Patent application number | Description | Published |
20080202814 | Earth-boring tools and cutter assemblies having a cutting element co-sintered with a cone structure, methods of using the same - Methods of forming cutter assemblies for use on earth-boring tools include sintering a cone structure to fuse one or more cutting elements thereto. In some embodiments, one or more green, brown, or fully sintered cutting elements may be positioned on a green or brown cone structure prior to sintering the cone structure to a final density. Cutter assemblies may be formed by such methods, and such cutter assemblies may be used in earth-boring tools such as, for example, earth-boring rotary drill bits and hole openers. | 08-28-2008 |
20080223622 | Earth-boring tools having pockets for receiving cutting elements therein and methods of forming such pockets and earth-boring tools - Methods of forming cutting element pockets in earth-boring tools include machining at least one recess to define at least one surface of a cutting element pocket using a cutter oriented at an angle to a longitudinal axis of the cutting element pocket. Methods of forming earth-boring tools include forming a bit body and forming at least one cutting element pocket therein using a rotating cutter oriented at an angle relative to a longitudinal axis of the cutting element pocket being formed. Earth-boring tools have a bit body comprising a first surface defining a lateral sidewall of a cutting element pocket, a second surface defining an end wall of the cutting element pocket, and another surface defining a groove located between the first and second surfaces that extends into the body to enable a cutting element to abut against an area of the lateral sidewall and end wall of the pocket. | 09-18-2008 |
20080236899 | Shrink fit sleeve assembly for a drill bit, including nozzle assembly and method thereof - A shrink-fit sleeve assembly comprising a bit body includes at least one sleeve port with a substantially tubular sleeve disposed therein and interferingly engaged therewith. The sleeve port includes an internal surface of substantially circular cross-section, and the tubular sleeve includes an internal nozzle port and an external surface of substantially circular cross-section. A lateral dimension of the external surface is equal to or greater than the first dimension at ambient temperature. A nozzle assembly and a method of manufacturing or retrofitting a drill bit are also disclosed. | 10-02-2008 |
20080251297 | PASSIVE AND ACTIVE UP-DRILL FEATURES ON FIXED CUTTER EARTH-BORING TOOLS AND RELATED METHODS - Earth-boring tools include at least one up-drill feature disposed on a transition surface so as to be passive during down drilling and active during up drilling and/or back reaming operations. Systems for down drilling and up drilling with drill bits comprising one or more up-drill features are also disclosed. Furthermore, methods for forming a borehole with an earth-boring tool including such up-drill features and for forming an earth-boring tool comprising such up-drill features are also disclosed. | 10-16-2008 |
20090031863 | BONDING AGENTS FOR IMPROVED SINTERING OF EARTH-BORING TOOLS, METHODS OF FORMING EARTH-BORING TOOLS AND RESULTING STRUCTURES - Methods for forming earth-boring tools include providing a metal or metal alloy bonding agent at an interface between a first element and a second element and sintering the first element, the second element, and the boding agent to form a bond between the first element and the second element at the interface. The methods may be used, for example, to bond together portions of a body of an earth-boring tool (which may facilitate, for example, the formation of cutting element pockets) or to bond cutting elements to a body of an earth-boring tool (e.g., a bit body of a fixed-cutter earth-boring drill bit or a cone of a roller cone earth-boring drill bit). At least partially formed earth-boring tools include a metal or metal alloy bonding agent at an interface between two or more elements, at least one of which may comprise a green or brown structure. | 02-05-2009 |
20090032310 | EARTH-BORING TOOLS HAVING PARTICLE-MATRIX COMPOSITE BODIES, METHODS FOR WELDING PARTICLE-MATRIX COMPOSITE BODIES AND METHODS FOR REPAIRING PARTICLE-MATRIX COMPOSITE BODIES - Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate. | 02-05-2009 |
20090044663 | EARTH-BORING TOOLS HAVING POCKETS FOR RECEIVING CUTTING ELEMENTS AND METHODS FOR FORMING EARTH-BORING TOOLS INCLUDING SUCH POCKETS - Methods of forming cutting element pockets in blades of earth-boring tools include forming a first recess and a second recess intersecting at a location defining the a back of the pocket using a cutter oriented in a manner so as to avoid tool path interference with adjacent blades. A filler material is disposed in the second recess to the location of the back of the pocket. Earth-boring tools having such cutting element pockets are also disclosed. | 02-19-2009 |
20090301786 | METHODS OF FORMING EARTH-BORING TOOLS USING GEOMETRIC COMPENSATION AND TOOLS FORMED BY SUCH METHODS - Geometric compensation techniques are used to improve the accuracy by which features may be located on drill bits formed using particle compaction and sintering processes. In some embodiments, a positional error to be exhibited by at least one feature in a less than fully sintered bit body upon fully sintering the bit body is predicted and the at least one feature is formed on the less than fully sintered bit body at a location at least partially determined by the predicted positional error. In other embodiments, bit bodies of earth-boring rotary drill bits are designed to include a design drilling profile and a less than fully sintered bit body is formed including a drilling profile having a shape differing from a shape of the design drilling profile. Less than fully sintered bit bodies of earth-boring rotary drill bits are formed using such methods. | 12-10-2009 |
20090301788 | COMPOSITE METAL, CEMENTED CARBIDE BIT CONSTRUCTION - A manufacturing method and drill bit having either a preformed steel powder blank or machined steel core and abrasion and erosion resistant material components attached thereon. | 12-10-2009 |
20100006345 | INFILTRATED, MACHINED CARBIDE DRILL BIT BODY - Methods of forming bit bodies for earth-boring bits include assembling green components that have been infiltrated, brown components that have been infiltrated, or fully sintered components that have been infiltrated, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering or hot isostatic pressing the green body or brown body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material. | 01-14-2010 |
20100108399 | CARBURIZED MONOTUNGSTEN AND DITUNGSTEN CARBIDE EUTECTIC PARTICLES, MATERIALS AND EARTH-BORING TOOLS INCLUDING SUCH PARTICLES, AND METHODS OF FORMING SUCH PARTICLES, MATERIALS, AND TOOLS - Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of at least partially carburized monotungsten carbide and ditungsten carbide eutectic particles dispersed throughout a matrix material. In some embodiments, the particles are at least substantially fully carburized monotungsten carbide and ditungsten carbide eutectic particles. In further embodiments, the particles are generally spherical or at least substantially spherical. Methods of forming such particles include exposing a plurality of monotungsten carbide and ditungsten carbide eutectic particles to a gas containing carbon. Methods of manufacturing such tools include providing a plurality of at least partially carburized monotungsten carbide and ditungsten carbide eutectic particles or at least substantially completely carburized monotungsten carbide and ditungsten carbide eutectic particles within a matrix material. | 05-06-2010 |
20100133805 | COUPLING MEMBERS FOR COUPLING A BODY OF AN EARTH-BORING DRILL TOOL TO A DRILL STRING, EARTH-BORING DRILLING TOOLS INCLUDING A COUPLING MEMBER, AND RELATED METHODS - Coupling members for coupling an earth-boring drill tool to a drill string, drilling tools including a coupling member attached to a body of an earth-boring drill tool, methods for forming drilling tools including a coupling member, and methods for forming coupling members are disclosed. A coupling member may include a distal region comprising a first material composition and a proximal region comprising a second, different material composition. A drilling tool may include a body that is attached to a coupling member with a varied material composition for coupling the body to a drill string. | 06-03-2010 |
20100155147 | METHODS OF ENHANCING RETENTION FORCES BETWEEN INTERFERING PARTS, AND STRUCTURES FORMED BY SUCH METHODS - A shrink-fit sleeve assembly comprising a bit body includes at least one sleeve port with a substantially tubular sleeve disposed therein and interferingly engaged therewith. The sleeve port includes an internal surface of substantially circular cross-section, and the tubular sleeve includes an internal nozzle port and an external surface of substantially circular cross-section. A lateral dimension of an external surface is equal to or greater than a first dimension at ambient temperature. A nozzle assembly and a method of manufacturing or retrofitting a drill bit are also disclosed. | 06-24-2010 |
20100159157 | ROBOTICALLY APPLIED HARDFACING WITH PRE-HEAT - A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit. | 06-24-2010 |
20100192475 | METHOD OF MAKING AN EARTH-BORING METAL MATRIX ROTARY DRILL BIT - A method of making an earth-boring rotary drill bit includes providing a plurality of hard particles in a mold to define a particle precursor of the first region and the second region and infiltrating the particle precursor of the first region with a molten first matrix material forming a molten first particle-matrix mixture. The method also includes infiltrating the particle precursor of the second region with a molten second matrix material forming a molten second particle-matrix mixture; and cooling the molten first particle-matrix mixture and the molten second particle-matrix mixture to solidify the first matrix material and the second matrix material and form a bit body having a first particle-matrix composite material having a first material composition in the first region and a second particle-matrix composite material having a second material composition in the second region, wherein the first particle-matrix composite material and the second particle-matrix composite material are different. | 08-05-2010 |
20100193252 | CAST CONES AND OTHER COMPONENTS FOR EARTH-BORING TOOLS AND RELATED METHODS - The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one of carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder. In addition, the hard particles may comprise at least one of (i) cast carbide (WC+W2C) particles, (ii) transition metal carbide particles selected from the carbides of titanium, chromium, vanadium, zirconium, hafnium, tantalum, molybdenum, niobium, and tungsten, and (iii) sintered cemented carbide particles. | 08-05-2010 |
20100193255 | EARTH-BORING METAL MATRIX ROTARY DRILL BIT - An earth-boring rotary drill bit includes a bit body, with a first region configured to carry a plurality of cutters for engaging a subterranean earth formation of a first particle-matrix composite material and a second region configured for attachment to a drill string of a second particle-matrix composite material having a second material composition, and an annular shank extending from the second region. Each of the first particle-matrix composite material and second particle-matrix composite material has a cast microstructure. A method of making an earth-boring rotary drill bit includes providing a plurality of hard particles in a mold to define a particle precursor; infiltrating the particle precursor sequentially with a plurality of molten matrix materials to form a corresponding plurality of layers, each comprising a particle-matrix mixture; and cooling the plurality of particle-matrix mixtures to solidify the matrix materials and form the bit body. | 08-05-2010 |
20100263935 | EARTH BORING ROTARY DRILL BITS AND METHODS OF MANUFACTURING EARTH BORING ROTARY DRILL BITS HAVING PARTICLE MATRIX COMPOSITE BIT BODIES - Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material. | 10-21-2010 |
20100276205 | METHODS OF FORMING EARTH-BORING ROTARY DRILL BITS - Methods of forming earth-boring rotary drill bits include providing a bit body, providing a shank that is configured for attachment to a drill string, and attaching the shank to the bit body. Providing a bit body includes providing a green powder component having a first region having a first composition and a second region having a second, different composition, and at least partially sintering the green powder component. Other methods include providing a powder mixture, pressing the powder mixture to form a green component, and sintering the green component to a final density. A shank is provided that includes an aperture, and a feature is machined in a surface of the bit body. The aperture is aligned with the feature, and a retaining member is inserted through the aperture. An earth-boring bit includes a bit body comprising a particle-matrix composite material including a plurality of hard particles dispersed throughout a matrix material. A shank is attached to the bit body using a retaining member. | 11-04-2010 |
20100307838 | METHODS SYSTEMS AND COMPOSITIONS FOR MANUFACTURING DOWNHOLE TOOLS AND DOWNHOLE TOOL PARTS - Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part. | 12-09-2010 |
20100319492 | METHODS OF FORMING BODIES OF EARTH-BORING TOOLS - Methods for forming bodies of earth-boring drill bits and other tools include milling a plurality of hard particles and a plurality of particles comprising a matrix material to form a mill product comprising powder particles, separating the particles into a plurality of particle size fractions. Some of the particles from the fractions may be combined to form a powder mixture, which may be pressed to form a green body. Additional methods include mixing a plurality of hard particles and a plurality of particles comprising a matrix material to form a powder mixture, and pressing the powder mixture with pressure having an oscillating magnitude to form a green body. In yet additional methods a powder mixture may be pressed within a deformable container to form a green body and drainage of liquid from the container is enabled as the powder mixture is pressed. | 12-23-2010 |
20100326739 | EARTH-BORING TOOLS COMPRISING SILICON CARBIDE COMPOSITE MATERIALS, AND METHODS OF FORMING SAME - Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC—SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC—SiC material, and the ABC—SiC material may be toughened to increase a fracture toughness exhibited by the ABC—SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed. | 12-30-2010 |
20110030509 | METHODS FOR FORMING EARTH BORING TOOLS HAVING POCKETS FOR RECEIVING CUTTING ELEMENTS - Methods of forming cutting element pockets in earth-boring tools may include forming a first recess and a second recess. A filler material is disposed in the second recess to the form at least a portion of a back surface of the pocket. Methods of forming cutting element pockets in earth-boring tools may include orienting a rotating cutter generally parallel to a longitudinal axis of a cutting element pocket to be formed in a body of an earth-boring tool and machining the cutting element pocket in the earth-boring tool. Methods of forming earth-boring tools include forming a body comprising at least one blade and forming at least one cutting element pocket in the at least one blade. | 02-10-2011 |
20110073233 | Method of Applying Hardfacing Sheet - A method of hardfacing a bit using a hardfacing sheet. The hardfacing sheet includes a hardfacing composition in a carrier material. The sheet is placed on a portion of the bit body, the sheet is heated at a designated spot using a localized heating source. At the same time, oxygen is substantially purged from the zone adjacent the designated spot. The heat debinds the carrier material from the sheet leaving the hardfacing composition. Continued heating transforms the hardfacing composition into hardfacing that is fused to the bit body. | 03-31-2011 |
20110094341 | METHODS OF FORMING EARTH BORING ROTARY DRILL BITS INCLUDING BIT BODIES COMPRISING REINFORCED TITANIUM OR TITANIUM BASED ALLOY MATRIX MATERIALS - Earth-boring rotary drill bits include bit bodies comprising a composite material including a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material. The bits further include a cutting structure disposed on a face of the bit body. In some embodiments, the bit bodies may include a plurality of regions having differing material compositions. For example, the bit bodies may include a first region comprising a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material, and a second region comprising a titanium or a titanium-based alloy material. Methods for forming such drill bits include at least partially sintering a plurality of hard particles and a plurality of particles comprising titanium or a titanium-based alloy material to form a bit body comprising a particle-matrix composite material. A shank may be attached directly to the bit body. | 04-28-2011 |
20110142707 | METHODS OF FORMING EARTH BORING ROTARY DRILL BITS INCLUDING BIT BODIES HAVING BORON CARBIDE PARTICLES IN ALUMINUM OR ALUMINUM BASED ALLOY MATRIX MATERIALS - Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating a plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body. | 06-16-2011 |
20110239545 | COMPOSITIONS FOR MANUFACTURING DOWNHOLE TOOLS AND DOWNHOLE TOOL PARTS - Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part. | 10-06-2011 |
20110259647 | SYSTEMS FOR MANUFACTURING DOWNHOLE TOOLS AND DOWNHOLE TOOL PARTS - Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part. | 10-27-2011 |