U.S. patent application number 16/311504 was filed with the patent office on 2019-08-01 for tools having a structural metal-matrix composite portion.
This patent application is currently assigned to Halliburton Energy Services, Inc.. The applicant listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Grant O. Cook, III, Matthew Steven Farny, Garrett T. Olsen.
Application Number | 20190234151 16/311504 |
Document ID | / |
Family ID | 61072843 |
Filed Date | 2019-08-01 |
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United States Patent
Application |
20190234151 |
Kind Code |
A1 |
Olsen; Garrett T. ; et
al. |
August 1, 2019 |
TOOLS HAVING A STRUCTURAL METAL-MATRIX COMPOSITE PORTION
Abstract
Structural metal-matrix composites (MMC) comprising a foam
matrix material infiltrated with a binder material, where the
binder material binds the foam matrix material to a structural
element of a tool, thereby enhancing three-dimensional
reinforcement of the tool. In some instances, the structural
element is a portion of a wellbore tool or a bit body, such that
portions of such tools or bit bodies are composed of the structural
MMC. The foam matrix material may be composed of a metallic foam, a
ceramic foam, and any combination thereof.
Inventors: |
Olsen; Garrett T.; (The
Woodlands, TX) ; Cook, III; Grant O.; (Spring,
TX) ; Farny; Matthew Steven; (Magnolia, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Halliburton Energy Services,
Inc.
Houston
TX
|
Family ID: |
61072843 |
Appl. No.: |
16/311504 |
Filed: |
August 2, 2016 |
PCT Filed: |
August 2, 2016 |
PCT NO: |
PCT/US2016/045122 |
371 Date: |
December 19, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 2998/10 20130101;
E21B 10/42 20130101; B22F 2999/00 20130101; B22F 7/08 20130101;
B22F 2999/00 20130101; B22F 2998/10 20130101; B22F 2999/00
20130101; E21B 10/54 20130101; B22F 2999/00 20130101; B22F 7/08
20130101; B22F 2998/10 20130101; B22F 7/08 20130101; C22C 32/00
20130101; B22F 3/11 20130101; B22F 2007/066 20130101; B22F 2007/066
20130101; C22C 2001/1057 20130101; E21B 10/46 20130101; B22F
2999/00 20130101; B22F 2007/066 20130101; C22C 1/08 20130101; C22C
2001/1073 20130101; B22F 7/08 20130101; C22C 29/00 20130101; C22C
1/08 20130101; C22C 2001/1073 20130101; B22F 2007/066 20130101;
B22F 2007/066 20130101; C22C 1/08 20130101; B22F 3/1039 20130101;
B22F 2999/00 20130101; B22F 3/11 20130101 |
International
Class: |
E21B 10/46 20060101
E21B010/46; B22F 7/08 20060101 B22F007/08 |
Claims
1. A structural metal-matrix composite (MMC) comprising: a foam
matrix material having a cellular structure, the foam matrix
material selected from the group consisting of a metallic foam, a
ceramic foam, and any combination thereof; a structural element of
a tool; and a binder material infiltrated through the cellular
structure of the foam matrix material to bind the foam matrix
material and the structural element of the tool.
2. The structural MMC of claim 1, wherein the cellular structure of
the foam matrix material is an open-cell foam structure or a
closed-cell foam structure.
3. The structural MMC of claim 1, wherein the foam matrix material
comprises the metallic foam composed of a metallic material
selected from the group consisting of a metal, a metal alloy, a
metal carbide, a superalloy, and any combination thereof.
4. The structural MMC of claim 1, wherein the foam matrix material
comprises the ceramic foam composed of a ceramic material selected
from the group consisting of an oxide ceramic, a boride ceramic, a
nitride ceramic, a silicate ceramic, a carbide ceramic, diamond,
and any combination thereof.
5. The structural MMC of claim 1, wherein the structural MMC
further comprises reinforcement particulates.
6. The structural MMC of claim 1, wherein the binder material is at
least partially selected from the group consisting of copper,
nickel, manganese, zinc, and any combination thereof.
7. The structural MMC of claim 1, wherein the structural element of
the tool corresponds to a portion of a wellbore tool.
8. The structural MMC of claim 1, wherein the structural element of
the tool corresponds to a bit body of a drill bit.
9. A method comprising: placing a foam matrix material in a region
of a mold, the foam matrix material having a cellular structure and
selected from the group consisting of a metallic foam, a ceramic
foam, and any combination thereof; placing a binder material in the
mold; placing a structural element of a tool in the mold; heating
the mold, the foam matrix material, the binder material, and the
structural element of the tool to a temperature above the melting
point of the binder material; infiltrating the cellular structure
of the foam matrix material with the binder material; and cooling
the mold, the foam matrix material, the binder material, and the
structural element of the tool, wherein the infiltrated binder
material binds the foam matrix material and the structural element
of the tool.
10. The method of claim 9, wherein the cellular structure of the
foam matrix material is an open-cell foam structure or a
closed-cell foam structure.
11. The method of claim 9, wherein the structural MMC further
comprises reinforcement particulates.
12. The method of claim 9, wherein the foam matrix material melts
into, dissolves into, diffuses into, or reacts with the binder
material during infiltration of the foam matrix material with the
binder material, thereby forming a networked ductile phase.
13. The method of claim 9, wherein the foam matrix material reacts
with the binder material during infiltration of the foam matrix
material with the binder material, thereby forming an intermetallic
phase.
14. The method of claim 9, wherein the mold corresponds to all or a
portion of a wellbore tool mold.
15. The method of claim 9, wherein the mold corresponds to all or a
portion of a drill bit.
16. The method of claim 9, wherein the mold corresponds to a bit
body of a drill bit.
17. A drilling assembly comprising: a drill string extendable from
a drilling platform and into a wellbore; a drill bit attached to an
end of the drill string and including a bit body and a plurality of
cutting elements coupled to an exterior portion of the bit body,
the bit body composed of a structural metal-matrix composite (MMC)
comprising: a foam matrix material having a cellular structure, the
foam matrix material selected from the group consisting of a
metallic foam, a ceramic foam, and any combination thereof; the bit
body; and a binder material infiltrated through the cellular
structure of the foam matrix material to bind the foam matrix
material and the bit body; and a pump fluidly connected to the
drill string and configured to circulate a drilling fluid to the
drill bit through the wellbore.
18. The drilling assembly of claim 17, wherein the cellular
structure of the foam matrix material is an open-cell foam
structure or a closed-cell foam structure.
19. The drilling assembly of claim 17, wherein the foam matrix
material comprises the metallic foam composed of a metallic
material selected from the group consisting of a metal, a metal
alloy, a metal carbide, a superalloy, and any combination
thereof.
20. The drilling assembly of claim 17, wherein the foam matrix
material comprises the ceramic foam composed of a ceramic material
selected from the group consisting of an oxide ceramic, a boride
ceramic, a nitride ceramic, a silicate ceramic, a carbide ceramic,
diamond, and any combination thereof.
Description
BACKGROUND
[0001] The present disclosure relates to tools having a structural
metal-matrix composite (MMC) portion and use thereof, and more
specifically to tools having a structural MMC portion including a
metallic and/or ceramic foam matrix material.
[0002] Traditional MMCs are composite materials having at least two
constituent parts, the first being necessarily metal or metal-based
and the second being the same metal in different form (e.g., a
foamed metal v. an un-foamed metal), a different metal, or a
non-metal material, such as an organic compound, where the first
constituent forms a matrix portion of the MMC and the second
constituent is dispersed or otherwise embedded into the matrix
portion, such as to provide structural reinforcement and/or to bind
the constituent parts together or to a structural element. Greater
than two constituent parts may additionally be used to form an MMC,
which may be termed hybrid composites. Such MMCs may include
structural elements and be used as structural components or
portions of various tools or equipment generally requiring erosion
resistance, temperature resistance, and/or high impact strength.
For example, MMCs may be used as part of the automotive industry
(e.g., as all or portions of engines, drive shafts, disc brakes,
and the like), the aviation industry (e.g., as all or portions of
landing gear, and the like), the electrical industry (e.g., as all
or portions of power electronic modules, power semiconductor
devices, and the like), as well as other industries.
[0003] The oil and gas industry additionally employs a wide variety
of wellbore tools used in downhole operations that may benefit from
the erosion resistance, temperature resistance, and/or high impact
strength of an MMC, such as wellbore tools for forming wellbores,
wellbore tools used in completing wellbores that have been drilled,
and wellbore tools used in producing hydrocarbons, such as oil and
gas, from the completed wellbores. Wellbore cutting tools, in
particular, are frequently used to drill oil and gas wells,
geothermal wells and water wells. Wellbore cutting tools may
include rotary drill bits (e.g., roller cone drill bits and fixed
cutter drill bits), reamers, coring bits, under reamers, hole
openers, stabilizers, and the like. For example, rotary drill bits
are often formed with a bit body (sometimes referred to in the
industry as a composite bit body or a matrix bit body when formed
using a MMC), having cutting elements or inserts disposed at select
locations about the exterior of the bit body. During drilling,
these cutting elements engage and remove adjacent portions of the
subterranean formation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following figures are included to illustrate certain
aspects of the disclosure, and should not be viewed as exclusive.
The subject matter disclosed is capable of considerable
modifications, alterations, combinations, and equivalents in form
and function, as will occur to those skilled in the art and having
the benefit of this disclosure.
[0005] FIG. 1 is a scanning electron microscope image of a closed
celled metallic foam matrix material composed of nickel, prepared
according to one or more examples described herein.
[0006] FIG. 2 is a cross-sectional view showing one example of a
drill bit having a bit body with at least one structural MMC
portion in accordance with the teachings of the present
disclosure.
[0007] FIG. 3 is an isometric view of the drill bit of FIG. 1.
[0008] FIG. 4 is an end view showing one example of a mold assembly
for use in forming a bit body in accordance with the teachings of
the present disclosure.
[0009] FIG. 5 is a cross-sectional view showing one example of a
mold assembly for use in forming a bit body in accordance with the
teachings of the present disclosure.
[0010] FIG. 6 is a cross-sectional view showing one example of a
drill bit in accordance with the teachings of the present
disclosure.
[0011] FIG. 7 is a cross-sectional view showing one example of a
drill bit in accordance with the teachings of the present
disclosure.
[0012] FIG. 8 is a cross-sectional view showing one example of a
drill bit in accordance with the teachings of the present
disclosure.
[0013] FIG. 9 is a cross-sectional view showing one example of a
matrix drill bit in accordance with the teachings of the present
disclosure.
[0014] FIG. 10 is a schematic drawing showing one example of a
drilling assembly suitable for use in conjunction with the drill
bits of the present disclosure.
DETAILED DESCRIPTION
[0015] The present disclosure relates to tools having a structural
metal-matrix composite (MMC) portion and use thereof, and more
specifically to tools having a structural MMC portion including a
metal-based (i.e., metallic and/or ceramic) foam matrix material, a
binder material, and a structural element. These portions are
distinguishable from other types of hard MMC portions that do not
contain metallic and/or ceramic foam matrix material and that do
not contain a structural element.
[0016] As used herein, the term "structural MMC," and grammatical
variants thereof, for use in the examples of the present disclosure
includes at least a metal-based (i.e., metal, ceramic, and any
combination thereof) foam matrix material, a binder material, and a
structural element. The term "foam matrix material," and
grammatical variants thereof, as used herein refers to an
inflexible material having a cellular structure of solid metal
and/or ceramic capable of having a binder material and optional
reinforcement (i.e., strengthening) material dispersed or otherwise
embedded within the cellular structure. As used herein, the term
"binder material," and grammatical variants thereof, refers to a
material dispersed or otherwise embedded within a foam matrix
material that is capable of binding the foam matrix material to a
structural element. The binder material may, in some instances,
additionally provide structural reinforcement to and/or alter the
physical properties (e.g., wear resistance, friction coefficient,
thermal conductivity, and the like) of the foam matrix material.
The term "structural element," and grammatical variants thereof, as
used herein refers to any portion of a tool providing a structural
form thereto for a specific application, such as a portion of a
wellbore tool (e.g., a drill bit, a leg of a drill bit, and the
like). For example, the structural element may be a mandrel, a leg,
a core, and insert, and/or a displacement structural element meant
to supply a void space to a particular tool, and the like, without
departing from the scope of the present disclosure.
[0017] The teachings of this disclosure may be applied to any tool
that can be formed at least partially of structural MMC materials
in accordance with the instant disclosure, including tools in any
industry, such as those described above. By way of example, the
teachings of the present disclosure may be illustrated with
reference to wellbore tools that experience wear during contact
with a wellbore or other downhole devices during downhole
operations. Such wellbore tools may include tools for drilling
wells, completing wells, and producing hydrocarbons from wells.
Examples of such tools may include, but are not limited to, cutting
tools, such as drill bits, reamers, stabilizers, and coring bits;
drilling tools such as rotary steerable devices, mud motors; and
other tools used downhole such as window mills, packers, tool
joints, and other wear-prone tools. Even more particularly,
examples of the teachings of the present disclosure may be
illustrated with reference to a drill bit having a bit body with at
least one portion thereof formed by a structural MMC comprising a
metallic and/or ceramic foam matrix material infiltrated with a
binder material, and a structural element. It is to be appreciated,
nevertheless, that the examples described herein are non-limiting
and the structural MMCs described herein are applicable to any tool
that can be formed at least partially therefrom, without departing
from the scope of the present disclosure.
[0018] Traditional composite materials may be formed by placing
loose reinforcement material in particulate powder form into a mold
and infiltrating the particulate powder matrix material with a
reinforcement and/or binder material, followed by solidification.
The structural MMCs described herein may exhibit comparatively
enhanced mechanical properties, even at low volume fractions, by
utilizing a metallic and/or ceramic foam matrix material
(collectively simply "foam matrix material"). The foam matrix
material may be composed of a metallic and/or ceramic material and
may be used in lieu of traditional particulate powder matrix
material. Alternatively, the foam matrix material described herein
may be used in combination with an optional reinforcement material,
without departing from the scope of the present disclosure
(referred to herein as "optional reinforcement material"). The term
"optional reinforcement material," and grammatical variants
thereof, refers to herein as a material that is dispersed or
otherwise embedded within the foam matrix material of the instant
disclosure to provide structural reinforcement and/or alteration of
physical properties to the foam matrix material, and may be in
particulate (encompassing particles, fibers, and powder forms). In
any examples described herein, the foam matrix material may be used
in combination with optional reinforcement material(s) (e.g.,
optional particulate reinforcement material(s)), without departing
from the scope of the present disclosure.
[0019] The foam matrix material described herein provides a
structurally rigid, three-dimensional reinforcement that may behave
in a similar nature to bundled fiber material. However, the foam
matrix material is not designed using aspect ratios and length (as
would be true for bundled fiber material), but instead based on
cell type (e.g., open cell or closed cell) and cell size. The cell
type and the cell size of the foam matrix material defines the type
of structure it is able to provide to a structural MMC, including
structural MMCs forming all or a portion of a tool, such as a
wellbore tool. The rigid (inflexible), three-dimensional structure
of the foam matrix materials described herein additionally
physically support themselves and can be shaped as needed (and hold
their shape) to provide desired capabilities for particular tools
(e.g., drill bits). Indeed, the foam matrix materials described
herein may be shaped (e.g., machine shaped) into various shapes to
easily fit the desired shape of the structural MMC, including any
all or a portion of a tool or wellbore tool it forms. Accordingly,
the shape of the foam matrix material can be customized.
[0020] The structural MMCs of the present disclosure may be formed
by placing a foam matrix material in a region of a mold comprising
a structural element (e.g., a tool mold, such as a wellbore tool
mold). The foam matrix material is then infiltrated with a binder
material as a result of heating the mold. The mold is thereafter
cooled, along with the foam matrix material and the binder
material.
[0021] More specifically, and as discussed in greater detail below,
the mold may initially have one or more displacement structural
elements placed at strategic locations corresponding to the desired
exterior and/or interior portions of a desired tool, for example.
Thereafter, a foam matrix material is placed in the mold. The foam
matrix material for use in the present disclosure is at least a
metallic and/or ceramic foam matrix material and may optionally
include optional reinforcement material (e.g., tungsten carbide
particulates). Next, a binder material is placed in the mold, which
may remain atop the foam matrix material. The mold and its contents
are then heated, and when the temperature exceeds the melting point
of the binder material, it infiltrates (or flows into) the foam
matrix material and contacts the interior displacement structural
elements. The mold and its contents (i.e., the foam matrix
material, the binder material, any optional reinforcement material,
and the structural element(s)) are then cooled to form the
resultant structural MMC.
[0022] The foam matrix material may be placed in the mold in a
pre-formed configuration (i.e., in a solid configuration, which may
be preferred) or may be formed through the process of forming the
structural MMC, depending on the binder material selected. The foam
matrix material may be formed by introducing gas bubbles into a
molten form of the material used to form the foam matrix material.
The gas bubbles may be formed by injecting gas into the molten
material, causing an in situ gas formation, or causing
precipitation of gas previously dissolved in the molten material.
Alternatively, the foam matrix material may be machined from the
solid material selected to form the foam matrix material.
[0023] Advantageously, the rigid, three-dimensional structure of
the foam matrix material may allow increased control over the
structure and any reinforcement of the structural MMC. For example,
in traditional MMCs, the use of loose matrix materials (e.g.,
particulates (which include powders, particles, and fibers herein))
can result in irregularities of a reinforcement structure, such as
due to non-uniform physical properties, anisotrophic properties
(e.g., in the case of fibers that may tend to "lie down" due to
such properties), vibrational forces, gravitational forces,
non-uniform infiltration, and the like. Such irregularities may
cause areas of the resultant MMC to have variable properties
throughout (e.g., areas of concentrated matrix material, areas of
concentrated binder material, and the like). The use of the foam
matrix material described herein, however, may provide a porous
structure to permit flow of the binder material and any additional
optional reinforcement material, thus providing better and more
controlled placement therein. Additionally, where optional
reinforcement material such those that are fiber-shaped are used,
the fiber-shaped material may be held in place within the foam
matrix material, while the pores allow the flow of any optional
particulate reinforcement material and the binder material into the
structure of the foam matrix material. After solidification of the
structural MMC, it may be used to provide reinforcement or
toughness to a portion of a tool (e.g., a bit body), depending on
the composition of the foam matrix material and the remaining
components of the structural MMC, such as the binder material and
any optional reinforcement material.
[0024] The foam matrix material described herein comprises a metal,
a ceramic, or a combination of a metal and a ceramic and has a
cellular structure, as defined above. The cellular structure of the
foam matrix material may be an open cell or closed cell, which may
be utilized to alter the properties of the structural MMC. A
"closed cell" foam matrix material, and grammatical variants
thereof, refers to a foam having sealed pores (i.e., the pores are
sealed from adjacent pores). Differently, an "open cell" foam
matrix material, and grammatical variants thereof, refers to a foam
having an interconnected network of pores (i.e., the pores are open
to adjacent pores). FIG. 1 is a scanning electron microscope image
of an open cell metallic foam matrix material composed of nickel,
prepared according to one or more examples described herein. Closed
cell configurations may allow for localized areas of toughness
within the structural MMC, while open cell configurations lend to
structural reinforcement that may have improved material
properties, such as compression, tensile strength, and/or fracture
toughness.
[0025] The size of the cell, whether open or closed, in a foam
matrix material as described herein may additionally be controlled
or otherwise varied to adjust the properties of a resultant
structural MMC. For example, the cell size in an open celled foam
matrix material may allow control over how much reinforcement is
present in the structural MMC (e.g., generally the larger the
openings, the less reinforcement, and vice versa). Furthermore, the
foam matrix material may be customized based on the inclusion of
additional optional reinforcement materials, their type, their
shape, and/or their amount. In other examples, small cell size in a
foam matrix material may be used to prevent or hinder optional
particulate reinforcement material in certain areas, thus resulting
in a binder-rich zone that may impart increased toughness and/or
crack resistance to certain portions of the structural MMC.
Similarly, small cell size in the foam matrix material may be used
to prevent or hinder other optional reinforcement materials from
entering into the foam matrix material, additionally resulting in a
binder-rich zone to impart similar qualities to the structural MMC.
That is, the foam matrix material may act as a filter to allow
certain materials (e.g., binder materials, optional reinforcement
materials, and the like, and combinations thereof) to be layered or
otherwise varied relative to each other and/or to achieve specified
configurations and compositions, thus imparting specific qualities
to the structural MMC.
[0026] Alternatively or additionally to cell type and cell size,
cell shape of the foam matrix material described herein may be used
to impart certain qualities to the structural MMCs. For example,
cell shape of the pores of a foam matrix material may be selected
or otherwise designed to preferentially allow certain additional
optional reinforcement materials having particular morphologies to
pass through while precluding other morphologies. For instance,
spherical or substantially spherical cell shapes may permit
similarly shaped optional reinforcement materials to pass, whereas
optional reinforcement materials of other shapes (e.g., irregular,
plate-like, and the like) may be precluded. Use of cell shapes may
thus result in certain properties, such as more dense packing or
even distribution of any optional reinforcement material. Moreover,
such packing or distribution of any optional reinforcement material
may result in non-uniform or uniform infiltration of binder
material, additionally allowing customization of the properties of
the subsequent structural MMC.
[0027] The foam matrix materials described herein may be composed
of any metal, ceramic, or combination thereof capable of being
formed into a foam and used to form a structural MMC, as defined
herein. Selection of such materials may depend on the use of the
structural MMC, such as the tool or portion of the tool that it is
used to form. For example, if the structural MMC forms a portion of
a wellbore tool, the foam matrix material(s) should be selected for
use in a downhole environment (e.g., downhole temperatures,
downhole pressures, downhole friction forces, and the like).
[0028] The melting point of the foam matrix material may be
selected to have a melting point greater than or less than the
melting point of the binder material, without departing from the
scope of the present disclosure. In any or all specific examples
described herein, the composition of the foam matrix material may
be selected to have a melting point greater than the melting point
of the binder material(s), discussed below, selected to form the
structural MMC, which may be greater than 1000.degree. C. in some
instances. The term "melting point," and grammatical variants
thereof, as used herein, refers to the temperature at which a solid
(e.g., the foam matrix material) melts. In an example, the
composition of the foam matrix material may be selected to have a
melting point in the range of 1000.degree. C. to 4000.degree. C.,
encompassing any value and subset therebetween. For example, the
composition of the foam matrix material may be selected to have a
melting point of 1000.degree. C. to 1500.degree. C., or
1500.degree. C. to 2000.degree. C., or 2000.degree. C. to
2500.degree. C., or 2500.degree. C. to 3000.degree. C., or
3000.degree. C. to 3500.degree. C., or 3500.degree. C. to
4000.degree. C., or 1500.degree. C. to 3500.degree. C., or
2000.degree. C. to 3000.degree. C., encompassing any value and
subset therebetween. Alternatively or additionally, the composition
of the foam matrix material may be selected to have an oxidation
temperature for the given atmospheric conditions that is greater
than the melting point of the binder material(s).
[0029] In one or all examples, the foam matrix material described
herein may have a composition that bonds with the binder
material(s), so that an increased amount of thermal and mechanic
stresses (or loads) can be transferred to the foam matrix material.
Further, a composition that bonds with the binder material(s) may
be less likely to pull out from the binder material as a crack
potentially propagates in the structural MMC. That is, the binder
material serves to bond the foam matrix material to one or more
structural elements, and may additionally bond to the foam matrix
material itself, without departing from the scope of the present
disclosure.
[0030] Additionally, in one or all examples, the composition of the
foam matrix material may endure temperatures and pressures
experienced when forming a structurally MMC, as described in
greater detail below, with little to no alloying with the binder
material(s) or oxidation. However, in some instances, the
atmospheric conditions may be changed (e.g., reduced oxygen content
achieved via reduced pressures or gas purge) to mitigate oxidation
of the foam matrix material to allow for a composition that may not
be suitable for use in standard atmospheric oxygen
concentrations.
[0031] In some instances, the foam matrix material is a metallic
foam composed of a metal (e.g., an alkali metal, an alkaline metal,
a transition metal, a post-transition metal, a lanthanide, an
actinide), a metal alloy, a metal carbide, a superalloy, and the
like, and any combination thereof. Specific examples of metallic
foams suitable for use in conjunction as the foam matrix material
described herein may include, but are not limited to, aluminum,
iron, cadmium, cobalt, copper, carbon, vitreous carbon, gold, lead,
molybdenum, nickel, niobium, rhenium, silicon, silver, tantalum,
tin, titanium, tungsten, zinc, zirconium, copper-aluminum alloy,
hafnium-carbide alloy, an iron alloy (e.g., iron-chromium alloy,
iron-chromium-aluminum alloy, and the like), lanthanated molybdenum
alloy, a nickel alloy (e.g., nickel-chromium-aluminum alloy,
nickel-chromium alloy, nickel-iron alloy, nickel-iron-chromium
alloy, nickel-manganese-gallium alloy, nickel-copper-chromium
alloy, and the like), tungsten-nickel alloy, N-155 alloy, steel,
stainless steel, austenitic stainless steel, ferritic steel,
martensitic steel, a chromium alloy, boron carbide, silicon
carbide, tantalum carbide, zinc carbide, zirconium carbide,
molybdenum carbide, titanium carbide, niobium carbide, chromium
carbide, vanadium carbide, iron, carbide, tungsten carbide,
nickel-based superalloys, silicon nitride carbide, graphite, and
the like, and any combination thereof.
[0032] Examples of suitable commercially available superalloys for
use in forming the metallic foam matrix materials described herein
may include, but are not limited to, INCONEL.RTM. alloys
(austenitic nickel-chromium containing superalloys, available from
Special Metals Corporation), WASPALOYS.RTM. (austenitic
nickel-based superalloys), RENE.RTM. alloys (nickel-chrome
containing alloys, available from Altemp Alloys, Inc.), HAYNES.RTM.
alloys (nickel-chromium containing superalloys, available from
Haynes International), INCOLOY.RTM. alloys (iron-nickel containing
superalloys, available from Mega Mex), MP98T (a
nickel-copper-chromium superalloy, available from SPS
Technologies), TMS alloys, CMSX.RTM. alloys (nickel-based
superalloys, available from C-M Group), and the like, and any
combination thereof.
[0033] In some instances, the foam matrix material is a ceramic
foam composed of an oxide ceramic, a boride ceramic, a nitride
ceramic, a silicate ceramic, a carbide ceramic, diamond (e.g.,
natural diamond, synthetic diamond, and the like), and the like,
and any combination thereof. Specific examples of ceramic foams
suitable for use in conjunction as the foam matrix material
described herein may include, but are not limited to, silicon
oxide, silicon dioxide, aluminum oxide, aluminum titanate,
beryllium oxide, zirconium oxide, magnesium oxide, titanium
dioxide, lead zirconium titanate, titanium diboride, zirconium
diboride, hafnium diboride, silicon nitride, aluminum nitride,
boron nitride, titanium nitride, zirconium nitride, vanadium
nitride, niobium nitride, tantalum nitride, hafnium nitride,
porcelain, steatite, cordierite, mullite, and the like, and any
combination thereof.
[0034] Combinations of the aforementioned metallic foams and
ceramic foams may additionally be used to compose the foam matrix
materials described herein, without departing from the scope of the
present disclosure. Accordingly, the foam matrix materials of the
present disclosure can utilize desirable benefits from one or more
of the metallic and/or ceramic foams in combination.
[0035] The selection of the particular foam matrix material may
depend on a number of factors, including those described above. The
particular foam matrix material may be selected based on its
particular eventual use in a structural MMC (including the type and
use of any tool in which it is used), the selected binder
material(s), any optional reinforcement material, and the like.
[0036] For example, the foam matrix material may be selected such
that it will melt into, dissolve into, diffuse into, or react with
the selected binder material(s) during infiltration of the foam
matrix material with the binder material, as described below,
thereby forming a networked ductile phase. As used herein, the term
"networked ductile phase," and grammatical variants thereof, refers
to a network of material that has an ability to absorb an impact or
shock load with a lower propensity to fracture due to the networked
material structure. Such networked ductile phase may possess
pliability and/or flexibility, which may then impart toughness to
the resultant structural MMC.
[0037] Alternatively, the foam matrix material may be selected such
that it will react with the selected binder material(s) during
infiltration of the foam matrix material with the binder material,
thereby forming an intermetallic phase. As used herein, the term
"intermetallic phase" refers to one or more phases comprising two
elements in a covalent or ionic bond with a different crystal
structure than that of the surrounding phase. Such intermetallic
phase may possess high strength and/or stiffness, which may then
impart strengthening, stiffening, and/or erosion resistance to the
resultant structural MMC (as opposed to toughness, for example).
Indeed, for example, when the structural MMC forms a portion of a
wellbore tool, such as a drill bit, and is located at or near the
surface of the drill bit (e.g., the bit body), stiffness of the
structural MMC (e.g., by virtue of the intermetallic phase) to
enhance erosion resistance of the drill bit. Stiffness may further
be enhanced by including additional large particle sized optional
reinforcement material within the foam matrix material.
[0038] Alternatively, the foam matrix material and binder
material(s) may be selected such that they will dissolve into or
react with each other during infiltration, such that after
infiltration the shape of the structural MMC resembles tetrahedral
molecular geometry comprising six straight edges, where the
straight edges are evenly spaced and independent of one another.
The tetrahedral geometry may impart high bond strength to the
structural MMC. This geometry may be also be enhanced when the
outer surface of the foam matrix material is designed to be thick.
This geometry may provide an enhanced combination of strength and
stiffness because the foam matrix material imparts strengthening
(e.g., stiffness, ultimate tensile strength, and the like) in
discrete, independent modules (which may or may not be themselves
individual tetrahedrons) and, thus, may be less prone or not prone
to crack propagation and/or crack failure. Any groupings forming
the tetrahedral geometry may form the shape of the structural MMC
described herein, without departing from the scope of the present
disclosure.
[0039] Accordingly, the shape of the foam matrix material may be
customized--the cell type, size, and shape of the foam matrix
material may be customized; and/or the toughness, stiffness, or
other qualities of the foam matrix material may be customized
(e.g., due to the selection of certain foam matrix material
types(s)). The inclusion of optional reinforcement material and its
distribution within the foam matrix material, in combination with
the type and reactivity of the selected binder material(s) allows
further customization. Thus, the resultant structural MMC may have
portions that are tough, portions that are stiff, portions that are
brittle, portions that are erosion resistant, and the like by
strategically forming the structural MMC. Moreover, such
customization allows prudent use of certain components or
compositional elements that may be expensive or in short supply, as
these components and others can be selectively included in the
structural MMC.
[0040] In any or all examples, the selected foam matrix material
may itself be further treated to alter the material properties of
the selected foam material. For example, the selected foam material
may be a metallic foam composed of a metal alloy, and the metal
alloy may be itself heat treated such that increased strength or
stiffness is imparted prior to forming it into the foam matrix
material. Alternatively or in addition to, the material properties
of the foam material selected for forming the foam matrix material
can be altered during the infiltration process (e.g., to impart
increased strength or stiffness). That is, the selected foam
material may be a metal alloy that is selected (or formulated) such
that the infiltration process alone during forming the structural
MMC imparts the requisite heat input to alter the properties of the
metal alloy, and thus the structural MMC, such as by causing
precipitation hardening throughout the foam material forming the
foam matrix material. Accordingly, no additional manufacturing
steps would be needed in addition to the manufacture of the
structural MMC alone to alter the properties of the foam matrix
material. Alternatively, the selected foam material forming the
foam matrix material may be a ceramic material that can be
pretreated to improve fracture resistance or bonding with the
selected binder material(s).
[0041] In any or all examples of the structural MMCs described
herein, an optional reinforcement material may be used in
combination with the ceramic and/or metallic foam matrix materials
and/or the binder material to further customize the structural MMC
(e.g., to provide additional reinforcement). Such optional
reinforcement materials may include, but are not limited to,
reinforcing particulates, encompassing powders, particles, and
fibers, and the like, and any combination thereof. These optional
reinforcement materials may be dispersed or embedded in the foam
matrix material prior to the step of infiltration with the binder
material(s) or may be directly included in the binder material(s)
and placed into the foam matrix material during the infiltration
process (e.g., with the binder material(s)), without departing from
the scope of the present disclosure.
[0042] As used herein, the "reinforcing particulates" have a shape
such that they are substantially spherical, polygonal, or fibrous
in shape. As used herein, the term "substantially spherical," and
grammatical variants thereof, refers to a material that has a
morphology that includes spherical geometry and elliptic geometry,
including oblong spheres, ovoids, ellipsoids, capsules, and the
like, and hybrids thereof. The term "polygonal," and grammatical
variants thereof, as used herein, refers to shapes having at least
two straight sides and angles. Examples of polygonal shapes may
include, but are not limited to, a cube, cone, pyramid, cylinder,
rectangular prism, cuboid, triangular prism, icosahedron,
dodecahedron, octahedron, pentagonal prism, hexagonal prism,
hexagonal pyramid, and the like, and hybrids thereof. As used
herein, the term "fibrous," and grammatical variants thereof,
refers to fiber-shaped substances having aspect ratios of greater
than 2, or in the range of 2 to 500, encompassing any value and
subset therebetween. For example, the fibrous reinforcing particles
may have an aspect ratio of 2 to 50, or 50 to 100, or 100 to 200,
or 200 to 300, or 300 to 400, or 400 to 500, or 50 to 450, or 100
to 400, or 150 to 350, or 200 to 300, encompassing any value and
subset therebetween. Accordingly, "fibrous" shapes encompass
fibers, rods, wires, dog bones, whiskers, ribbons, discs, wafers,
flakes, rings, and the like, and hybrids thereof. As used herein,
the term "dog bone" refers to an elongated structure like a fiber,
whisker, or rod where the cross-sectional area at or near the ends
of the structure are greater than a cross-sectional area
therebetween. As used herein, the "aspect ratio" refers to the
ratio of the longest dimension to the thickness.
[0043] A collection of fiber-shaped reinforcing particulates may be
arranged to form a 2-dimensional or 3-dimensional structure (e.g.,
an oriented wool, a disoriented wool, or a mesh). As used herein,
the term "oriented wool" refers to an entangled mass of fibers
where at least 90% of the fibers are oriented within 25.degree. of
each other (e.g., steel wool), which may be a result of the
manufacturing process, entanglement method, or an orienting process
(e.g., stretching a disoriented wool). As used herein, the term
"disoriented wool" is an entangled mass of continuous fibers that
are less oriented than an oriented wool. As used herein, the term
"wool" encompasses both oriented wools and disoriented wools.
[0044] The size of the reinforcing particulates may be such that
they have a unit mesh particle size in the range of 0.05 micrometer
(.mu.m) to 2000 .mu.m, encompassing any value and subset
therebetween. Accordingly, the term "reinforcing particulates"
encompasses powder forms. For example, the size of the reinforcing
particulates may have a unit mesh size of 0.05 .mu.m to 5 .mu.m, or
5 .mu.m to 400 .mu.m, or 400 .mu.m to 8000 .mu.m, or 800 .mu.m to
1200 .mu.m, or 1200 .mu.m to 1600 .mu.m, or 1600 .mu.m to 2000
.mu.m, or 400 .mu.m to 1600 .mu.m, or 800 .mu.m to 1200 .mu.m,
encompassing any value and subset therebetween. As used herein, the
term "unit mesh particle size" or simply "unit mesh size" refers to
a size of an object (e.g., a particulate) that is able to pass
through a square area having each side thereof equal to the
specified numerical value provided herein. One skilled in the art
would recognize that the length of the any fiber-shaped reinforcing
particulate will depend on their unit mesh size diameter.
[0045] The optional reinforcing particulates may be composed of any
material described above with reference to the metallic foam and/or
ceramic foams for use in forming the foam matrix materials
described herein and below with reference to the binder materials.
The optional reinforcement particulates may additionally be
composed of sand, glass materials, polymer materials (e.g.,
polystyrene, polyethylene, etc.), nut shell pieces, wood, cements
(e.g., Portland cements), fly ash, carbon black powder, silica,
alumina, alumino-silicates, fumed carbon, carbon black, graphite,
mica, titanium dioxide, barite, meta-silicate, calcium silicate,
calcium carbonate, dolomite, nepheline syenite, feldspar, pumice,
volcanic material, kaolin, talc, zirconia, boron, shale, clay,
sandstone, mineral carbonates, mineral oxide, iron oxide, formation
minerals, any of the aforementioned mixed with a resin to form
cured resinous particulates, and any combination thereof.
[0046] Additionally, the optional reinforcing particulates may be
selected to have one, more than one, or all of the various
characteristics discussed above with reference to the foam matrix
material (e.g., a melting point above the melting point of the
binder material; an oxidation temperature for the given atmospheric
conditions that is greater than the melting point of the binder
material(s); a material that melts into, dissolves into, diffuses
into, or reacts with the binder material during infiltration; and
the like; and any combination thereof).
[0047] Binder material compositions may be any material suitable
for use in forming a structural MMC in accordance with the present
disclosure, and may be the same material in different form (i.e., a
non-foam) or a different material selected for forming the foam
matrix material, provided that it is able to at least bond the foam
matrix material and the structural element. As an example, the
binder material may be nickel and the foam matrix material may also
be nickel. Accordingly, the materials available for forming the
binder material and the foam matrix material may be identical,
without departing from the scope of the present disclosure. In
some, but not all examples of the instant disclosure, the
composition of the foam matrix materials may be chosen to have a
melting point equal to or greater than the melting point of the
binder material for a particular structural MMC.
[0048] Examples of suitable binder materials for use in the present
disclosure may 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. Additional specific examples of binder
materials may include, but are not limited to, 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 may include, but are not limited to, VIRGIN.TM. Binder
material 453D (copper-manganese-nickel-zinc, available from Belmont
Metals, Inc.); copper-tin-manganese-nickel and
copper-tin-manganese-nickel-iron grades 516, 519, 523, 512, 518,
and 520 available from ATI Firth Sterling; and any combination
thereof. Binder materials comprising copper, nickel, manganese,
zinc, and any combination thereof, alone or with other materials
may be preferred.
[0049] By way of non-limiting example, FIGS. 2-9 provide examples
of implementing the structural MMCs comprising a metallic and/or
ceramic foam matrix material infiltrated with a binder material(s),
and including a structural element, described herein in drill bits.
One skilled in the art will recognize how to adapt these teachings
to other tools or wellbore tools, including, but not limited to,
all those mentioned herein, or portions thereof.
[0050] FIG. 2 is a cross-sectional view showing one example of a
drill bit 20 formed with a bit body 50 that has a structural MMC
portion 131 comprising a foam matrix material, a binder material
infiltrated through the foam matrix material, and one or more
structural elements. As used herein, the term "drill bit"
encompasses rotary drag bits, drag bits, fixed cutter drill bits,
and any other drill bits having a bit body capable of incorporating
the teachings of the present disclosure (i.e., capable of
incorporating a structural MMC).
[0051] As shown in FIG. 2, the drill bit 20 may include a
structural element metal shank 30 with a structural element metal
blank 36 securely attached thereto (e.g., at weld location 39). The
metal blank 36 may extend into the bit body 50. The metal shank 30
may have a threaded connection 34 distal to the metal blank 36. The
metal shank 30 and metal blank 36 are generally cylindrical
structural elements that at least partially define corresponding
fluid cavities 32 that fluidly communicate with each other. The
fluid cavity 32 of the metal blank 36 may further extend into the
bit body 50. At least one structural element flow passageway (shown
as two flow passageways 42 and 44) may extend from the fluid cavity
32 to the exterior portions of the bit body 50. Structural element
nozzle openings 54 may be defined at the ends of the flow
passageways 42 and 44 at the exterior portions of the bit body
50.
[0052] A plurality of indentations or pockets 58 may be formed at
the exterior portions of the bit body 50 and may be shaped to
receive corresponding cutting elements (shown in FIG. 3).
[0053] Regarding crack propagation in a bit body 50, in some
instances, cracks may originate at or near the nozzle openings 54
and propagate up flow passageways 42 and 44 in the direction of
arrows A and B, respectively. As described further herein, the
stress (or load) of the fracture may transfer to the structural
MMC, and more particularly to the foam matrix material described
herein, and mitigate crack propagation. Therefore, strengthening of
the foam matrix material that is at a location non-parallel to the
crack propagation direction provide some degree of load transfer
and mitigation of crack propagation, which may be achieved using
the foam shape and size; cell type, size, and shape; foam material
selection; and the like, as described above. In some instances, the
foam matrix material (or a portion thereof) is strengthened at a
location substantially perpendicular (e.g., within 25.degree. of
perpendicular) to the crack propagation direction to maximize
stress transfer and minimize crack propagation.
[0054] FIG. 3 is an isometric view showing one example of a drill
bit 20 that may be formed with the bit body 50 formed by a
structural MMC comprising a foam matrix material, a binder material
infiltrated through the foam matrix material, and a plurality of
structural elements in accordance with the teachings of the present
disclosure. As illustrated, the drill bit 20 includes the metal
blank 36 and the metal shank 30, as generally described above with
reference to. FIG. 2. The bit body 50 includes a plurality of
cutter blades 52 formed on the exterior of the bit body 50. Cutter
blades 52 may be spaced from each other on the exterior of the
structural MMC bit body 50 to form fluid flow paths or junk slots
62 therebetween.
[0055] As illustrated, the plurality of pockets 58 may be formed in
the cutter blades 52 at selected locations to receive corresponding
cutting elements 60 (also known as cutting inserts), securely
mounted (e.g., via brazing) in positions oriented to engage and
remove adjacent portions of a subterranean formation during
drilling operations. More particularly, the cutting elements 60 may
scrape and gouge formation materials from the bottom and sides of a
wellbore during rotation of the drill bit 20 by an attached drill
string (not shown). For some applications, various types of
polycrystalline diamond compact (PDC) cutters may be used as
cutting elements 60. A drill bit having such PDC cutters may
sometimes be referred to as a "PDC bit".
[0056] A nozzle 56 may be disposed in each nozzle opening 54. For
example, nozzles 56 may be described or otherwise characterized as
"interchangeable" nozzles.
[0057] Regarding crack propagation in a bit body 50, in some
instances, cracks may develop in the blades 52 from any direction
due to impact and torque experienced during drilling. Because the
cracks may originate from all directions, the foam matrix material
of the structural MMC may be uniformly strengthened using one or
more methods described above, including the inclusion of additional
reinforcing particulates, to reinforce the blades 52.
[0058] A wide variety of molds may be used to form a structural MMC
bit body and associated drill bit in accordance with the teachings
of the present disclosure.
[0059] FIG. 4 is an end view showing one example of a mold assembly
100 for use in forming a bit body incorporating teachings of the
present disclosure. A plurality of structural element mold inserts
106 may be placed within a cavity 104 defined by or otherwise
provided within the mold assembly 100. The mold inserts 106 may be
used to form the respective pockets in blades of the bit body. The
location of mold inserts 106 in cavity 104 corresponds with desired
locations for installing the cutting elements in the associated
blades. Mold inserts 106 may be formed from various types of
material such as, but not limited to, consolidated sand and
graphite, or any material described herein with reference to the
foam matrix material, the binder material, and the optional
reinforcement material.
[0060] FIG. 5 is a cross-sectional view of the mold assembly 100 of
FIG. 4 that may be used in forming a bit body incorporating
teachings of the present disclosure. The mold assembly 100 may
include several components such as mold 102, a gauge ring or
connector ring 110, and a funnel 120. Mold 102, gauge ring 110, and
funnel 120 may be formed from any material described herein with
reference to the foam matrix material, the binder material, such as
from graphite. Various techniques may be used to manufacture the
mold assembly 100 including, but not limited to, machining a
graphite blank to produce the mold assembly 100 with the associated
cavity 104 having a negative profile or a reverse profile of
desired exterior features for a resulting bit body. For example,
the cavity 104 may have a negative profile that corresponds with
the exterior profile or configuration of the blades 52 and the junk
slots 62 formed therebetween, as shown in FIGS. 2-3.
[0061] Various types of temporary structural element displacement
materials may be installed within cavity 104, depending upon the
desired configuration of a resulting drill bit. Additional
structural element mold inserts (not expressly shown) may be formed
from various materials (e.g., consolidated sand and/or graphite)
may be disposed within cavity 104. Such mold inserts may have
configurations corresponding to the desired exterior features of
the drill bit (e.g., junk slots).
[0062] Displacement materials (e.g., consolidated sand) may be
installed within the mold assembly 100 at desired locations to form
the desired exterior features of the drill bit (e.g., the fluid
cavity and the flow passageways). Such structural element
displacement materials may have various configurations. For
example, the orientation and configuration of the consolidated sand
legs 142 and 144 may be selected to correspond with desired
locations and configurations of associated flow passageways and
their respective nozzle openings. The consolidated sand legs 142
and 144 may be coupled to threaded receptacles (not expressly
shown) for forming the threads of the nozzle openings that couple
the respective nozzles thereto.
[0063] Other structural elements, such as a relatively large,
generally cylindrically-shaped consolidated sand core 150 may be
placed on the legs 142 and 144. Core 150 and legs 142 and 144 may
be sometimes described as having the shape of a "crow's foot." Core
150 may also be referred to as a "stalk." The number of legs 142
and 144 extending from core 150 will depend upon the desired number
of flow passageways and corresponding nozzle openings in a
resulting bit body. The legs 142 and 144 and the core 150 may also
be formed from graphite or other suitable materials, including any
of those described herein with reference to the foam matrix
material(s), the binder material(s), and the optional reinforcement
material(s).
[0064] After desired displacement materials, including for example
core 150 and legs 142 and 144, have been installed within the mold
assembly 100, the foam matrix material 130 may then be placed
within or otherwise introduced into the mold assembly 100. In an
example, the foam matrix material described herein may be placed in
a desired area or portion of the mold assembly 100 and optional
reinforcement material (e.g., particulate powder of tungsten
carbide) added around the placed foam matrix material.
Alternatively, the foam matrix material may have optional
reinforcement material(s) (e.g., particulate powder of tungsten
carbide) mixed therein. In another example, the foam matrix
material described herein may be formed into a specific shape for
use in forming the solidified or hardened structural MMC, and if
present, optional reinforcement material (e.g., particulate powder
of tungsten carbide) may be dispersed or otherwise embedded
therein. For example, the foam matrix material as a whole may be
spiral-shaped, a mesh, or an oriented wool and placed around the
legs 142 and 144, which, with reference to FIG. 2, may be oriented
to mitigate crack propagation up flow passageways 42 and 44 in the
direction of arrows A and B, respectively. In another example, the
foam matrix material may be formed to have cell sizes allowing
sufficient interstitial spacing for optional reinforcement material
particles to flow therethrough. In some instances, the foam matrix
material may be fabricated with such small cell sizes that they do
not allow optional reinforcement material particles to migrate into
the voids defined by the pores in the foam matrix material.
[0065] Vibration may be used to increase the packing efficiency of
the foam matrix material 130 (e.g., to pack optional reinforcement
material(s) or the binder material within the structure of a foam
matrix material). In an example, after the foam matrix material 130
has been added to the mold assembly 100, the structural element
metal blank 36 may then be placed within the mold assembly 100. In
one or all examples, the foam matrix material 130 may be designed
to have inserts for placing the metal blank 36. The metal blank 36
preferably includes inside diameter 37, which is larger than the
outside diameter 154 of sand core 150. Additional foam matrix
material 130 may be added to a desired level within the cavity 104,
which may be designed to a specific shape for inclusion
therein.
[0066] As illustrated, binder material 160 may be placed on top of
the foam matrix material 130, metal blank 36, and core 150.
Alternatively, the binder material 160 may be included with at
least a portion of the foam matrix material 130. The binder
material 160 may be covered with a flux layer (not expressly
shown). Alternatively, a binder material 160 bowl (not expressly
shown) disposed at the top of the funnel 120 may be used to contain
the binder material 160, which, during infiltration, will then flow
down into the foam matrix material 130, which may or may not
include optional reinforcement material. In alternative examples,
the binder material 160 includes optional reinforcement material
(e.g., particulate powder tungsten carbide), regardless of whether
the foam matrix material 130 includes such optional materials,
without departing from the scope of the present disclosure.
[0067] A cover or lid (not expressly shown) may be placed over the
mold assembly 100. The mold assembly 100 and materials disposed
therein may then be preheated and then placed in a furnace, or
directly placed in a furnace. When the furnace temperature reaches
or optionally exceeds the melting point of the binder material 160,
the binder material 160 may liquefy and infiltrate the foam matrix
material 130, binding the foam matrix material 130 to the various
structural elements.
[0068] After a predetermined amount of time allotted for the
liquefied binder material 160 to infiltrate the foam matrix
material 130, the mold assembly 100 may then be removed from the
furnace and cooled at a controlled rate. Once cooled, the mold
assembly 100 may be broken away to expose the bit body having a
structural MMC comprising a foam matrix material, a binder
material, various structural elements, and any optional
reinforcement material. Subsequent processing and machining,
according to well-known techniques, may be used to, produce a drill
bit having the desired bit body, if necessary.
[0069] The structural MMC portion may be homogeneous throughout or
heterogeneous throughout the bit body as illustrated in FIGS.
2-3.
[0070] In an example, the structural MMC portion may be localized
within a portion of the bit body with the remaining portion being
formed by a hard composite that is not a structural MMC. In some
instances, localization may provide mitigation for crack initiation
and propagation while minimizing the additional cost that may be
associated with some structural MMC materials and/or processing.
Further, the inclusion of the foam matrix material in the bit body
may, in some instances, reduce erosion properties of the bit body
because of the lower concentration of reinforcing particles.
Therefore, in some instances, localization of the foam matrix
material to only a portion of the bit body may mitigate any
reduction in erosion properties thereat.
[0071] For example, FIG. 6 is a cross-sectional view showing one
example of a drill bit 20 formed with a bit body 50 having a hard
composite portion 132 that is not a structural MMC in combination
with one or more structural MMC portions 131 (two shown) in
accordance with the teachings of the present disclosure. The
structural MMC portions 131 are shown to be located proximal to the
nozzle openings 54 and an apex 64, two structural element areas of
bit bodies that typically have an increased propensity for
cracking. As used herein, the term "apex," and grammatical variants
thereof, refers to the central portion of the exterior surface of
the bit body that engages the formation during drilling. Typically,
the apex of a drill bit is located at or proximal to where the
blades 52 (FIG. 3) meet on the exterior surface of the bit body
that engages the formation during drilling.
[0072] In another example, FIG. 7 is a cross-sectional view showing
one example of a drill bit 20 formed with a bit body 50 having a
hard composite portion 132 and a structural MMC portion 131 in
accordance with the teachings of the present disclosure. The
structural MMC portion 131 is shown to be located proximal to the
nozzle openings 54 and the pockets 58.
[0073] In some examples, the configuration of the foam matrix
material (e.g., shape, cell type, cell size, cell shape, foam
material, and the like) may be different in different portions of
the structural MMC 131 to achieve different qualitative results,
such as to mitigate crack initiation and propagation, mitigate
erosion, and/or minimize the additional cost that may be associated
with some foam matrix materials.
[0074] For example, FIG. 8 is a cross-sectional view showing one
example of a drill bit 20 formed with a bit body 50 having a
structural MMC portion 131 in accordance with the teachings of the
present disclosure. The cell size of the foam matrix material
decreases or progressively decreases from apex to the shank of the
bit body 50 (as illustrated by the degree or concentration of
stippling in the bit body 50). As illustrated, the smallest cell
sizes of the foam matrix material are adjacent the nozzle openings
54 and the pockets 58 of the structural MMC 131 and the largest
cell sizes of the foam matrix material are adjacent the metal blank
36 of the structural MMC 131.
[0075] In some instances, the concentration change of the cell
sizes of a foam matrix material (or multiple foam matrix materials)
of a structural MMC may be gradual. Alternatively, the
concentration change may be more distinct and resemble layering or
localization. For example, FIG. 9 is a cross-sectional view showing
one example of a drill bit 20 formed with a bit body 50 having a
hard composite portion 132 that is not a structural MMC and a
structural MMC portion 131 in accordance with the teachings of the
present disclosure. The structural MMC portion 131 is shown to be
located proximal to the nozzle openings 54 and the pockets 58 in
layers 131a, 131b, and 131c. The layer 131a is shown to be located
proximal to the nozzle openings 54 and the pockets 58 and may have
the smallest cell sizes of a foam matrix material. The layer 131c
with the largest cell sizes of a foam matrix material is shown to
be located proximal to the hard composite portion 132. The layer
131b with the intermediate cell sizes of the foam matrix material
is shown to be disposed between layers 131a and 131c. It is to be
appreciated that the layers 131a, 131b, and 131c may be made of the
same or different material, and may be a continuous or
discontinuous foam matrix material. Alternatively or additionally,
the structural MMC 131 portion of layers 131a, 131b, and 131c may
vary by the type of material forming the foam matrix material, the
cell shape, the cell type, the foam matrix material shape, and the
like, without departing from the scope of the present
disclosure.
[0076] One skilled in the art would recognize the various
configurations and locations for the hard composite portions that
are not structural MMCs and the structural MMC portions (including
with varying configurations thereof) that would be suitable for
producing a particular tool, or wellbore tool, such as a bit body
and a resultant drill bit to achieve certain qualities, such as a
reduced propensity to have cracks initiate and propagate.
[0077] Further, one skilled in the art would recognize the
modifications to the composition of the reinforcement material 130
of FIG. 5 to form a bit body according to the above examples in
FIGS. 6-9 and other configurations within the scope of the present
disclosure.
[0078] FIG. 10 is a schematic showing one example of a drilling
assembly 200 suitable for use in conjunction with the drill bits of
the present disclosure. It should be noted that while FIG. 10
generally depicts a land-based drilling assembly, those skilled in
the art will readily recognize that the principles described herein
are equally applicable to subsea drilling operations that employ
floating or sea-based platforms and rigs, without departing from
the scope of the disclosure.
[0079] The drilling assembly 200 may include a drilling platform
202 coupled to a drill string 204. The drill string 204 may
include, but is not limited to, drill pipe and coiled tubing, as
generally known to those skilled in the art. A drill bit 206
according to any of the examples described herein may be attached
to the distal end of the drill string 204 and may be driven either
by a downhole motor and/or via rotation of the drill string 204
from the well surface. As the drill bit 206 rotates, it creates a
wellbore 208 that penetrates the subterranean formation 210. The
drilling assembly 200 may also include a pump 212 that circulates a
drilling fluid through the drill string (as illustrated as flow
arrows C) and other pipes 214.
[0080] One skilled in the art would recognize other equipment
suitable for use in conjunction with drilling assembly 200, which
may include, but is not limited to, retention pits, mixers, shakers
(e.g., shale shaker), centrifuges, hydrocyclones, separators
(including magnetic and electrical separators), desilters,
desanders, filters (e.g., diatomaceous earth filters), heat
exchangers, any fluid reclamation equipment, and the like. Further,
the drilling assembly may include one or more sensors, gauges,
pumps, compressors, and the like.
[0081] The structural MMC portion comprising foam matrix material
infiltrated with a binder material(s) described herein may be
implemented in other tools or wellbore tools or portions thereof
and systems relating thereto, without departing from the scope of
the present disclosure. Examples of such wellbore tools where a
structural MMC portion described herein may be implemented in at
least a portion thereof may include, but are not limited to,
reamers, coring bits, rotary cone drill bits, centralizers, pads
used in conjunction with formation evaluation (e.g., in conjunction
with logging tools), packers, and the like. In some instances,
portions of wellbore tools where a structural MMC described herein
may be implemented may include, but are not limited to, wear pads,
inlay segments, cutters, fluid ports (e.g., the nozzle openings
described herein), convergence points within the wellbore tool
(e.g., the apex described herein), and the like, and any
combination thereof.
[0082] Examples disclosed herein include:
[0083] Example A: A structural metal-matrix composite (MMC)
comprising: a foam matrix material having a cellular structure, the
foam matrix material selected from the group consisting of a
metallic foam, a ceramic foam, and any combination thereof; a
structural element of a tool; and a binder material infiltrated
through the cellular structure of the foam matrix material to bind
the foam matrix material and the structural element of the
tool.
[0084] Example B: A method comprising: placing a foam matrix
material in a region of a mold, the foam matrix material having a
cellular structure and selected from the group consisting of a
metallic foam, a ceramic foam, and any combination thereof; placing
a binder material in the mold; placing a structural element of a
tool in the mold; heating the mold, the foam matrix material, the
binder material, and the structural element of the tool to a
temperature above the melting point of the binder material;
infiltrating the cellular structure of the foam matrix material
with the binder material; and cooling the mold, the foam matrix
material, the binder material, and the structural element of the
tool, wherein the infiltrated binder material binds the foam matrix
material and the structural element of the tool.
[0085] Example C: A drilling assembly comprising: a drill string
extendable from a drilling platform and into a wellbore; a drill
bit attached to an end of the drill string and including a bit body
and a plurality of cutting elements coupled to an exterior portion
of the bit body, the bit body composed of a structural metal-matrix
composite (MMC) comprising: a foam matrix material having a
cellular structure, the foam matrix material selected from the
group consisting of a metallic foam, a ceramic foam, and any
combination thereof; the bit body; and a binder material
infiltrated through the cellular structure of the foam matrix
material to bind the foam matrix material and the bit body; and a
pump fluidly connected to the drill string and configured to
circulate a drilling fluid to the drill bit through the
wellbore.
[0086] Exemplary additional elements applicable to A, B, and/or C
may include the following in any suitable combination:
[0087] Element 1: Wherein the cellular structure of the foam matrix
material is an open-cell foam structure or a closed-cell foam
structure.
[0088] Element 2: Wherein the structural MMC further comprises
reinforcement particulates.
[0089] Element 3: Wherein the foam matrix material comprises the
metallic foam composed of a metallic material selected from the
group consisting of a metal, a metal alloy, a metal carbide, a
superalloy, and any combination thereof.
[0090] Element 4: Wherein the foam matrix material comprises the
ceramic foam composed of a ceramic material selected from the group
consisting of an oxide ceramic, a boride ceramic, a nitride
ceramic, a silicate ceramic, a carbide ceramic, diamond, and any
combination thereof.
[0091] Element 5: Wherein the binder material is at least partially
selected from the group consisting of copper, nickel, manganese,
zinc, and any combination thereof.
[0092] Element 6: Wherein the structural element of the tool
corresponds to a portion of a wellbore tool.
[0093] Element 7: Wherein the structural element of the tool
corresponds to a bit body of a drill bit.
[0094] Element 8: Wherein the foam matrix material melts into,
dissolves into, diffuses into, or reacts with the binder material
during infiltration of the foam matrix material with the binder
material, thereby forming a networked ductile phase.
[0095] Element 9: Wherein the foam matrix material reacts with the
binder material during infiltration of the foam matrix material
with the binder material, thereby forming an intermetallic
phase.
[0096] Element 10: Wherein a mold is used to form a structural
metal-matrix composite, and the mold corresponds to all or a
portion of a wellbore tool mold.
[0097] Element 11: Wherein a mold is used to form a structural
metal-matrix composite, wherein the mold corresponds to all or a
portion of a drill bit.
[0098] Element 12: Wherein a mold is used to form a structural
metal-matrix composite, wherein the mold corresponds to a bit body
of a drill bit.
[0099] By way of non-limiting example, exemplary combinations
applicable to A, B, and C include: 1-12; 1, 3, and 10; 4, 5, 7, and
12; 8 and 9; 2, 4, 11, and 12; 6 and 7; 8, 9, and 11; and the
like.
[0100] One or more illustrative examples are presented herein. Not
all features of a physical implementation are described or shown in
this application for the sake of clarity. It is understood that in
the development of a physical embodiment incorporating the examples
described herein, numerous implementation-specific decisions must
be made to achieve the developer's goals, such as compliance with
system-related, business-related, government-related and other
constraints, which vary by implementation and from time to time.
While a developer's efforts might be time-consuming, such efforts
would be, nevertheless, a routine undertaking for those of ordinary
skill in the art and having benefit of this disclosure.
[0101] Therefore, the present disclosure is well adapted to attain
the ends and advantages mentioned as well as those that are
inherent therein. The particular examples disclosed above are
illustrative only, as 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 examples disclosed above may be altered, combined, or
modified and all such variations are considered within the scope
and spirit of the present disclosure. The examples illustratively
disclosed herein suitably may 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. 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 element 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.
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