U.S. patent application number 14/710997 was filed with the patent office on 2015-11-19 for fully infiltrated rotary drill bit.
The applicant listed for this patent is Longyear TM, Inc.. Invention is credited to CHRISTIAN M. LAMBERT, CODY A. PEARCE, MICHAEL D. RUPP.
Application Number | 20150330154 14/710997 |
Document ID | / |
Family ID | 54480599 |
Filed Date | 2015-11-19 |
United States Patent
Application |
20150330154 |
Kind Code |
A1 |
PEARCE; CODY A. ; et
al. |
November 19, 2015 |
FULLY INFILTRATED ROTARY DRILL BIT
Abstract
A fully infiltrated rotary drill bit having a bit body that
includes at least one particle-matrix composite material having a
particle material composition and a binder material having a binder
material composition that differs from the particle material
composition. The particle material composition has a particle
material melting temperature and the binder material composition
has a binder melting temperature that is lower than the particle
material melting temperature.
Inventors: |
PEARCE; CODY A.; (MIDVALE,
UT) ; RUPP; MICHAEL D.; (MURRAY, UT) ;
LAMBERT; CHRISTIAN M.; (DRAPER, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Longyear TM, Inc. |
South Jordan |
UT |
US |
|
|
Family ID: |
54480599 |
Appl. No.: |
14/710997 |
Filed: |
May 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61992654 |
May 13, 2014 |
|
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Current U.S.
Class: |
175/425 |
Current CPC
Class: |
E21B 10/48 20130101;
E21B 10/42 20130101; E21B 10/54 20130101; E21B 10/62 20130101 |
International
Class: |
E21B 10/54 20060101
E21B010/54; E21B 10/42 20060101 E21B010/42 |
Claims
1. A rotary drill bit, comprising: a bit body having a distal
cutting region configured to engage a subterranean earth formation
and a proximal treaded region configured to be selectively coupled
to a drill sting, the bit body comprising: at least one
particle-matrix composite material, each particle-matrix composite
material having a particle material composition that has a particle
material melting temperature, and a binder material having a binder
material composition differing from the particle material
composition and having a binder material melting temperature that
is lower than the particle material melting temperature, wherein at
least one of the particle-matrix material composition and the
binder material composition is comprised of a matrix material and a
plurality of hard particles dispersed throughout the matrix
materials, and wherein the binder material is infiltrated within
the particle-matrix material to form a substantially uniform
particle grain microstructure.
2. The rotary drill bit of claim 1, wherein each particle-matrix
composite material is substantially comprised of the matrix
material having the plurality of hard particles dispersed
throughout.
3. The rotary drill bit of claim 2, wherein the binder material
comprises a second particle-matrix composite material.
4. The rotary drill bit of claim 3, wherein the binder material is
substantially comprised of a matrix material having a plurality of
hard particles dispersed throughout.
5. The rotary drill bit of claim 4, wherein the binder material
comprises copper (Cu), nickel (Ni), cobalt (Co), iron (Fe),
molybdenum (Mo) individually or alloys based on these metals.
6. The rotary drill bit of claim 4, wherein the binder material
comprises non-magnetic materials.
7. The rotary drill bit of claim 4, wherein the binder material
comprises wear resistant materials.
8. The rotary drill bit of claim 4, wherein the hard particles
comprise diamond, or metal or semi-metal carbides, nitrides,
oxides, or borides.
9. The rotary drill bit of claim 5, wherein the matrix materials
comprise cobalt-based alloys, iron-based alloys, nickel-based
alloys, cobalt and nickel-based alloys, iron and nickel-based
alloys, iron and cobalt-based alloys, aluminum-based alloys,
copper-based alloys, magnesium-based alloys, tungsten-based and
titanium-based alloys.
10. The rotary drill bit of claim 2, wherein the matrix material in
the particle-matrix composite material comprises non-magnetic
materials.
11. The rotary drill bit of claim 2, wherein the matrix material in
the particle-matrix composite material comprises wear resistant
materials.
12. The rotary drill bit of claim 1, wherein the binder material
comprises a second particle-matrix composite material.
13. The rotary drill bit of claim 12, wherein the binder material
is substantially comprised of the matrix material having the
plurality of hard particles dispersed throughout.
14. The rotary bit of claim 1, wherein the at least one
particle-matrix composite material is in an unmelted state in the
formed substantially uniform particle grain microstructure.
15. The rotary bit of claim 1, wherein the at least one
particle-matrix composite material comprises a plurality of
particle-matrix composite materials, and wherein each
particle-matrix composite material is disposed in a layer
positioned transverse to a longitudinal axis of the bit body.
16. The rotary drill bit of claim 4, wherein the matrix of the
particle-matrix composite composition comprises a tungsten-based
alloy.
17. The rotary drill bit of claim 16, wherein the matrix of the
binder material composition is selected from a group comprising a
copper-based alloy, a zinc-based alloy, and a nickel-based
alloy.
18. The rotary drill bit of claim 4, wherein the matrix of the
particle-matrix composite composition comprises a tungsten
carbide-based alloy.
19. The rotary drill bit of claim 18, wherein the matrix of the
binder material composition is selected from a group comprising a
copper-based alloy, a zinc-based alloy, and a nickel-based
alloy.
20. The rotary drill bit of claim 1, wherein the proximal treaded
region defines an open internal cavity extending along a
longitudinal axis of the bit body, and wherein a helical thread is
formed on an interior wall surface of the open internal cavity, the
helical thread being configured matingly engage and attach to the
drill string.
21. The rotary drill bit of claim 1, wherein the proximal treaded
region defines an exterior surface, and wherein a helical thread is
formed on at least a portion of the exterior surface, the helical
thread being configured matingly engage and attach to the drill
string.
22. The rotary drill bit of claim 1, wherein the particle-matrix
composite material is substantially encapsulated by the infiltrated
binder material.
23. The rotary drill bit of claim 1, wherein the difference between
the binder material melting temperature and the particle material
melting temperature is greater than 500.degree. F.
24. The rotary drill bit of claim 1, wherein the difference between
the binder material melting temperature and the particle material
melting temperature is greater than 1000.degree. F.
25. The rotary drill bit of claim 1, wherein the difference between
the binder material melting temperature and the particle material
melting temperature is greater than 1,500.degree. F.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 61/992,654 filed May 13, 2014, which is herein
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a rotary drill bit. More
specifically, this invention relates to a fully infiltrated rotary
drill bit.
BACKGROUND OF THE INVENTION
[0003] Rotary drill bits are commonly used for subterranean
drilling of bore holes or wells. Many types of drills and
associated methods have been employed for such drilling. A common
type of drilling employs a rotary drill bit affixed to the end of a
drill string. Rotary drill bits typically include a plurality of
cutting elements secured to a face region of a bit body. The drill
string includes tubular pipe and equipment segments that couple the
drill bit located at the bottom of the borehole to other drilling
equipment at the surface. A rotary table or top drive may be used
for rotating the drill string and the drill bit within the
borehole. Alternatively, the shank of the drill bit may be coupled
directly to the drive shaft of a down-hole motor, which then may be
used to rotate the drill bit.
[0004] Rotary drill bits generally have either a disk shape or a
substantially cylindrical shape, particularly on the cutting end
that houses the cutting elements. The cutting elements each have a
cutting surface that is generally made from a hard, super-abrasive
material, such as polycrystalline diamond, often in the form of a
substantially circular end surface of the element, and are often
referred to as "polycrystalline diamond compact" (PDC) cutters.
Many forms of such bits are possible; however, the cutting elements
are often fabricated separately from the bit body and then fixed
into pockets formed in its outer surface. The cutting elements may
be fixed in any suitable manner, such as, for example, by use of a
bonding material, including various adhesives or, more typically,
various braze alloys. The bit body is secured to a hardened steel
shank having an American Petroleum Institute (API) thread
connection for attaching the drill bit to the drill string. In use,
the cutting elements and their cutting surfaces are placed in
contact with the earth formation to be drilled. As the bit is
rotated, the cutting elements progressively shear away the surface
of the underlying formation to form the borehole.
[0005] The bit body of a rotary drill bit may be formed from steel;
however, such bit bodies experience abrasive wear, the rate of
which can vary significantly as a function of the drilling
environment. In order to reduce the wear and extend their life, bit
bodies have also been made from particle-matrix composite
materials.
[0006] Particle-matrix composite bit bodies have been fabricated in
graphite molds with machined cavities. Additional fine features may
be added to the cavity of the graphite mold by hand-held tools.
Inserts or cores made from sand, clay or other materials may also
be used to obtain the desired configuration of some features of the
bit body. Where necessary, preform elements or displacements (which
may be made from any suitable material, including ceramic
components, graphite components, or resin-coated sand compact
components) may be positioned within the mold and used to define
various features, including internal passages, cutting element
pockets, junk slots, and other external topographic or internal
features of the bit body. The cavity of the graphite mold is filled
with hard particulate carbide material (such as tungsten carbides,
titanium carbides, tantalum carbides, etc.). The preformed steel
blank is then positioned in the mold at the appropriate location
and orientation, which typically is at least partially submerged in
the particulate carbide material within the mold.
[0007] The mold then may be vibrated or the particles otherwise
packed to increase the packing density of the carbide powder and
produce the powder form. A matrix material, such as a copper-based
alloy, is melted and introduced to the carbide powder so as to
cause infiltration of the powder form by the molten matrix
material. The mold and bit body are allowed to cool to solidify the
matrix material and bond the steel blank to the particle-matrix
composite material forming a crown. The mold and any displacements
are removed from the bit body. Destruction of the graphite mold
typically is required to remove the bit body.
[0008] After the bit body has been removed from the mold, the bit
body is conventionally secured to the steel shank. Thread forms may
be machined on an exposed surface of the steel blank to provide a
threaded connection between the bit body and the steel shank.
[0009] While steel blanks afford a generally acceptable means of
connecting the steel shank and the bit body, shifting of the blank
in the mold during infiltration can occur resulting in misalignment
of the blank with respect to the bit body, thereby causing the bit
body to be unusable, or requiring additional machining or other
rework of the bit body. Further, introduction of the blank as an
additional component requires that it be degreased or otherwise
cleaned prior to infiltration to ensure a metallurgical bond
between the blank and the metal matrix. Still further, depending on
the material used for the blank, interaction between the blank and
matrix material may lead to the formation of phases at the
interface between them that can result in crack formation and
propagation during use of the bit.
[0010] While bit bodies that include particle-matrix composite
materials offer significant advantages over all-steel bit bodies in
terms of abrasion and erosion-resistance, the lower strength and
toughness of such bit bodies limit their use in certain
applications. Improvement of the particle-matrix composite to
increase the toughness, strength or other properties would increase
the applications where such bit bodies may be used.
SUMMARY
[0011] The invention relates to a rotary drill bit comprising a bit
body that comprises at least one particle-matrix composite material
and a binder material. In one aspect, each of the at least one
particle-matrix composite material has a particle material
composition, which also has a particle material melting
temperature. In another aspect, the binder material has a binder
material composition that differs from the particle material
composition. In this aspect, the binder material composition has a
binder material melting temperature that is lower than the particle
material melting temperature.
[0012] In a further aspect, at least one of the particle-matrix
material composition and the binder material composition can be
comprised of a matrix material and a plurality of hard particles
dispersed throughout the matrix materials.
[0013] When formed, the binder material is infiltrated within and
substantially encapsulates particle-matrix composite material to
form a substantially uniform particle grain microstructure. In this
aspect, it is contemplated that the particle-matrix composite
material is substantially non-melted in the formation process of
the drill bit.
DETAILED DESCRIPTION OF THE FIGURES
[0014] These and other features of the preferred embodiments of the
invention will become more apparent in the detailed description in
which reference is made to the appended drawings wherein:
[0015] FIG. 1 is a schematic partial cross-sectional view of an
exemplary embodiment of a rotary drill bit disclosed herein.
[0016] FIG. 2 is a schematic partial cross-sectional view of a
second exemplary embodiment of a rotary drill bit disclosed
herein.
[0017] The illustrations presented herein, are not meant to be
actual views of any particular material, apparatus, system, or
method, but are merely idealized representations of that which is
disclosed herein. Additionally, elements common between figures may
retain the same numerical designation.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention can be understood more readily by
reference to the following detailed description, examples, drawing,
and claims, and their previous and following description. However,
before the present devices, systems, and/or methods are disclosed
and described, it is to be understood that this invention is not
limited to the specific devices, systems, and/or methods disclosed
unless otherwise specified, as such can, of course, vary. It is
also to be understood that the terminology used herein is for the
purpose of describing particular aspects only and is not intended
to be limiting.
[0019] The following description of the invention is provided as an
enabling teaching of the invention in its best, currently known
embodiment. To this end, those skilled in the relevant art will
recognize and appreciate that many changes can be made to the
various aspects of the invention described herein, while still
obtaining the beneficial results of the present invention. It will
also be apparent that some of the desired benefits of the present
invention can be obtained by selecting some of the features of the
present invention without utilizing other features. Accordingly,
those who work in the art will recognize that many modifications
and adaptations to the present invention are possible and can even
be desirable in certain circumstances and are a part of the present
invention. Thus, the following description is provided as
illustrative of the principles of the present invention and not in
limitation thereof.
[0020] As used throughout, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a particle-matrix
composite material" can include two or more such particle-matrix
composite material unless the context indicates otherwise.
[0021] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint.
[0022] As used herein, the terms "optional" or "optionally" mean
that the subsequently described event or circumstance may or may
not occur, and that the description includes instances where said
event or circumstance occurs and instances where it does not.
[0023] As used herein, the term "[metal]-based alloy" (where
[metal] is any metal) means commercially pure [metal] in addition
to metal alloys wherein the weight percentage of [metal] in the
alloy is greater than the weight percentage of any other component
of the alloy. Where two or more metals are listed in this manner,
the weight percentage of the listed metals in combination is
greater than the weight percentage of any other component of the
alloy.
[0024] As used herein, the term "material composition" means the
chemical composition and microstructure of a material. In other
words, materials having the same chemical composition but a
different microstructure are considered to have different material
compositions.
[0025] As used herein, the term "tungsten carbide" means any
material composition that contains chemical compounds of tungsten
and carbon in any stoichiometric or non-stoichiometric ratio or
proportion, such as, for example, WC, W.sub.2C, and combinations of
WC and W.sub.2C. Tungsten carbide includes any morphological form
of this material, for example, cast tungsten carbide, sintered
tungsten carbide, monocrystalline tungsten carbide, and
macrocrystalline tungsten carbide.
[0026] An exemplary embodiment of an earth-boring rotary drill bit
10 having a bit body 20 is illustrated in FIG. 1. The bit body 20
has a distal cutting region 22 configured to engage a subterranean
earth formation and a proximal treaded region 24 configured to be
selectively coupled to a drill sting. In one aspect, the proximal
treaded region defines an open internal cavity 26 extending along a
longitudinal axis of the bit body. It is further contemplated that
a helical thread 28, which is configured to matingly engage and
attach to the drill string, can be formed on an interior wall
surface of the open internal cavity. As contemplated in the
invention, the bit body is fully infiltrated and, as such, will not
be required to be conventionally secured to an underlying support
shank.
[0027] In another aspect, the bit body 20 comprises at least one
particle-matrix composite material that is infiltrated by a binder
material so that the at least one particle-matrix composite
material is fully infiltrated by and is substantially encapsulated
by the binder material to form a substantially uniform particle
grain microstructure. In one aspect, each particle-matrix composite
material has a particle material composition that has a particle
material melting temperature. In another aspect, the binder
material has a binder material composition that has a binder
material melting temperature that is lower than the particle
material melting temperature. Further, the particle material
composition and the binder material composition are different
material compositions.
[0028] It is contemplated that at least one of the particle-matrix
material composition and the binder material composition is
comprised of a matrix material and a plurality of hard particles
dispersed throughout the matrix materials. The plurality of hard
particles can be dispersed substantially randomly throughout the
matrix material. In another aspect, each particle-matrix composite
material is substantially comprised of the matrix material having
the plurality of hard particles dispersed throughout.
[0029] In a further aspect, the binder material can comprises a
second particle-matrix composite material. In this aspect, the
second particle-matrix composite material is substantially
comprised of a matrix material having a plurality of hard particles
dispersed throughout. In a further aspect, the binder material can
comprises non-magnetic materials and/or wear resistant materials.
Similarly, the matrix material in the particle-matrix composition
material can comprise non-magnetic materials and/or wear resistant
materials. In one aspect, it is contemplated that the formed drill
bit would be entirely formed from non-magnetic materials and/or
wear resistant materials.
[0030] The matrix material of the binder composite material may
include, for example, cobalt-based, iron-based, nickel-based, iron
and nickel-based, cobalt and nickel-based, iron and cobalt-based,
aluminum-based, copper-based, magnesium-based, molybdenum based,
and titanium-based alloys. The alloying elements can include, but
are not limited to, one or more of the following
elements--manganese (Mn), nickel (Ni), tin (Sn) zinc (In), silicon
(Si), molybdenum (Mo), tungsten (W), boron (B) and phosphorous (P).
The matrix material of the binder composite material can also be
selected from commercially pure elements such as cobalt, aluminum,
copper, magnesium, titanium, iron, and nickel. By way of example
and not limitation, the matrix material of the binder composite
material may include carbon steel, alloy steel, stainless steel,
tool steel, Hadfield manganese steel, nickel or cobalt superalloy
material, and low thermal expansion iron or nickel based
alloys.
[0031] The hard particles can comprise the hard particles can
comprise diamond, or metal or semi-metal carbides, nitrides,
oxides, or borides. For example, and without limitation, the hard
particles can comprise diamond or ceramic materials such as
carbides, nitrides, oxides, and borides (including boron carbide
(B.sub.4C)) and combinations of them, such as carbonitrides. More
specifically, the hard particles can comprise carbides and borides
made from elements such as W, Ti, Mo, Nb, V, Hf, Ta, Cr, Zr, Al,
and Si. By way of example and without limitation, materials that
may be used to form hard particles include tungsten carbide (WC,
W.sub.2C), titanium carbide (TiC), tantalum carbide (TaC), titanium
diboride (TiB.sub.2), chromium carbides, titanium nitride (TiN),
vanadium carbide (VC), aluminium oxide (Al.sub.2O.sub.3), aluminium
nitride (AlN), boron nitride (BN), and silicon carbide (SiC).
Furthermore, combinations of different hard particles may be used
to tailor the physical properties and characteristics of the
particle-matrix composite material. The hard particles may be
formed using techniques known to those of ordinary skill in the
art. Most suitable materials for hard particles are commercially
available and the formation of the remainder is within the ability
of one of ordinary skill in the art.
[0032] In one example, and not meant to be limiting, the matrix of
the particle-matrix composite composition can comprise a
tungsten-based alloy and the matrix of the binder material
composition can be selected from a group comprising a copper based
alloy, a zinc based alloy, and a nickel based alloy. In a further
example, and not meant to be limiting, the matrix of the
particle-matrix composite composition can comprise a tungsten
carbide-based alloy and the matrix of the binder material
composition can be selected from a group comprising a copper based
alloy, a zinc based alloy, and a nickel based alloy. The use of
tungsten and or tungsten carbide is desirable for use because of
its higher hardness, which allows the use of smaller particles due
to its high melting point, and suitability for use in an
infiltration process because of the generally shorter times at high
temperature prior to solidification and cooling of the matrix
materials (in contrast with other methods of making a
particle-matrix composite materials such as various powder
metallurgy processes, such as sintering, that typically employ much
longer times at high temperatures).
[0033] Because the binder material has a binder material
composition that has a binder material melting temperature that is
lower than the particle material melting temperature, the at least
one particle-matrix composite material is in an unmelted state in
the formed substantially uniform particle grain microstructure of
the drill bit. When formed, it is desired that the particle-matrix
composite material is substantially encapsulated by the infiltrated
binder material. Further, to accomplish the desired infiltration
without melting of the particle-matrix composite composition, the
difference between the binder material melting temperature and the
particle material melting temperature is greater than 500.degree.
F., preferably greater than 1000.degree. F., and more preferred
being greater than 1,500.degree. F.
[0034] In a further aspect, and as shown in FIG. 2, it is further
contemplated that the at least one particle-matrix composite
material can comprise a plurality of particle-matrix composite
materials. In this aspect, each particle-matrix composite material
can be disposed in a layer positioned transverse to a longitudinal
axis of the bit body. This layered approach allows for a fully
infiltrated bit body using a common binder material that can have
separate desired mechanical properties for the respective
layers.
[0035] Although several embodiments of the invention have been
disclosed in the foregoing specification, it is understood by those
skilled in the art that many modifications and other embodiments of
the invention will come to mind to which the invention pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is thus understood that the
invention is not limited to the specific embodiments disclosed
hereinabove, and that many modifications and other embodiments are
intended to be included within the scope of the appended claims.
Moreover, although specific terms are employed herein, as well as
in the claims which follow, they are used only in a generic and
descriptive sense, and not for the purposes of limiting the
described invention, nor the claims which follow.
* * * * *