly 300 and the funnel 306 may instead be operatively coupled directly to the mold 302 , such as via a corresponding threaded engagement, without departing from the scope of the disclosure.
- the mold assembly 300 may further include a binder bowl 308 and a cap 310 placed above the funnel 306 .
- the mold 302 , the gauge ring 304 , the funnel 306 , the binder bowl 308 , and the cap 310 may each be made of or otherwise comprise graphite or alumina (Al 2 O 3 ), for example, or other suitable materials.
- An infiltration chamber 312 may be defined or otherwise provided within the mold assembly 300 .
- Various techniques may be used to manufacture the mold assembly 300 and its components including, but not limited to, machining graphite blanks to produce the various components and thereby define the infiltration chamber 312 to exhibit a negative or reverse profile of desired exterior features of the drill bit 100 ( FIGS. 2 and 3 ).
- Materials such as consolidated sand or graphite, may be positioned within the mold assembly 300 at desired locations to form various features of the drill bit 100 ( FIGS. 2 and 3 ).
- one or more nozzle displacements or legs 314 may be positioned to correspond with desired locations and configurations of the flow passageways 206 ( FIG. 3 ) and their respective nozzle openings 122 ( FIGS. 2 and 3 ).
- One or more junk slot displacements 315 may also be positioned within the mold assembly 300 to correspond with the junk slots 124 ( FIG. 2 ).
- a cylindrically-shaped central displacement 316 may be placed on the legs 314 .
- the number of legs 314 extending from the central displacement 316 will depend upon the desired number of flow passageways and corresponding nozzle openings 122 in the drill bit 100 . Further, cutter-pocket displacements (shown as part of mold 302 in FIG. 4 ) may be placed in the mold 302 to form cutter pockets 116 .
- reinforcement materials 318 may then be placed within or otherwise introduced into the mold assembly 300 .
- the reinforcement materials 318 may include, for example, various types of reinforcing particles.
- the reinforcement materials 318 may include one or more ceramic or intermetallic workpieces fabricated in accordance with the method 10 of FIG. 1 .
- the ceramic or intermetallic workpieces may prove advantageous in strengthening the bit body 108 ( FIGS. 2 and 3 ) in select locations and, more particularly, strengthening the hard composite portion 208 ( FIG. 3 ) thereof.
- Suitable reinforcing particles include, but are not limited to, particles of metals, metal alloys, superalloys, intermetallics, borides, carbides, nitrides, oxides, ceramics, diamonds, and the like, or any combination thereof.
- examples of reinforcing particles suitable for use in conjunction with the embodiments described herein may include particles that include, but are not limited to, tungsten, molybdenum, niobium, tantalum, rhenium, iridium, ruthenium, beryllium, titanium, chromium, rhodium, iron, cobalt, uranium, nickel, nitrides, silicon nitrides, boron nitrides, cubic boron nitrides, natural diamonds, synthetic diamonds, cemented carbide, spherical carbides, low-alloy sintered materials, cast carbides, silicon carbides, boron carbides, cubic boron carbides, molybdenum carbides, titanium carbides, tantalum carbides, niobium carbides, chromium carbides, vanadium carbides, iron carbides, tungsten carbides, macrocrystalline tungsten carbides, cast tungsten carbides, crushed sintered tungsten carbides
- the reinforcing particles described herein may have a diameter ranging from a lower limit of 1 micron, 10 microns, 50 microns, or 100 microns to an upper limit of 1000 microns, 800 microns, 500 microns, 400 microns, or 200 microns, wherein the diameter of the reinforcing particles may range from any lower limit to any upper limit and encompasses any subset therebetween.
- the metal blank 202 may be supported at least partially by the reinforcement materials 318 within the infiltration chamber 312 . More particularly, after a sufficient volume of the reinforcement materials 318 (including both reinforcing particles and one or more selectively placed ceramic or intermetallic workpieces) has been added to the mold assembly 300 , the metal blank 202 may then be placed within mold assembly 300 .
- the metal blank 202 may include an inside diameter 320 that is greater than an outside diameter 322 of the central displacement 316 , and various fixtures (not expressly shown) may be used to position the metal blank 202 within the mold assembly 300 at a desired location.
- the reinforcement materials 318 may then be filled to a desired level within the infiltration chamber 312 .
- Binder material 324 may then be placed on top of the reinforcement materials 318 , the metal blank 202 , and the core 316 .
- Suitable binder materials 324 include, but are not limited to, copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, any mixture thereof, any alloy thereof, and any combination thereof.
- Non-limiting examples of the binder material 324 may include copper-phosphorus, copper-phosphorous-silver, copper-manganese-phosphorous, copper-nickel, copper-manganese-nickel, copper-manganese-zinc, copper-manganese-nickel-zinc, copper-nickel-indium, copper-tin-manganese-nickel, copper-tin-manganese-nickel-iron, gold-nickel, gold-palladium-nickel, gold-copper-nickel, silver-copper-zinc-nickel, silver-manganese, silver-copper-zinc-cadmium, silver-copper-tin, cobalt-silicon-chromium-nickel-tungsten, cobalt-silicon-chromium-nickel-tungsten-boron, manganese-nickel-cobalt-boron, nickel-silicon-chromium, nickel-chromium-silicon-manganese, nickel
- binder materials 324 include, but are not limited to, VIRGINTM Binder 453D (copper-manganese-nickel-zinc, available from Belmont Metals, Inc.), and copper-tin-manganese-nickel and copper-tin-manganese-nickel-iron grades 516, 519, 523, 512, 518, and 520 available from ATI Firth Sterling.
- VIRGINTM Binder 453D copper-manganese-nickel-zinc, available from Belmont Metals, Inc.
- the binder material 324 may be covered with a flux layer (not expressly shown).
- the amount of binder material 324 (and optional flux material) added to the infiltration chamber 312 should be at least enough to infiltrate the reinforcement materials 318 and, optionally, the one or more ceramic or intermetallic workpieces during the infiltration process.
- some or all of the binder material 324 may be placed in the binder bowl 308 , which may be used to distribute the binder material 324 into the infiltration chamber 312 via various conduits 326 that extend therethrough.
- the cap 310 (if used) may then be placed over the mold assembly 300 .
- the mold assembly 300 and the materials disposed therein may then be preheated and then placed in a furnace (not shown). When the furnace temperature reaches the melting point of the binder material 324 , the binder material 324 will liquefy and proceed to infiltrate the reinforcement materials 318 .
- the mold assembly 300 may then be removed from the furnace and cooled at a controlled rate. Once cooled, the mold assembly 300 may be broken away to expose the bit body 108 ( FIGS. 2 and 3 ) that includes the hard composite portion 208 ( FIG. 3 ). Subsequent processing according to well-known techniques may be used to finish the drill bit 100 ( FIG. 2 ).
- one or more ceramic or intermetallic workpieces may also be included in the reinforcement materials 318 to be infiltrated by the binder material 324 .
- the ceramic or intermetallic workpieces described herein may prove advantageous in reinforcing the hard composite portion 208 ( FIG. 3 ) of the drill bit 100 of FIGS. 2 and 3 and thereby helping to increase strength, hardness, and/or erosion resistance, thereby resisting deflection, deformation, erosion, and/or abrasion during operation. Such properties may increase the lifetime of the drill bit 100 once in use.
- the material or composition of the ceramic or intermetallic workpieces may bond with the binder material 324 , so that an increased amount of thermal and mechanical stresses (or loads) can be transferred to the ceramic or intermetallic workpieces. Further, a composition that bonds with the binder material 324 may be less likely to pull out from the binder material 324 as a crack propagates. In some embodiments, the material or composition of the ceramic or intermetallic workpieces may be designed to endure temperatures and pressures experienced when forming the hard composite portion 208 ( FIG. 3 ) with little to no alloying with the binder material 324 or oxidation.
- the atmospheric conditions may be altered (e.g., reduced oxygen content achieved via reduced pressures or gas purge or vacuum) to mitigate oxidation of the ceramic or intermetallic workpieces and thereby enhance bonding between the ceramic or intermetallic workpieces and the binder.
- Such atmospheric conditions may allow for a binder composition that may not be suitable for use in standard atmospheric oxygen concentrations.
- the ceramic or intermetallic workpieces may be fabricated to exhibit any desired shape, configuration, and size, depending primarily on the fabrication capabilities of the selected additive manufacturing technique used to initially fabricate the porous metallic workpieces.
- the ceramic or intermetallic workpieces may positioned in select regions of the hard composite portion 208 ( FIG. 3 ) prior to infiltration.
- a ceramic or intermetallic workpiece may be positioned in each blade 102 ( FIG. 2 ) region to provide structural reinforcement and erosion-resistance.
- one or more ceramic or intermetallic workpieces may be arranged or otherwise positioned to form the cutter pockets 116 ( FIGS.
- the entire bit body 108 may comprise a single ceramic or intermetallic workpiece to be infiltrated by the binder material 324 .
- one or more ceramic or intermetallic workpieces may be arranged or otherwise positioned to form a macroscopic reinforcing structure that connects at least one of the blades to at least one other blade (e.g., a gear-like shape positioned with teeth protruding into each blade).
- FIGS. 5-7 provide examples of implementing ceramic or intermetallic workpieces described herein into the bit body 108 of the drill bit 100 of FIGS. 2 and 3 .
- MMC composite
- placement of the ceramic or intermetallic workpieces within the bit body 108 or the hard composite portion 208 may be localized. Localization, in some instances, may provide enhanced strength and stiffness and may reduce the erosion properties of the drill bit 100 .
- FIG. 5 illustrates a cross-sectional side view of the drill bit 100 as comprising the hard composite portion 208 and one or more localized ceramic or intermetallic workpieces 502 , according to one or more embodiments.
- the ceramic or intermetallic workpiece(s) 502 may be localized in the bit body 108 in one or more locations with the remaining portion of the bit body 108 being formed by the hard composite portion 208 (e.g., comprising binder material 324 and reinforcing particles without the ceramic or intermetallic workpiece(s) 502 ).
- the localized ceramic or intermetallic workpiece(s) 502 is shown in FIG.
- the term “apex” refers to the central portion of the exterior surface of the bit body 108 that engages the formation during drilling and generally at or near where the cutter blades 102 ( FIG. 1 ) meet on the exterior surface of the bit body 108 to engage the formation during drilling.
- localization of the ceramic or intermetallic workpiece(s) 502 may help mitigate crack initiation and propagation, while also manipulating the erosion properties of the bit body 108 because of the lower concentration of reinforcing particles at the localized areas.
- FIG. 6 illustrates a cross-sectional side view of the drill bit 100 as comprising the hard composite portion 208 and one or more localized ceramic or intermetallic workpieces 502 , according to one or more embodiments.
- the ceramic or intermetallic workpiece(s) 502 may comprise a monolithic structure or it may denote a region that is reinforced with mesoscale reinforcing structures or workpieces.
- the ceramic or intermetallic workpiece(s) 502 may be located proximal the nozzle openings 122 and the pockets 116 , and otherwise encompassing the blades 102 ( FIG. 1 ) and/or the center of the bit body 108 .
- the porosity of the ceramic or intermetallic workpiece(s) 502 may change in concentration, geometry, or both along radial, circumferential, and/or longitudinal directions. Similar to localization, changing the concentration, geometry, or both of the ceramic or intermetallic workpiece(s) 502 may, in some instances, be used to enhance strength and stiffness and further to maintain suitable erosion resistance.
- FIG. 7 illustrates a cross-sectional side view of the drill bit 100 as comprising the hard composite portion 208 and multiple ceramic or intermetallic workpieces 502 , according to one or more embodiments.
- the workpieces 502 illustrated in FIG. 7 may be monolithic structures or they may denote regions reinforced with mesoscale reinforcing structures or workpieces. More particularly, the ceramic or intermetallic workpieces 502 are shown to be located proximal the nozzle openings 122 and the pockets 116 in separate layers or workpieces 502 a , 502 b , and 502 c .
- the porosity of the workpieces 502 a - c may vary from one another and/or within themselves so as to vary the mechanical properties of the bit body 108 following infiltration.
- the porosity of the first workpiece 502 a may be greater than the porosity of the second workpiece 502 b , which may be greater than the porosity of the third workpiece 502 c .
- the first workpiece 502 a may be harder than the third workpiece 502 c following infiltration.
- the first workpiece 502 a is depicted as being located proximal the nozzle openings 122 and the pockets 116 to provide increased erosion-resistance.
- FIG. 8 illustrated is an exemplary drilling system 800 that may employ one or more principles of the present disclosure.
- Boreholes may be created by drilling into the earth 802 using the drilling system 800 .
- the drilling system 800 may be configured to drive a bottom hole assembly (BHA) 804 positioned or otherwise arranged at the bottom of a drill string 806 extended into the earth 802 from a derrick 808 arranged at the surface 810 .
- the derrick 808 includes a kelly 812 and a traveling block 813 used to lower and raise the kelly 812 and the drill string 806 .
- the BHA 804 may include a drill bit 814 operatively coupled to a tool string 816 which may be moved axially within a drilled wellbore 818 as attached to the drill string 806 .
- the drill bit 814 may be fabricated and otherwise created in accordance with the principles of the present disclosure and, more particularly, using one or more ceramic or intermetallic workpieces infiltrated into the bit body 108 .
- the drill bit 814 penetrates the earth 802 and thereby creates the wellbore 118 .
- the BHA 804 provides directional control of the drill bit 814 as it advances into the earth 802 .
- the tool string 816 can be semi-permanently mounted with various measurement tools (not shown) such as, but not limited to, measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools, that may be configured to take downhole measurements of drilling conditions.
- measurement tools such as, but not limited to, measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools, that may be configured to take downhole measurements of drilling conditions.
- the measurement tools may be self-contained within the tool string 816 , as shown in FIG. 9 .
- Fluid or “mud” from a mud tank 820 may be pumped downhole using a mud pump 822 powered by an adjacent power source, such as a prime mover or motor 824 .
- the mud may be pumped from the mud tank 820 , through a stand pipe 826 , which feeds the mud into the drill string 806 and conveys the same to the drill bit 814 .
- the mud exits one or more nozzles arranged in the drill bit 814 and in the process cools the drill bit 814 .
- the mud circulates back to the surface 810 via the annulus defined between the wellbore 818 and the drill string 806 , and in the process returns drill cuttings and debris to the surface.
- the cuttings and mud mixture are passed through a flow line 828 and are processed such that a cleaned mud is returned down hole through the stand pipe 826 once again.
- drills and drill rigs used in embodiments of the disclosure may be used onshore (as depicted in FIG. 1 ) or offshore (not shown).
- Offshore oil rigs that may be used in accordance with embodiments of the disclosure include, for example, floaters, fixed platforms, gravity-based structures, drill ships, semi-submersible platforms, jack-up drilling rigs, tension-leg platforms, and the like. It will be appreciated that embodiments of the disclosure can be applied to rigs ranging anywhere from small in size and portable, to bulky and permanent.
- embodiments of the disclosure may be used in many other applications.
- disclosed methods can be used in drilling for mineral exploration, environmental investigation, natural gas extraction, underground installation, mining operations, water wells, geothermal wells, and the like.
- embodiments of the disclosure may be used in weight-on-packers assemblies, in running liner hangers, in running completion strings, etc., without departing from the scope of the disclosure.
- a method of manufacturing a part that includes printing a three-dimensional porous metallic workpiece via an additive manufacturing process, and subjecting the porous metallic workpiece to a diffusion-based process and thereby converting at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece, wherein the porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process.
- a method of fabricating a drill bit that includes positioning one or more ceramic or intermetallic workpieces into a mold assembly that defines at least a portion of an infiltration chamber, wherein each ceramic or intermetallic workpiece is made by printing a three-dimensional porous metallic workpiece via an additive manufacturing process, and subjecting the porous metallic workpiece to a diffusion-based process and thereby converting at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece, wherein the porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process.
- the method further including depositing reinforcing materials into the infiltration chamber, and infiltrating the one or more ceramic or intermetallic workpieces and the reinforcing materials with a binder material and thereby producing a composite.
- Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element 1: wherein the additive manufacturing process is selected from the group consisting of laser sintering, laser melting, electron-beam melting, laser metal deposition, fused deposition modeling, fused filament fabrication, selective laser sintering, stereolithography, laminated object manufacturing, polyjet, and any combination thereof.
- the additive manufacturing process is selected from the group consisting of laser sintering, laser melting, electron-beam melting, laser metal deposition, fused deposition modeling, fused filament fabrication, selective laser sintering, stereolithography, laminated object manufacturing, polyjet, and any combination thereof.
- Element 2 wherein the part is selected from the group consisting of an oilfield drill bit or cutting tool, a non-retrievable drilling component, an aluminum drill bit body, a drill-string stabilizer, a cone for a roller-cone drill bit, a model for forging dies, an arm for a fixed reamer, an arm for an expandable reamer, an internal component associated with an expandable reamer, a sleeve attachable to an uphole end of a rotary drill bit, a rotary steering tool, a logging-while-drilling tool, a measurement-while-drilling tool, a side-wall coring tool, a fishing spear, a washover tool, a rotor, a stator and/or housing for a downhole drilling motor, a blade for a downhole turbine, armor plating, an automotive component, a bicycle frame, a brake fin, an aerospace component, a turbopump component, a screen, a filter, a porous catalyst
- porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process.
- Element 4 wherein the metal is selected from the group consisting of aluminum, antimony, barium, beryllium, bismuth, boron, cadmium, calcium, cerium, cesium, chromium, cobalt, copper, erbium, europium, gadolinium, gallium, germanium, hafnium, holmium, indium, iron, lanthanum, lead, lutetium, lithium, magnesium, manganese, molybdenum, neodymium, nickel, niobium, osmium, palladium, platinum, potassium, praseodymium, rhenium, rhodium, rubidium, ruthenium, samarium, scandium, silicon, sodium, strontium, tantalum, tellurium, terbium, thulium, tin, titanium, tungsten, vanadium, yttrium, ytterbium, zinc, and zirconium.
- the metal is selected from
- the metal alloy is an alloy resulting from the combination of at least two metals selected from the group consisting of aluminum, antimony, barium, beryllium, bismuth, boron, cadmium, calcium, cerium, cesium, chromium, cobalt, copper, erbium, europium, gadolinium, gallium, germanium, hafnium, holmium, indium, iron, lanthanum, lead, lutetium, lithium, magnesium, manganese, molybdenum, neodymium, nickel, niobium, osmium, palladium, platinum, potassium, praseodymium, rhenium, rhodium, rubidium, ruthenium, samarium, scandium, silicon, sodium, strontium, tantalum, tellurium, terbium, thulium, tin, titanium, tungsten, vanadium, yttrium, ytterbium, zinc
- Element 6 wherein some or all of the metallic workpiece is subjected to the reaction atmosphere during the diffusion-based process, the reaction atmosphere comprising a media selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof.
- Element 7 wherein the ceramic workpiece or the intermetallic workpiece is infiltrated with a binder material to produce a composite.
- the binder material is a material selected from the group consisting of copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, and alloy thereof.
- Element 9 further comprising infiltrating the ceramic workpiece or the intermetallic workpiece with a binder material and thereby producing a composite.
- Element 10 wherein infiltrating the ceramic workpiece or the intermetallic workpiece with a binder material comprises liquefying the binder material, and infiltrating at least a portion of a porous network of the ceramic workpiece or the intermetallic workpiece with a liquefied binder material.
- Element 11 further comprising penetrating at least a portion of a porous network of the porous metallic workpiece with a media of the reaction atmosphere, wherein the media is selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof.
- subjecting the porous metallic 0 workpiece to the diffusion-based process comprises masking at least a portion of the porous metallic workpiece and thereby preventing a media of the reaction atmosphere from accessing at least a portion of the porous metallic workpiece.
- Element 13 further comprising terminating the diffusion-based process prematurely to prevent a media of the reaction atmosphere from accessing at least a portion of the porous metallic workpiece.
- Element 14 wherein infiltrating the one or more ceramic or intermetallic workpieces with the binder material comprises liquefying the binder material, and infiltrating at least a portion of a porous network of the one or more ceramic or intermetallic workpieces with a liquefied binder material.
- Element 15 further comprising penetrating at least a portion of a porous network of the porous metallic workpiece with a media of the reaction atmosphere, wherein the media is selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof.
- infiltrating the one or more ceramic or intermetallic workpieces with the binder material comprises infiltrating the one or more ceramic or intermetallic workpieces with a binder material selected from the group consisting of copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, and alloy thereof.
- a binder material selected from the group consisting of copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, ha
- Element 17 wherein the mold assembly defines one or more cutter pockets, and wherein positioning the one or more ceramic or intermetallic workpieces into the mold assembly comprises positioning the one or more ceramic or intermetallic workpieces adjacent or near the one or more cutter pockets.
- Element 18 wherein the mold assembly defines one or more blade regions, and wherein positioning the one or more ceramic or intermetallic workpieces into the mold assembly comprises positioning at least one ceramic or intermetallic workpiece into each blade region.
- exemplary combinations applicable to A, B, and C include: Element 3 with Element 4; Element 3 with Element 5; Element 3 with Element 6; Element 7 with Element 8; and Element 9 with Element 10.
- compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values.
- the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item).
- the phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items.
- the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
Abstract
Description
- Additive manufacturing (e.g., 3D printing) can provide certain advantages over traditional manufacturing processes. For manufacturing drill bits used in the oil and gas industry, for example, one of the most significant advantages of additive manufacturing is the design flexibility and the ability to create forms and features not feasible any other way. Similar advantages of additive manufacturing are applicable to other industries. Additive manufacturing systems, such as direct metal laser sintering or electron-beam melting, are currently available for fabricating or “printing” metal components. Printing ceramic materials via additive manufacturing, however, poses significant challenges.
- In general, ceramic materials are bonded together using water or a binding agent, such as a polymer or a metal. The bonded structure is then fired using conventional ceramic processing steps to convert the bonded structure to a ceramic. In additive manufacturing, it is difficult to bond or melt ceramic particles to build up an additive manufactured structure due to the high melting temperature of the ceramic particles. Moreover, ceramics particles are brittle and therefore sensitive to thermal stresses common to additive manufacturing as each successive layer is melted or sintered and cooled to build up the desired structure or part.
- The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.
-
FIG. 1 is a schematic flowchart of an exemplary method of fabricating a part. -
FIG. 2 is a perspective view of an exemplary drill bit that may be at least partially fabricated in accordance with the principles of the present disclosure. -
FIG. 3 is a cross-sectional view of the drill bit ofFIG. 2 . -
FIG. 4 is a cross-sectional side view of an exemplary mold assembly for use in forming the drill bit ofFIG. 2 . -
FIG. 5 is a cross-sectional side view of the drill bit ofFIG. 2 as comprising a hard composite portion and one or more localized ceramic or intermetallic workpieces. -
FIG. 6 is a cross-sectional side view of the drill bit ofFIG. 2 as comprising a hard composite portion and a ceramic or intermetallic workpiece. -
FIG. 7 is a cross-sectional view of the drill bit ofFIG. 2 as comprising a hard composite portion and multiple ceramic or intermetallic workpieces. -
FIG. 8 is a schematic drawing showing one example of a drilling assembly suitable for use in conjunction with the drill bits of the present disclosure. - The present disclosure relates to part manufacturing and, more particularly, to fabricating ceramic or intermetallic parts using additive manufacturing.
- Embodiments described herein provide processes or methods that allow ceramic or intermetallic materials to be fabricated using additive manufacturing techniques. The presently disclosed methods may be used, for example, to print a three-dimensional porous metallic workpiece via an additive manufacturing process. The porous metallic workpiece is subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece. Burnout of binding agents typically included in a ceramic is not necessary since the resulting ceramic or intermetallic structure is initially produced as a metallic structure or workpiece, after which a suitable diffusion-based process transforms the metallic workpiece in situ to a ceramic or intermetallic. In one specific embodiment, a part may be manufactured by printing and carburizing a tungsten structure resulting in a tungsten carbide structure, such as a drill bit or a drill bit component, which may subsequently be infiltrated to form a tungsten carbide metal-matrix composite. It will be appreciated that many different shapes and structures are possible beyond those common to particle production methods, foam production methods, and resulting structures of packed powder.
- The principles of the present disclosure may be applied to manufacturing tools or parts commonly used in the oil and gas industry for the exploration and recovery of hydrocarbons. Such tools and parts include, but are not limited to, oilfield drill bits or cutting tools (e.g., fixed-angle drill bits, roller-cone drill bits, coring drill bits, bi-center drill bits, impregnated drill bits, reamers, stabilizers, hole openers, cutters), non-retrievable drilling components, aluminum drill bit bodies associated with casing drilling of wellbores, drill-string stabilizers, cones for roller-cone drill bits, models for forging dies used to fabricate support arms for roller-cone drill bits, arms for fixed reamers, arms for expandable reamers, internal components associated with expandable reamers, sleeves attached to an uphole end of a rotary drill bit, rotary steering tools, logging-while-drilling tools, measurement-while-drilling tools, side-wall coring tools, fishing spears, washover tools, rotors, stators and/or housings for downhole drilling motors, blades and housings for downhole turbines, and other downhole tools having complex configurations and/or asymmetric geometries associated with forming a wellbore.
- It will be appreciated, however, that the principles of the present disclosure may be equally be applied to manufacturing tools or parts used in any other industry or field that may benefit from the fabrication of ceramic or intermetallic parts. For instance, the methods described herein may be applied to fabricating armor plating, automotive components (e.g., sleeves, cylinder liners, driveshafts, exhaust valves, brake rotors), bicycle frames, brake fins, aerospace components (e.g., landing-gear components, structural tubes, struts, shafts, links, ducts, waveguides, guide vanes, rotor-blade sleeves, ventral fins, actuators, exhaust structures, cases, frames, fuel nozzles), turbopump components, a screen, a filter, and a porous catalyst, without departing from the scope of the disclosure. Those skilled in the art will readily appreciate that the foregoing list is not a comprehensive listing, but only exemplary. Accordingly, the foregoing listing of parts and/or components should not be limiting to the scope of the present disclosure.
- As used herein, the term “part” refers to any tool, part, component, or structure that may benefit from being manufactured as a ceramic or intermetallic, either in its entirety or in part. It should be noted that the shape, configuration, design, or size of the part fabricated using the principles or methods described herein is only limited by the selected additive manufacturing process used to fabricate the desired part. For instance, a ceramic or intermetallic part produced by additive manufacturing and the principles disclosed herein may take a variety of forms, such as a completed part, a porous network that is subsequently infiltrated or filled in to form a metal-matrix or ceramic-matrix composite, or various components or reinforcement formats that may be used to reinforce a composite material. Examples of the ceramic or intermetallic material formed by additive manufacturing include powders, mesoscale structures, and building-block components to be used in creating larger structures. Examples of suitable composite materials include sites, and the like. Such ceramic or intermetallic components may be used to reinforce metals, alloys, or metal-matrix composites such that the parts become suitable replacements for oxide dispersion-strengthened alloys. Furthermore, the production of ceramic-matrix composites using such ceramic or intermetallic components may produce additional strengthening in a porous network of mesoscale structures that is not achievable by the conventional fiber-reinforcement method. The principles disclosed herein can also be employed to create ceramic parts where an open porous structure is required such as a filter, a screen, a catalyst, and the like.
- Intermetallics are generally classified in two groups: stoichiometric and non-stoichiometric. Stoichiometric intermetallics, such as Al3Ni, have a fixed composition (e.g., a vertical line on a phase diagram) and, similar to ceramic materials, are generally very hard, strong, and brittle. Non-stoichiometric intermetallics, such as AlNi, occur over a range of compositions and are generally more ductile than stoichiometric intermetallics. As a result, non-stoichiometric intermetallics provide intermediate properties between those of ceramics and stoichiometric intermetallics and those of pure metals and solid-solution alloys. More particularly, stoichiometric intermetallic structures provide enhanced stiffness and strength, similar to ceramics, whereas non-stoichiometric intermetallic structures provide intermediate reinforcing properties (e.g., still stiffer than matrix materials, that is to say, binder or alloy materials, but with some ductility compared to ceramic and stoichiometric intermetallic materials).
- Referring to
FIG. 1 , illustrated is a schematic flowchart of anexemplary method 10 of fabricating a part, according to one or more embodiments. Themethod 10 may include printing a three-dimensional porous metallic workpiece using an additive manufacturing process, as at 12. The additive manufacturing process (e.g., 3D printing) may include, but is not limited to, laser sintering (LS) [e.g., selective laser sintering (SLS), direct metal laser sintering (DMLS)], laser melting (LM) [e.g., selective laser melting (SLM), lasercusing], electron-beam melting (EBM), laser metal deposition [e.g., direct metal deposition (DMD), laser engineered net shaping (LENS), directed light fabrication (DLF), direct laser deposition (DLD), direct laser fabrication (DLF), laser rapid forming (LRF), laser melting deposition (LMD)], any combination thereof, and the like. The resulting metallic workpiece may be printed to any desired shape, configuration, design, or size to correspond to the specific part being fabricated. - The metallic workpiece may be made out of any base metal or base metal alloy that can form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to appropriate conditions. Carbides may be formed by using aluminum, boron, calcium, cerium, chromium, erbium, iron, hafnium, lanthanum, lithium, magnesium, manganese, molybdenum, niobium, praseodymium, scandium, silicon, tantalum, titanium, vanadium, tungsten, yttrium, ytterbium, and zirconium. Nitrides may be formed by using aluminum, boron, calcium, cerium, cobalt, chromium, iron, gallium, hafnium, indium, lithium, magnesium, manganese, molybdenum, niobium, nickel, scandium, silicon, tantalum, titanium, vanadium, tungsten, yttrium, and zirconium. Borides may be formed by using aluminum, barium, beryllium, calcium, cerium, cobalt, chromium, dysprosium, erbium, europium, iron, gadolinium, hafnium, holmium, lanthanum, lithium, lutetium, magnesium, manganese, molybdenum, niobium, neodymium, nickel, osmium, palladium, praseodymium, platinum, rhenium, rhodium, ruthenium, scandium, samarium, strontium, tantalum, terbium, titanium, thulium, vanadium, tungsten, yttrium, ytterbium, and zirconium. Oxides may be formed by using aluminum, barium, beryllium, bismuth, calcium, cadmium, cerium, cobalt, chromium, cesium, copper, erbium, iron, gallium, germanium, hafnium, indium, potassium, lanthanum, lithium, magnesium, manganese, molybdenum, sodium, niobium, neodymium, nickel, lead, praseodymium, rubidium, antimony, scandium, silicon, tin, strontium, tantalum, terbium, tellurium, titanium, vanadium, tungsten, yttrium, zinc, and zirconium. Silicides may be formed by using barium, boron, calcium, cerium, cobalt, chromium, dysprosium, erbium, iron, gadolinium, hafnium, holmium, iridium, lanthanum, lithium, lutetium, magnesium, manganese, molybdenum, niobium, neodymium, nickel, osmium, palladium, praseodymium, platinum, rhenium, rhodium, ruthenium, scandium, samarium, strontium, tantalum, terbium, tellurium, titanium, thulium, vanadium, tungsten, yttrium, ytterbium, and zirconium.
- Intermetallics (both stoichiometric and non-stoichiometric) may be formed by using at least two metallic elements that form intermetallic compounds. In addition to the ceramic materials already listed herein, examples of elements that form refractory aluminum-based intermetallics include cobalt, chromium, copper, iron, hafnium, iridium, manganese, molybdenum, niobium, nickel, palladium, platinum, rhenium, ruthenium, scandium, tantalum, titanium, vanadium, tungsten, and zirconium. Other examples of refractory intermetallic systems include silver-titanium, silver-zirconium, gold-hafnium, gold-manganese, gold-niobium, gold-scandium, gold-tantalum, gold-titanium, gold-thulium, gold-vanadium, gold-zirconium, beryllium-copper, beryllium-iron, beryllium-niobium, beryllium-nickel, beryllium-palladium, beryllium-titanium, beryllium-vanadium, beryllium-tungsten, beryllium-zirconium, any combination thereof, and the like. This skilled in the art will readily appreciate that the principles of the present disclosure can apply to several other potential intermetallics not listed herein, without departing from the scope of the disclosure.
- Suitable base metals that may be used to form the metallic workpiece and subsequently form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic include, but are not limited to, any element from any of the foregoing lists. Suitable base metal alloys that may be used to form the metallic workpiece and subsequently form a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic include, but are not limited to, any alloy wherein the most prevalent element, when measured by weight, is from one of the foregoing lists.
- Once printed, the porous metallic workpiece may then be subjected to a diffusion-based process to convert at least a portion of the metallic workpiece to a ceramic or intermetallic workpiece, as at 14. Suitable diffusion-based processes include, but are not limited to, carburizing, nitriding, bonding, and oxidizing, all of which may convert the metallic workpiece into a desired ceramic or intermetallic composition. During the diffusion-based process, some or all of the metallic workpiece may be subjected to a reaction atmosphere comprising any capable media that may result in the production of a ceramic (e.g., an oxide, a carbide, a boride, a nitride, a silicide) or an intermetallic material (e.g., AlNi, TiAl). Suitable media includes, but is not limited to, methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, vaporized metal (i.e., gas), molten metal, or any combination thereof.
- As will be appreciated, the porosity of the metallic workpiece may allow the media of the reaction atmosphere to access some or all of the internals of the metallic workpiece and thereby react with and diffuse into all desired regions thereof. In some embodiments, the metallic workpiece may be printed such that the porosity is relatively low in select regions or throughout all of the metallic workpiece. Such embodiments may result in a ceramic or intermetallic part that may be more ductile (e.g., still metallic) at its core or in selected regions. For instance, in such embodiments, the media of the reaction atmosphere may be unable to access and react with the center of the metallic workpiece, thereby resulting in a part that is more ductile at its core. In other embodiments, portions of the metallic workpiece may be masked off such that the media of the reaction atmosphere is unable to access the masked-off portions and a ceramic or intermetallic material will, therefore, not result at those regions. In yet other embodiments, the diffusion-based process may be terminated prematurely such that the media of the reaction atmosphere is unable to completely react with all portions of the metallic workpiece, thereby also potentially resulting in a ductile core, such as is done in case-hardening applications. Furthermore, in certain cases a gradient of materials (e.g., alloys, intermetallics, and ceramics) may result from the process, thereby producing a functional gradient of properties. As an example, a Ni core may remain with a NiAl intermediate layer and a NiAl3 outer layer.
- The diffusion-based process may be conducted at an elevated temperature within a furnace, for example. The furnace used to conduct the diffusion-based process may comprise a continuous or batch furnace capable of operating with the desired media of the reaction atmosphere. Suitable furnaces include, but are not limited to, a belt furnace, a vacuum furnace, a muffle furnace, a retort furnace, any combination thereof, and the like.
- In some embodiments, the diffusion-based process may incorporate the use of a liquid-metal bath. More particularly, the liquid-metal bath may be useful in reacting constituents together to create the ceramic or intermetallic part. In such embodiments, the metallic workpiece may be immersed in a liquid-metal bath to create the ceramic or intermetallic part. As an example, in an embodiment where the metallic workpiece is manufactured from a nickel-based metal, the nickel-based workpiece may be immersed in an aluminum bath to produce an intermetallic, such as AlNi3, AlNi, Al3Ni2, or Al3Ni. As noted above, this process may be carried to completion to completely transform the Ni to an intermetallic composition, or it may be carried to an intermediate stage that may produce one of these intermetallic phases throughout the part or a functional gradient of phases (and properties), depending on the time and temperature cycle of the diffusion-based process.
- As will be appreciated, the
method 10 may prove advantageous in fabricating parts from several commonly used ceramic or intermetallic material systems. Tungsten carbide (WC), for example, is commonly used in the oil and gas industry to fabricate hard and erosion-resistant parts. According to the present disclosure, WC parts may be fabricated using themethod 10. In such embodiments, a porous tungsten metallic workpiece may first be printed using additive manufacturing to a desired size and shape, as at 12. In at least one embodiment, the porous tungsten metallic workpiece may comprise a plurality of mesoscale reinforcement components. The printed tungsten metallic workpiece may then be carburized via the above-described diffusion-based processes to provide a WC part, as at 14. Other material systems that may be produced using themethod 10 include, but are not limited to, Al2O3, AlN, BN, B4C, CrB2, Cr2C3, NbC, SiC, Si3N4, TiB2, TiC, TiN, Ti(C,N), VC, MgO, Y2O3, or any carbide, oxide, boride, nitride, silicide or any intermetallic compound in which at least one metallic component of the resulting intermetallic or ceramic is capable of being printed using additive manufacturing. - Still referring to
FIG. 1 , in some embodiments, themethod 10 may optionally and further include infiltrating the ceramic or intermetallic workpiece with a binder material to produce a composite, as at 16. Example composites include metal-matrix, ceramic-matrix, and polymer-matrix composites. A metal-matrix composite (MMC) is generally made from a reinforcement material that is infiltrated with a binder or infiltration or matrix material. In the present embodiment, the ceramic or intermetallic workpiece may comprise the reinforcement material, and the binder material may include, but is not limited to, copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, any mixture thereof, any alloy thereof, and any combination thereof. - The infiltration process may include placing the ceramic or intermetallic workpiece and the binder material into a furnace. In some embodiments, the ceramic or intermetallic workpiece and the binder material may be deposited in a container or a mold prior to being introduced into the furnace. When the furnace temperature reaches the melting point of the binder material, the binder material will liquefy and proceed to infiltrate the porous network of the ceramic or intermetallic workpiece. After a predetermined amount of time allotted for the liquefied binder material to infiltrate the porous network of the ceramic or intermetallic workpiece, the resulting composite may then be removed from the furnace and cooled at a controlled rate. The resulting composite may be a sealed or solid composite part or tool.
- Referring now to
FIG. 2 , illustrated is a perspective view of anexemplary drill bit 100 that may be fabricated, at least in part, in accordance with the principles of the present disclosure. More particularly, one or more portions of thedrill bit 100 may be fabricated using themethod 10 ofFIG. 1 . It will be appreciated, however, that discussion of thedrill bit 100 may equally apply to any of the parts mentioned or described herein that may be used in the oil and gas industry or any other industry, without departing from the scope of the disclosure. - In some embodiments, all of the
drill bit 100 may be fabricated using themethod 10, but in other embodiments, only select portions of thedrill bit 100 may be fabricated using themethod 10. As illustrated inFIG. 2 , thedrill bit 100 may include or otherwise define a plurality ofcutter blades 102 arranged along the circumference of abit head 104. Thebit head 104 is connected to ashank 106 to form abit body 108. Theshank 106 may be connected to thebit head 104 by welding, such as using laser arc welding that results in the formation of aweld 110 around aweld groove 112. Theshank 106 may further include or otherwise be connected to a threadedpin 114, such as an American Petroleum Institute (API) drill pipe thread. - In the depicted example, the
drill bit 100 includes fivecutter blades 102, in which multiple recesses orpockets 116 are formed.Cutting elements 118 may be fixedly installed within eachrecess 116. This can be done, for example, by brazing each cuttingelement 118 into acorresponding recess 116. As thedrill bit 100 is rotated in use, the cuttingelements 118 engage the rock and underlying earthen materials, to dig, scrape or grind away the material of the formation being penetrated. - During drilling operations, drilling fluid or “mud” can be pumped downhole through a drill string (not shown) coupled to the
drill bit 100 at the threadedpin 114. The drilling fluid circulates through and out of thedrill bit 100 at one ormore nozzles 120 positioned innozzle openings 122 defined in thebit head 104.Junk slots 124 are formed between each adjacent pair ofcutter blades 102. Cuttings, downhole debris, formation fluids, drilling fluid, etc., may pass through thejunk slots 124 and circulate back to the well surface within an annulus formed between exterior portions of the drill string and the inner wall of the wellbore being drilled. -
FIG. 3 is a cross-sectional side view of thedrill bit 100 ofFIG. 2 . Similar numerals fromFIG. 2 that are used inFIG. 3 refer to similar components that are not described again. As illustrated, theshank 106 may be securely attached to a metal blank (or mandrel) 202 at theweld 110 and themetal blank 202 extends into thebit body 108. Theshank 106 and themetal blank 202 are generally cylindrical structures that define correspondingfluid cavities fluid cavity 204 b of themetal blank 202 may further extend longitudinally into thebit body 108. At least one flow passageway 206 (one shown) may extend from thefluid cavity 204 b to exterior portions of thebit body 108. The nozzle openings 122 (one shown inFIG. 2 ) may be defined at the ends of theflow passageways 206 at the exterior portions of thebit body 108. Thepockets 116 are formed in thebit body 108 and are shaped or otherwise configured to receive the cutting elements 118 (FIG. 2 ). Thebit body 108 may comprise a hardcomposite portion 208 and, in accordance with the teachings of the present disclosure, all or any portion of the hardcomposite portion 208 may be fabricated in accordance with the method ofFIG. 1 . -
FIG. 4 is a cross-sectional side view of amold assembly 300 that may be used to form thedrill bit 100 ofFIGS. 2 and 3 . While themold assembly 300 is shown and discussed as being used to help fabricate thedrill bit 100, those skilled in the art will readily appreciate that themold assembly 300 and its several variations described herein may be used to help fabricate any of the downhole tools or parts mentioned above, without departing from the scope of the disclosure. As illustrated, themold assembly 300 may include several components such as amold 302, agauge ring 304, and afunnel 306. In some embodiments, thefunnel 306 may be operatively coupled to themold 302 via thegauge ring 304, such as by corresponding threaded engagements, as illustrated. In other embodiments, thegauge ring 304 may be omitted from themold assembly 300 and thefunnel 306 may instead be operatively coupled directly to themold 302, such as via a corresponding threaded engagement, without departing from the scope of the disclosure. - In some embodiments, as illustrated, the
mold assembly 300 may further include abinder bowl 308 and acap 310 placed above thefunnel 306. Themold 302, thegauge ring 304, thefunnel 306, thebinder bowl 308, and thecap 310 may each be made of or otherwise comprise graphite or alumina (Al2O3), for example, or other suitable materials. Aninfiltration chamber 312 may be defined or otherwise provided within themold assembly 300. Various techniques may be used to manufacture themold assembly 300 and its components including, but not limited to, machining graphite blanks to produce the various components and thereby define theinfiltration chamber 312 to exhibit a negative or reverse profile of desired exterior features of the drill bit 100 (FIGS. 2 and 3 ). - Materials, such as consolidated sand or graphite, may be positioned within the
mold assembly 300 at desired locations to form various features of the drill bit 100 (FIGS. 2 and 3 ). For example, one or more nozzle displacements or legs 314 (one shown) may be positioned to correspond with desired locations and configurations of the flow passageways 206 (FIG. 3 ) and their respective nozzle openings 122 (FIGS. 2 and 3 ). One or morejunk slot displacements 315 may also be positioned within themold assembly 300 to correspond with the junk slots 124 (FIG. 2 ). Moreover, a cylindrically-shapedcentral displacement 316 may be placed on thelegs 314. The number oflegs 314 extending from thecentral displacement 316 will depend upon the desired number of flow passageways andcorresponding nozzle openings 122 in thedrill bit 100. Further, cutter-pocket displacements (shown as part ofmold 302 inFIG. 4 ) may be placed in themold 302 to form cutter pockets 116. - After the desired materials, including the
central displacement 316 and thelegs 314, have been installed within themold assembly 300,reinforcement materials 318 may then be placed within or otherwise introduced into themold assembly 300. Thereinforcement materials 318 may include, for example, various types of reinforcing particles. Moreover, according to the present disclosure, thereinforcement materials 318 may include one or more ceramic or intermetallic workpieces fabricated in accordance with themethod 10 ofFIG. 1 . The ceramic or intermetallic workpieces may prove advantageous in strengthening the bit body 108 (FIGS. 2 and 3 ) in select locations and, more particularly, strengthening the hard composite portion 208 (FIG. 3 ) thereof. - Suitable reinforcing particles include, but are not limited to, particles of metals, metal alloys, superalloys, intermetallics, borides, carbides, nitrides, oxides, ceramics, diamonds, and the like, or any combination thereof. More particularly, examples of reinforcing particles suitable for use in conjunction with the embodiments described herein may include particles that include, but are not limited to, tungsten, molybdenum, niobium, tantalum, rhenium, iridium, ruthenium, beryllium, titanium, chromium, rhodium, iron, cobalt, uranium, nickel, nitrides, silicon nitrides, boron nitrides, cubic boron nitrides, natural diamonds, synthetic diamonds, cemented carbide, spherical carbides, low-alloy sintered materials, cast carbides, silicon carbides, boron carbides, cubic boron carbides, molybdenum carbides, titanium carbides, tantalum carbides, niobium carbides, chromium carbides, vanadium carbides, iron carbides, tungsten carbides, macrocrystalline tungsten carbides, cast tungsten carbides, crushed sintered tungsten carbides, carburized tungsten carbides, steels, stainless steels, austenitic steels, ferritic steels, martensitic steels, precipitation-hardening steels, duplex stainless steels, ceramics, iron alloys, nickel alloys, cobalt alloys, chromium alloys, HASTELLOY® alloys (i.e., nickel-chromium containing alloys, available from Haynes International), INCONEL® alloys (i.e., austenitic nickel-chromium containing superalloys available from Special Metals Corporation), WASPALOYS® (i.e., austenitic nickel-based superalloys), RENE® alloys (i.e., nickel-chromium containing alloys available from Altemp Alloys, Inc.), HAYNES® alloys (i.e., nickel-chromium containing superalloys available from Haynes International), INCOLOY® alloys (i.e., iron-nickel containing superalloys available from Mega Mex), MP98T (i.e., a nickel-copper-chromium superalloy available from SPS Technologies), TMS alloys, CMSX® alloys (i.e., nickel-based superalloys available from C-M Group), cobalt alloy 6B (i.e., cobalt-based superalloy available from HPA), N-155 alloys, any mixture thereof, and any combination thereof. In some embodiments, the reinforcing particles may be coated. For example, by way of non-limiting example, the reinforcing particles may comprise diamond coated with titanium.
- In some embodiments, the reinforcing particles described herein may have a diameter ranging from a lower limit of 1 micron, 10 microns, 50 microns, or 100 microns to an upper limit of 1000 microns, 800 microns, 500 microns, 400 microns, or 200 microns, wherein the diameter of the reinforcing particles may range from any lower limit to any upper limit and encompasses any subset therebetween.
- The
metal blank 202 may be supported at least partially by thereinforcement materials 318 within theinfiltration chamber 312. More particularly, after a sufficient volume of the reinforcement materials 318 (including both reinforcing particles and one or more selectively placed ceramic or intermetallic workpieces) has been added to themold assembly 300, themetal blank 202 may then be placed withinmold assembly 300. Themetal blank 202 may include aninside diameter 320 that is greater than anoutside diameter 322 of thecentral displacement 316, and various fixtures (not expressly shown) may be used to position themetal blank 202 within themold assembly 300 at a desired location. Thereinforcement materials 318 may then be filled to a desired level within theinfiltration chamber 312. -
Binder material 324 may then be placed on top of thereinforcement materials 318, themetal blank 202, and thecore 316.Suitable binder materials 324 include, but are not limited to, copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, any mixture thereof, any alloy thereof, and any combination thereof. Non-limiting examples of thebinder material 324 may include copper-phosphorus, copper-phosphorous-silver, copper-manganese-phosphorous, copper-nickel, copper-manganese-nickel, copper-manganese-zinc, copper-manganese-nickel-zinc, copper-nickel-indium, copper-tin-manganese-nickel, copper-tin-manganese-nickel-iron, gold-nickel, gold-palladium-nickel, gold-copper-nickel, silver-copper-zinc-nickel, silver-manganese, silver-copper-zinc-cadmium, silver-copper-tin, cobalt-silicon-chromium-nickel-tungsten, cobalt-silicon-chromium-nickel-tungsten-boron, manganese-nickel-cobalt-boron, nickel-silicon-chromium, nickel-chromium-silicon-manganese, nickel-chromium-silicon, nickel-silicon-boron, nickel-silicon-chromium-boron-iron, nickel-phosphorus, nickel-manganese, copper-aluminum, copper-aluminum-nickel, copper-aluminum-nickel-iron, copper-aluminum-nickel-zinc-tin-iron, and the like, and any combination thereof. Examples of commercially-available binder materials 324 include, but are not limited to, VIRGIN™ Binder 453D (copper-manganese-nickel-zinc, available from Belmont Metals, Inc.), and copper-tin-manganese-nickel and copper-tin-manganese-nickel-iron grades 516, 519, 523, 512, 518, and 520 available from ATI Firth Sterling. - In some embodiments, the
binder material 324 may be covered with a flux layer (not expressly shown). The amount of binder material 324 (and optional flux material) added to theinfiltration chamber 312 should be at least enough to infiltrate thereinforcement materials 318 and, optionally, the one or more ceramic or intermetallic workpieces during the infiltration process. In some instances, some or all of thebinder material 324 may be placed in thebinder bowl 308, which may be used to distribute thebinder material 324 into theinfiltration chamber 312 viavarious conduits 326 that extend therethrough. The cap 310 (if used) may then be placed over themold assembly 300. Themold assembly 300 and the materials disposed therein may then be preheated and then placed in a furnace (not shown). When the furnace temperature reaches the melting point of thebinder material 324, thebinder material 324 will liquefy and proceed to infiltrate thereinforcement materials 318. - After a predetermined amount of time allotted for the liquefied
binder material 324 to infiltrate thereinforcement materials 318, themold assembly 300 may then be removed from the furnace and cooled at a controlled rate. Once cooled, themold assembly 300 may be broken away to expose the bit body 108 (FIGS. 2 and 3 ) that includes the hard composite portion 208 (FIG. 3 ). Subsequent processing according to well-known techniques may be used to finish the drill bit 100 (FIG. 2 ). - As mentioned above, along with reinforcing particles, one or more ceramic or intermetallic workpieces may also be included in the
reinforcement materials 318 to be infiltrated by thebinder material 324. The ceramic or intermetallic workpieces described herein may prove advantageous in reinforcing the hard composite portion 208 (FIG. 3 ) of thedrill bit 100 ofFIGS. 2 and 3 and thereby helping to increase strength, hardness, and/or erosion resistance, thereby resisting deflection, deformation, erosion, and/or abrasion during operation. Such properties may increase the lifetime of thedrill bit 100 once in use. - The material or composition of the ceramic or intermetallic workpieces may bond with the
binder material 324, so that an increased amount of thermal and mechanical stresses (or loads) can be transferred to the ceramic or intermetallic workpieces. Further, a composition that bonds with thebinder material 324 may be less likely to pull out from thebinder material 324 as a crack propagates. In some embodiments, the material or composition of the ceramic or intermetallic workpieces may be designed to endure temperatures and pressures experienced when forming the hard composite portion 208 (FIG. 3 ) with little to no alloying with thebinder material 324 or oxidation. In yet other instances, the atmospheric conditions may be altered (e.g., reduced oxygen content achieved via reduced pressures or gas purge or vacuum) to mitigate oxidation of the ceramic or intermetallic workpieces and thereby enhance bonding between the ceramic or intermetallic workpieces and the binder. Such atmospheric conditions may allow for a binder composition that may not be suitable for use in standard atmospheric oxygen concentrations. - As indicated and discussed above, the ceramic or intermetallic workpieces may be fabricated to exhibit any desired shape, configuration, and size, depending primarily on the fabrication capabilities of the selected additive manufacturing technique used to initially fabricate the porous metallic workpieces. In the present embodiment of fabricating the drill bit 100 (
FIGS. 2 and 3 ), the ceramic or intermetallic workpieces may positioned in select regions of the hard composite portion 208 (FIG. 3 ) prior to infiltration. For instance, in at least one embodiment, a ceramic or intermetallic workpiece may be positioned in each blade 102 (FIG. 2 ) region to provide structural reinforcement and erosion-resistance. In other embodiments, one or more ceramic or intermetallic workpieces may be arranged or otherwise positioned to form the cutter pockets 116 (FIGS. 2 and 3 ). In yet other embodiments, the entire bit body 108 (FIGS. 2 and 3 ) may comprise a single ceramic or intermetallic workpiece to be infiltrated by thebinder material 324. In further embodiments, one or more ceramic or intermetallic workpieces may be arranged or otherwise positioned to form a macroscopic reinforcing structure that connects at least one of the blades to at least one other blade (e.g., a gear-like shape positioned with teeth protruding into each blade). - By way of nonlimiting illustration,
FIGS. 5-7 provide examples of implementing ceramic or intermetallic workpieces described herein into thebit body 108 of thedrill bit 100 ofFIGS. 2 and 3 . One skilled in the art will readily recognize how to adapt these teachings to other types of composite (i.e., MMC) tools or parts in keeping with the scope of the disclosure. In some embodiments, placement of the ceramic or intermetallic workpieces within thebit body 108 or the hardcomposite portion 208 may be localized. Localization, in some instances, may provide enhanced strength and stiffness and may reduce the erosion properties of thedrill bit 100. -
FIG. 5 , for example, illustrates a cross-sectional side view of thedrill bit 100 as comprising the hardcomposite portion 208 and one or more localized ceramic orintermetallic workpieces 502, according to one or more embodiments. As illustrated, the ceramic or intermetallic workpiece(s) 502 may be localized in thebit body 108 in one or more locations with the remaining portion of thebit body 108 being formed by the hard composite portion 208 (e.g., comprisingbinder material 324 and reinforcing particles without the ceramic or intermetallic workpiece(s) 502). The localized ceramic or intermetallic workpiece(s) 502 is shown inFIG. 5 as being located proximal thenozzle openings 122 and generally at an apex 504 of thedrill bit 100, two areas of thebit body 108 that may benefit from structural reinforcement. As used herein, the term “apex” refers to the central portion of the exterior surface of thebit body 108 that engages the formation during drilling and generally at or near where the cutter blades 102 (FIG. 1 ) meet on the exterior surface of thebit body 108 to engage the formation during drilling. As will be appreciated, localization of the ceramic or intermetallic workpiece(s) 502 may help mitigate crack initiation and propagation, while also manipulating the erosion properties of thebit body 108 because of the lower concentration of reinforcing particles at the localized areas. - As another example,
FIG. 6 illustrates a cross-sectional side view of thedrill bit 100 as comprising the hardcomposite portion 208 and one or more localized ceramic orintermetallic workpieces 502, according to one or more embodiments. In the illustrated embodiments, the ceramic or intermetallic workpiece(s) 502 may comprise a monolithic structure or it may denote a region that is reinforced with mesoscale reinforcing structures or workpieces. As illustrated, the ceramic or intermetallic workpiece(s) 502 may be located proximal thenozzle openings 122 and thepockets 116, and otherwise encompassing the blades 102 (FIG. 1 ) and/or the center of thebit body 108. In some embodiments, the porosity of the ceramic or intermetallic workpiece(s) 502 may change in concentration, geometry, or both along radial, circumferential, and/or longitudinal directions. Similar to localization, changing the concentration, geometry, or both of the ceramic or intermetallic workpiece(s) 502 may, in some instances, be used to enhance strength and stiffness and further to maintain suitable erosion resistance. -
FIG. 7 illustrates a cross-sectional side view of thedrill bit 100 as comprising the hardcomposite portion 208 and multiple ceramic orintermetallic workpieces 502, according to one or more embodiments. Theworkpieces 502 illustrated inFIG. 7 may be monolithic structures or they may denote regions reinforced with mesoscale reinforcing structures or workpieces. More particularly, the ceramic orintermetallic workpieces 502 are shown to be located proximal thenozzle openings 122 and thepockets 116 in separate layers orworkpieces workpieces 502 a-c may vary from one another and/or within themselves so as to vary the mechanical properties of thebit body 108 following infiltration. For instance, the porosity of thefirst workpiece 502 a may be greater than the porosity of thesecond workpiece 502 b, which may be greater than the porosity of thethird workpiece 502 c. Accordingly, thefirst workpiece 502 a may be harder than thethird workpiece 502 c following infiltration. Advantageously, thefirst workpiece 502 a is depicted as being located proximal thenozzle openings 122 and thepockets 116 to provide increased erosion-resistance. One skilled in the art will readily recognize the various configurations and locations for theworkpieces 502 a-c (including varying concentrations, geometries, and sizes) that would be suitable for producing abit body 108, and aresultant drill bit 100, that has a reduced propensity to have cracks initiate and propagate. - Referring now to
FIG. 8 , illustrated is anexemplary drilling system 800 that may employ one or more principles of the present disclosure. Boreholes may be created by drilling into theearth 802 using thedrilling system 800. Thedrilling system 800 may be configured to drive a bottom hole assembly (BHA) 804 positioned or otherwise arranged at the bottom of adrill string 806 extended into theearth 802 from aderrick 808 arranged at thesurface 810. Thederrick 808 includes akelly 812 and a travelingblock 813 used to lower and raise thekelly 812 and thedrill string 806. - The
BHA 804 may include adrill bit 814 operatively coupled to atool string 816 which may be moved axially within a drilledwellbore 818 as attached to thedrill string 806. Thedrill bit 814 may be fabricated and otherwise created in accordance with the principles of the present disclosure and, more particularly, using one or more ceramic or intermetallic workpieces infiltrated into thebit body 108. During operation, thedrill bit 814 penetrates theearth 802 and thereby creates thewellbore 118. TheBHA 804 provides directional control of thedrill bit 814 as it advances into theearth 802. Thetool string 816 can be semi-permanently mounted with various measurement tools (not shown) such as, but not limited to, measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools, that may be configured to take downhole measurements of drilling conditions. In other embodiments, the measurement tools may be self-contained within thetool string 816, as shown inFIG. 9 . - Fluid or “mud” from a
mud tank 820 may be pumped downhole using amud pump 822 powered by an adjacent power source, such as a prime mover ormotor 824. The mud may be pumped from themud tank 820, through astand pipe 826, which feeds the mud into thedrill string 806 and conveys the same to thedrill bit 814. The mud exits one or more nozzles arranged in thedrill bit 814 and in the process cools thedrill bit 814. After exiting thedrill bit 814, the mud circulates back to thesurface 810 via the annulus defined between thewellbore 818 and thedrill string 806, and in the process returns drill cuttings and debris to the surface. The cuttings and mud mixture are passed through aflow line 828 and are processed such that a cleaned mud is returned down hole through thestand pipe 826 once again. - Although the
drilling system 800 is shown and described with respect to a rotary drill system inFIG. 9 , those skilled in the art will readily appreciate that many types of drilling systems can be employed in carrying out embodiments of the disclosure. For instance, drills and drill rigs used in embodiments of the disclosure may be used onshore (as depicted inFIG. 1 ) or offshore (not shown). Offshore oil rigs that may be used in accordance with embodiments of the disclosure include, for example, floaters, fixed platforms, gravity-based structures, drill ships, semi-submersible platforms, jack-up drilling rigs, tension-leg platforms, and the like. It will be appreciated that embodiments of the disclosure can be applied to rigs ranging anywhere from small in size and portable, to bulky and permanent. - Further, although described herein with respect to oil drilling, various embodiments of the disclosure may be used in many other applications. For example, disclosed methods can be used in drilling for mineral exploration, environmental investigation, natural gas extraction, underground installation, mining operations, water wells, geothermal wells, and the like. Further, embodiments of the disclosure may be used in weight-on-packers assemblies, in running liner hangers, in running completion strings, etc., without departing from the scope of the disclosure.
- Embodiments disclosed herein include:
- A. A part that includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.
- B. A method of manufacturing a part that includes printing a three-dimensional porous metallic workpiece via an additive manufacturing process, and subjecting the porous metallic workpiece to a diffusion-based process and thereby converting at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece, wherein the porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process.
- C. A method of fabricating a drill bit that includes positioning one or more ceramic or intermetallic workpieces into a mold assembly that defines at least a portion of an infiltration chamber, wherein each ceramic or intermetallic workpiece is made by printing a three-dimensional porous metallic workpiece via an additive manufacturing process, and subjecting the porous metallic workpiece to a diffusion-based process and thereby converting at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece, wherein the porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process. The method further including depositing reinforcing materials into the infiltration chamber, and infiltrating the one or more ceramic or intermetallic workpieces and the reinforcing materials with a binder material and thereby producing a composite.
- Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element 1: wherein the additive manufacturing process is selected from the group consisting of laser sintering, laser melting, electron-beam melting, laser metal deposition, fused deposition modeling, fused filament fabrication, selective laser sintering, stereolithography, laminated object manufacturing, polyjet, and any combination thereof. Element 2: wherein the part is selected from the group consisting of an oilfield drill bit or cutting tool, a non-retrievable drilling component, an aluminum drill bit body, a drill-string stabilizer, a cone for a roller-cone drill bit, a model for forging dies, an arm for a fixed reamer, an arm for an expandable reamer, an internal component associated with an expandable reamer, a sleeve attachable to an uphole end of a rotary drill bit, a rotary steering tool, a logging-while-drilling tool, a measurement-while-drilling tool, a side-wall coring tool, a fishing spear, a washover tool, a rotor, a stator and/or housing for a downhole drilling motor, a blade for a downhole turbine, armor plating, an automotive component, a bicycle frame, a brake fin, an aerospace component, a turbopump component, a screen, a filter, a porous catalyst and any combination thereof. Element 3: wherein the porous metallic workpiece comprises a metal or a metal alloy that forms one of a carbide, a nitride, a boride, an oxide, a silicide, or an intermetallic upon being subjected to a reaction atmosphere of the diffusion-based process. Element 4: wherein the metal is selected from the group consisting of aluminum, antimony, barium, beryllium, bismuth, boron, cadmium, calcium, cerium, cesium, chromium, cobalt, copper, erbium, europium, gadolinium, gallium, germanium, hafnium, holmium, indium, iron, lanthanum, lead, lutetium, lithium, magnesium, manganese, molybdenum, neodymium, nickel, niobium, osmium, palladium, platinum, potassium, praseodymium, rhenium, rhodium, rubidium, ruthenium, samarium, scandium, silicon, sodium, strontium, tantalum, tellurium, terbium, thulium, tin, titanium, tungsten, vanadium, yttrium, ytterbium, zinc, and zirconium. Element 5: wherein the metal alloy is an alloy resulting from the combination of at least two metals selected from the group consisting of aluminum, antimony, barium, beryllium, bismuth, boron, cadmium, calcium, cerium, cesium, chromium, cobalt, copper, erbium, europium, gadolinium, gallium, germanium, hafnium, holmium, indium, iron, lanthanum, lead, lutetium, lithium, magnesium, manganese, molybdenum, neodymium, nickel, niobium, osmium, palladium, platinum, potassium, praseodymium, rhenium, rhodium, rubidium, ruthenium, samarium, scandium, silicon, sodium, strontium, tantalum, tellurium, terbium, thulium, tin, titanium, tungsten, vanadium, yttrium, ytterbium, zinc, and zirconium. Element 6: wherein some or all of the metallic workpiece is subjected to the reaction atmosphere during the diffusion-based process, the reaction atmosphere comprising a media selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof. Element 7: wherein the ceramic workpiece or the intermetallic workpiece is infiltrated with a binder material to produce a composite. Element 8: wherein the binder material is a material selected from the group consisting of copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, and alloy thereof.
- Element 9: further comprising infiltrating the ceramic workpiece or the intermetallic workpiece with a binder material and thereby producing a composite. Element 10: wherein infiltrating the ceramic workpiece or the intermetallic workpiece with a binder material comprises liquefying the binder material, and infiltrating at least a portion of a porous network of the ceramic workpiece or the intermetallic workpiece with a liquefied binder material. Element 11: further comprising penetrating at least a portion of a porous network of the porous metallic workpiece with a media of the reaction atmosphere, wherein the media is selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof. Element 12: wherein subjecting the porous metallic 0workpiece to the diffusion-based process comprises masking at least a portion of the porous metallic workpiece and thereby preventing a media of the reaction atmosphere from accessing at least a portion of the porous metallic workpiece. Element 13: further comprising terminating the diffusion-based process prematurely to prevent a media of the reaction atmosphere from accessing at least a portion of the porous metallic workpiece.
- Element 14: wherein infiltrating the one or more ceramic or intermetallic workpieces with the binder material comprises liquefying the binder material, and infiltrating at least a portion of a porous network of the one or more ceramic or intermetallic workpieces with a liquefied binder material. Element 15: further comprising penetrating at least a portion of a porous network of the porous metallic workpiece with a media of the reaction atmosphere, wherein the media is selected from the group consisting of methane, air, oxygen, endogas, exogas, nitrogen, ammonia, charcoal, carbon, graphite, nitriding salts, boron, silicon, a vaporized metal, a molten metal, and any combination thereof. Element 16: wherein infiltrating the one or more ceramic or intermetallic workpieces with the binder material comprises infiltrating the one or more ceramic or intermetallic workpieces with a binder material selected from the group consisting of copper, nickel, cobalt, iron, aluminum, molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten, boron, phosphorous, gold, silver, palladium, indium, titanium, vanadium, zirconium, niobium, hafnium, tantalum, rhenium, ruthenium, osmium, iridium, and alloy thereof. Element 17: wherein the mold assembly defines one or more cutter pockets, and wherein positioning the one or more ceramic or intermetallic workpieces into the mold assembly comprises positioning the one or more ceramic or intermetallic workpieces adjacent or near the one or more cutter pockets. Element 18: wherein the mold assembly defines one or more blade regions, and wherein positioning the one or more ceramic or intermetallic workpieces into the mold assembly comprises positioning at least one ceramic or intermetallic workpiece into each blade region.
- By way of non-limiting example, exemplary combinations applicable to A, B, and C include: Element 3 with Element 4; Element 3 with Element 5; Element 3 with Element 6; Element 7 with Element 8; and Element 9 with
Element 10. - Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
- As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
Claims (12)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/656,999 US20200047253A1 (en) | 2015-04-24 | 2019-10-18 | Methods Of Fabricating Ceramic Or Intermetallic Parts |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2015/027495 WO2016171715A1 (en) | 2015-04-24 | 2015-04-24 | Methods of fabricating ceramic or intermetallic parts |
US201614909889A | 2016-02-03 | 2016-02-03 | |
US16/656,999 US20200047253A1 (en) | 2015-04-24 | 2019-10-18 | Methods Of Fabricating Ceramic Or Intermetallic Parts |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2015/027495 Division WO2016171715A1 (en) | 2015-04-24 | 2015-04-24 | Methods of fabricating ceramic or intermetallic parts |
US14/909,889 Division US10471507B2 (en) | 2015-04-24 | 2015-04-24 | Methods of fabricating ceramic or intermetallic parts |
Publications (1)
Publication Number | Publication Date |
---|---|
US20200047253A1 true US20200047253A1 (en) | 2020-02-13 |
Family
ID=57144626
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/909,889 Expired - Fee Related US10471507B2 (en) | 2015-04-24 | 2015-04-24 | Methods of fabricating ceramic or intermetallic parts |
US16/656,999 Pending US20200047253A1 (en) | 2015-04-24 | 2019-10-18 | Methods Of Fabricating Ceramic Or Intermetallic Parts |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/909,889 Expired - Fee Related US10471507B2 (en) | 2015-04-24 | 2015-04-24 | Methods of fabricating ceramic or intermetallic parts |
Country Status (5)
Country | Link |
---|---|
US (2) | US10471507B2 (en) |
CN (1) | CN107405687A (en) |
CA (1) | CA2979669A1 (en) |
GB (1) | GB2552283A (en) |
WO (1) | WO2016171715A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105461301A (en) * | 2015-12-14 | 2016-04-06 | 珠海市香之君科技股份有限公司 | Modified ceramic knife and preparation method thereof |
Families Citing this family (35)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20150047463A1 (en) | 2012-06-26 | 2015-02-19 | California Institute Of Technology | Systems and methods for implementing bulk metallic glass-based macroscale gears |
US20140342179A1 (en) | 2013-04-12 | 2014-11-20 | California Institute Of Technology | Systems and methods for shaping sheet materials that include metallic glass-based materials |
US10144065B2 (en) | 2015-01-07 | 2018-12-04 | Kennametal Inc. | Methods of making sintered articles |
US10471507B2 (en) * | 2015-04-24 | 2019-11-12 | Halliburton Energy Services, Inc. | Methods of fabricating ceramic or intermetallic parts |
US10968527B2 (en) | 2015-11-12 | 2021-04-06 | California Institute Of Technology | Method for embedding inserts, fasteners and features into metal core truss panels |
US11118433B2 (en) * | 2016-09-19 | 2021-09-14 | Halliburton Energy Services, Inc. | High angle and fractal printed screen |
DE102017200945B3 (en) * | 2017-01-20 | 2018-05-09 | Ford Global Technologies, Llc | Method for producing hybrid lightweight brake discs |
US11065863B2 (en) | 2017-02-20 | 2021-07-20 | Kennametal Inc. | Cemented carbide powders for additive manufacturing |
WO2018157545A1 (en) | 2017-03-02 | 2018-09-07 | 华为技术有限公司 | Thermally-conductive component and mobile terminal |
US11198181B2 (en) | 2017-03-10 | 2021-12-14 | California Institute Of Technology | Methods for fabricating strain wave gear flexsplines using metal additive manufacturing |
EP3630395A4 (en) | 2017-05-24 | 2020-11-25 | California Institute of Technology | Hypoeutectic amorphous metal-based materials for additive manufacturing |
US11591857B2 (en) | 2017-05-31 | 2023-02-28 | Schlumberger Technology Corporation | Cutting tool with pre-formed hardfacing segments |
US11123797B2 (en) | 2017-06-02 | 2021-09-21 | California Institute Of Technology | High toughness metallic glass-based composites for additive manufacturing |
US11407034B2 (en) | 2017-07-06 | 2022-08-09 | OmniTek Technology Ltda. | Selective laser melting system and method of using same |
US10662716B2 (en) | 2017-10-06 | 2020-05-26 | Kennametal Inc. | Thin-walled earth boring tools and methods of making the same |
TWI682107B (en) * | 2017-12-11 | 2020-01-11 | 至興精機股份有限公司 | Manufacturing method of composite material floating disk |
CN108486429A (en) * | 2018-05-04 | 2018-09-04 | 上海康速金属材料有限公司 | Rare earth er element enhances the special AlSi7Mg Al alloy powders of SLM and its application |
CN108396203A (en) * | 2018-05-04 | 2018-08-14 | 上海康速金属材料有限公司 | Rare earth er element enhances the special AlSi10Mg Al alloy powders of SLM and its application |
WO2019221748A1 (en) * | 2018-05-18 | 2019-11-21 | Siemens Aktiengesellschaft | Systems and methods of additve manufacturing |
US11801551B2 (en) * | 2018-06-27 | 2023-10-31 | Baker Hughes Holding LLC | Methods of forming earth-boring tools using inserts and molds |
US20210114110A1 (en) * | 2018-07-13 | 2021-04-22 | Desktop Metal, Inc. | Additive fabrication with infiltration barriers |
US11167375B2 (en) | 2018-08-10 | 2021-11-09 | The Research Foundation For The State University Of New York | Additive manufacturing processes and additively manufactured products |
CN109307613B (en) * | 2018-10-18 | 2021-07-02 | 中国石油天然气股份有限公司 | Method and device for preparing artificial rock core |
CN109630547B (en) * | 2018-12-13 | 2020-05-22 | 武汉东顺汽车配件有限公司 | Automobile antifriction bush |
US11680629B2 (en) | 2019-02-28 | 2023-06-20 | California Institute Of Technology | Low cost wave generators for metal strain wave gears and methods of manufacture thereof |
US11400613B2 (en) | 2019-03-01 | 2022-08-02 | California Institute Of Technology | Self-hammering cutting tool |
US11591906B2 (en) | 2019-03-07 | 2023-02-28 | California Institute Of Technology | Cutting tool with porous regions |
CN109973021B (en) * | 2019-04-24 | 2020-09-01 | 西迪技术股份有限公司 | Drill bit of integrated nozzle structure |
CN110218417B (en) * | 2019-06-19 | 2022-04-15 | 裕克施乐塑料制品(太仓)有限公司 | Hierarchical pore boron nitride structural member/epoxy resin composite material |
US11965398B2 (en) * | 2019-06-27 | 2024-04-23 | Schlumberger Technology Corporation | Wear resistant self-lubricating additive manufacturing parts and part features |
FR3100143B1 (en) | 2019-08-30 | 2021-11-12 | Safran | Improved method of manufacturing a ceramic core for the manufacture of turbine engine blades |
CN111842853B (en) * | 2020-07-30 | 2022-02-01 | 南昌工程学院 | Porous metal ceramic matrix composite material for preparing self-lubricating bearing and preparation method thereof |
US20230347425A1 (en) * | 2020-08-18 | 2023-11-02 | Milwaukee Electric Tool Corporation | Hole saw arbor assembly |
CN112159213B (en) * | 2020-10-29 | 2023-07-18 | 贵州赛义光电科技有限公司 | Zero-light-attenuation luminous ceramic and preparation method thereof |
CN113146042B (en) * | 2021-03-12 | 2022-10-18 | 中国工程物理研究院材料研究所 | Laser welding B capable of effectively reducing welding holes 4 Method for producing C/Al |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5330016A (en) * | 1993-05-07 | 1994-07-19 | Barold Technology, Inc. | Drill bit and other downhole tools having electro-negative surfaces and sacrificial anodes to reduce mud balling |
US20040173335A1 (en) * | 2002-09-27 | 2004-09-09 | Schaffer Graham Barry | Infiltrated aluminum preforms |
US20130316149A1 (en) * | 2010-11-29 | 2013-11-28 | William Brian Atkins | Forming objects by infiltrating a printed matrix |
US10471507B2 (en) * | 2015-04-24 | 2019-11-12 | Halliburton Energy Services, Inc. | Methods of fabricating ceramic or intermetallic parts |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6200514B1 (en) | 1999-02-09 | 2001-03-13 | Baker Hughes Incorporated | Process of making a bit body and mold therefor |
BR0308522B1 (en) * | 2002-03-18 | 2013-04-16 | system and method for the recovery of a borehole return fluid. | |
JP4051569B2 (en) * | 2004-03-22 | 2008-02-27 | 修 山田 | Method for producing intermetallic compound porous material |
US7398840B2 (en) * | 2005-04-14 | 2008-07-15 | Halliburton Energy Services, Inc. | Matrix drill bits and method of manufacture |
US8037950B2 (en) * | 2008-02-01 | 2011-10-18 | Pdti Holdings, Llc | Methods of using a particle impact drilling system for removing near-borehole damage, milling objects in a wellbore, under reaming, coring, perforating, assisting annular flow, and associated methods |
US8656983B2 (en) * | 2010-11-22 | 2014-02-25 | Halliburton Energy Services, Inc. | Use of liquid metal filters in forming matrix drill bits |
GB2488508B (en) | 2010-11-29 | 2015-10-07 | Halliburton Energy Services Inc | 3D-printed bodies for molding downhole equipment |
WO2014052754A1 (en) * | 2012-09-27 | 2014-04-03 | Allomet Corporation | Methods of forming a metallic or ceramic article having a novel composition of functionally graded material and articles containing the same |
US10232441B2 (en) * | 2014-03-18 | 2019-03-19 | United Technologies Corporation | Fabrication of articles from nanowires |
CN104388723B (en) * | 2014-11-20 | 2016-10-26 | 厦门钨业股份有限公司 | Granular gradient hard alloy prepared by a kind of liquid infiltration method and preparation method thereof |
-
2015
- 2015-04-24 US US14/909,889 patent/US10471507B2/en not_active Expired - Fee Related
- 2015-04-24 WO PCT/US2015/027495 patent/WO2016171715A1/en active Application Filing
- 2015-04-24 CA CA2979669A patent/CA2979669A1/en not_active Abandoned
- 2015-04-24 GB GB1714603.6A patent/GB2552283A/en not_active Withdrawn
- 2015-04-24 CN CN201580078194.XA patent/CN107405687A/en active Pending
-
2019
- 2019-10-18 US US16/656,999 patent/US20200047253A1/en active Pending
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5330016A (en) * | 1993-05-07 | 1994-07-19 | Barold Technology, Inc. | Drill bit and other downhole tools having electro-negative surfaces and sacrificial anodes to reduce mud balling |
US20040173335A1 (en) * | 2002-09-27 | 2004-09-09 | Schaffer Graham Barry | Infiltrated aluminum preforms |
US20130316149A1 (en) * | 2010-11-29 | 2013-11-28 | William Brian Atkins | Forming objects by infiltrating a printed matrix |
US10471507B2 (en) * | 2015-04-24 | 2019-11-12 | Halliburton Energy Services, Inc. | Methods of fabricating ceramic or intermetallic parts |
Non-Patent Citations (1)
Title |
---|
Alexey Sverdlin, Types of Heat Treating Furnaces, Steel Heat Treating Technologies, Vol 4B, ASM Handbook, Edited By Jon L. Dossett, George E. Totten, ASM International, 2014, p 83–107 (Year: 2014) * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105461301A (en) * | 2015-12-14 | 2016-04-06 | 珠海市香之君科技股份有限公司 | Modified ceramic knife and preparation method thereof |
Also Published As
Publication number | Publication date |
---|---|
GB201714603D0 (en) | 2017-10-25 |
US20170050241A1 (en) | 2017-02-23 |
GB2552283A (en) | 2018-01-17 |
CN107405687A (en) | 2017-11-28 |
CA2979669A1 (en) | 2016-10-27 |
WO2016171715A1 (en) | 2016-10-27 |
US10471507B2 (en) | 2019-11-12 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20200047253A1 (en) | Methods Of Fabricating Ceramic Or Intermetallic Parts | |
US10641045B2 (en) | Mesoscale reinforcement of metal matrix composites | |
US10208366B2 (en) | Metal-matrix composites reinforced with a refractory metal | |
US10399144B2 (en) | Surface coating for metal matrix composites | |
US8616089B2 (en) | Method of making an earth-boring particle-matrix rotary drill bit | |
US10655399B2 (en) | Magnetic positioning of reinforcing particles when forming metal matrix composites | |
CA2929296A1 (en) | Fiber-reinforced tools for downhole use | |
US10774402B2 (en) | Reinforcement material blends with a small particle metallic component for metal-matrix composites | |
US10655397B2 (en) | Mechanical-interlocking reinforcing particles for use in metal matrix composite tools | |
US20160369568A1 (en) | Two-phase manufacture of metal matrix composites | |
US10119339B2 (en) | Alternative materials for mandrel in infiltrated metal-matrix composite drill bits | |
US11358220B2 (en) | Segregation mitigation when producing metal-matrix composites reinforced with a filler metal | |
US11499375B2 (en) | Methods of removing shoulder powder from fixed cutter bits |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: HALLIBURTON ENERGY SERVICES, INC., TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:THOMAS, JEFFREY G.;COOK, GRANT O., III;SIGNING DATES FROM 20150319 TO 20150423;REEL/FRAME:050762/0162 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |