Abstract: A wear insert comprised of cemented metal carbide is welded to a workpiece made of steel or cemented metal carbide without causing fracturing of the carbide or creating residual stresses that reduce the impact resistance of the part. The part is fabricated using a microwave sintering process prior to welding.

Abstract: A radial bearing having a wear surface with improved wear characteristics comprises a steel support, to which is bonded a metal carbide composite wear surface made by first arranging, within a cavity defined between a steel mold and the steel support, tiles made of microwave sintered, cemented metal carbide, closely packing the voids between the tiles with metal carbide powder, and infiltrating the mold cavity with a metal brazing alloy by subjecting the filled mold to rapid heating. The brazing alloy fills voids between the metal carbide particles, the microwave sintered metal carbide tiles, and the metal support, thereby relatively rapidly consolidating the carbide into a wear layer bonded with the steel support without substantially damaging the properties of the microwave-sintered metal carbide tiles.

Abstract: A downhole tool utilizing microwave energy for stimulating production of hydrocarbons from a drilled well. A microwave generator is disposed within the body of the tool and supplied with power from the surface. Microwaves generated by the tool are applied to a refractory dielectric material disposed at a lower end of the tool or to dielectric material in fluids circulated into the wellbore, or directly to the formation.

Abstract: A drilling tool (10) includes a pilot bit (14) and a plurality of mills (16) encircling the pilot bit. The pilot bit and the plurality of mills are each driven by a separate, hydraulically powered turbine or positive displacement motor. (20) The drilling tool does not include a transmission for transmitting power from the turbine or motor to any of the plurality of mills or the pilot bit.

Abstract: A head for a golf club used for hitting balls long distances, or for putting, has a hitting or contact surface formed by an insert placed within a pocket formed within the club head face. The insert has at least a surface layer made of polycrystalline diamond or cubic boron nitride. The insert may be polished very smooth to place less backspin on the ball and reduce surface flaws. The edges of the insert may also be rounded or chamfered to reduce chipping or cracking of the insert. Furthermore, the pocket into which the insert is set may be reinforced to reduce deformation of the pocket during ball contact that places stress on the insert.

Abstract: This disclosure features a process of making a two part drill bit insert, namely, a body portion of hard particles such as tungsten carbide particles mixed in an alloy binding the particles. The alloy preferably comprises 6% cobalt with amounts up to about 10% permitted. The body is sintered into a solid member, and also joined to a PDC crown covering the end. The crown is essentially free of cobalt. The process sinters the crown and body while preserving the body and crown cobalt differences.

Abstract: The present disclosure is summarized as an improved cutting tooth for mounting on a stump cutting wheel driven by a suitable power plant. The tooth itself includes a long root to enable it to be clamped on the cutting wheel. When appropriately clamped, it is held with an extending neck terminating in a planar face. The face is constructed with an improved PDC hard surface layer. This is attached by a suitable WC-Co sintered alloy which joins the PDC layer to the tooth. This enables more certain anchoring of the PDC layer to the tooth. This enables more certain anchoring of the PDC face so that it does not break or flake during use and operation.

Abstract: The present disclosure is directed to a method of converting green particles to form finished particles. The apparatus used for sintering incorporates an elongate hollow tube, an insulative sleeve there about to define an elevated temperature zone, and a microwave generator coupled through a wave guide into a microwave cavity incorporated the tube. The particles are moved through the tube at a controlled rate to assure adequate exposure to the microwave radiation. Another form sintered a solid part in a cavity or mold.

Abstract: This disclosure features a process of making a two part drill bit insert, namely, a body portion of hard particles such as tungsten carbide particles mixed in an alloy binding the particles. The alloy preferably comprises 6% cobalt with amounts up to about 10% permitted. The body is sintered into a solid member, and also joined to a PDC crown covering the end. The crown is essentially free of cobalt. The process sinters the crown and body while preserving the body and crown cobalt differences.

Abstract: An insert construction is set forth comprising a right cylinder insert body crowned with a PDC crown bonded thereto defining an interface between the two materials. The interface construction is described in geometric terms. The interface includes irregular curvilinear sided depressions to enhance the interface grip between the two materials thereby reducing shear stress concentration which might damage the PDC crown. Other failure modes are reduced also. Relationships are set forth in the amount, depth, and shape of the depressions.

Abstract: This invention is directed toward a material which is used to coat or create a surface for machine cutting tools, all types of drill bit teeth, saw teeth, bearing surfaces valve seats, nozzles and the like, thereby producing surfaces which are highly abrasion and erosion resistant. Furthermore, this invention includes some of the possible methods for producing such a material given that the methods and apparatus required provide a significant cost reduction over those required for producing prior art surface materials with similar abrasion and erosion resistant properties. More specifically, the material set forth can be formed at relatively low temperatures and relatively low pressures by sintering mixtures for a relatively short period of time.

Abstract: A drag bit is formed of an elongate tooth made of tungsten carbide and having an elongate right cylinder construction. The end face is circular at the end of a conic taper. The tapered surface is truncated with two 180.degree. spaced flat faces at 15.degree. to about 45.degree. with respect to the axis of the body. The end is capped by a PDC layer.

Abstract: A cutting element which has a metal carbide stud having a conic tip formed with a reduced diameter hemispherical outer tip end portion of said metal carbide stud. A layer of polycrystalline material, resistant to corrosive and abrasive materials, is disposed over the outer end portion of the metal carbide stud to form a cap. An alternate conic form has a flat tip face. A chisel insert has a transecting edge and opposing flat faces. It is also covered with a PDC layer.

Abstract: An insert for a drill bit is set forth. The insert is formed with an elongate body, typically having a cylindrical cross section terminating at an exposed outer end. The outer end is covered with a polycrystalline disc. In the present disclosure, the polycrystalline disc is reinforced with an insert which is wholly captured in the polycrystalline material. In one form, a circular disc is set forth. In another aspect, multiple reinforcing members can be incorporated. They have the form of multiple discs. This reduces stress concentration in the polycrystalline clad insert.

Abstract: The present disclosure sets forth various forms of inserts for operating as elements in bearing drill bits and similar devices. A single insert is formed with an external side face of cylindrical construction. One or more strips of hardened materials such as diamond or other hard material are provided along the side face. At the end face, the insert incorporates exposed tungsten carbide, diamond or other hard material. A PDC layer is optionally placed over the end face. The PDC layer has the form of a covering terminating at a radius of curvature.

Abstract: A mud motor bearing assembly is defined by and constructed with a support or base ring having an exposed upper or planar face. On the planar face, a number of PCD disc are attached to define a bearing surface at a common plane. The improved bearing assembly further includes a separate ring or an integral lip serving as a deflector ring brazed to the face of the support ring. The brazed deflector ring alters the fluid flow patterns of drilling fluid in the bearing assembly to reduce support ring erosion.

Abstract: The present system is directed to both a method and apparatus for manufacture of teeth for use in drill bits. The desired tooth is formed by a hard carbide, a protective disc placed on the end of the support, the joinder being accomplished by a braze metal layer. The process contemplates positioning the disc in a matching receptacle within the head of a molding apparatus wherein the head and cavity of the head are exposed to the terminus of several coolant flow lines through the head so that the disc is brought into contact with flowing coolant. The fluid coolant is delivered by a compressor at elevated pressure and is a flow of cooled gas after dehydration. Rapid flow of heat into cooled support at the base prevent deterioration of the diamond layer while allowing use of higher temperature braze metals.

Abstract: An improved bifurcated drill bit is set forth. It has a shank for connection with a chuck, a cylindrical head having an outer face, and duplicate cutter faces. Each cutter is formed of PDC inserts which are cylindrical (or segments thereof). The PDC inserts are formed from a circular disk or ring which has an alignment hole in the center. When mounted, the insert presents a PDC face which bears against the drill hole. The drill hole is formed by cutting action of the inserts. Impact and shock loading occurs at the PDC surface.

Abstract: The present system is directed to both a method and apparatus for manufacture of teeth for use in drill bits. The desired tooth is formed by a hard carbide, a protective disc placed on the end of the support, the joinder being accomplished by a braze metal layer. The process contemplates positioning the disc in a matching receptacle within the head of a molding apparatus wherein the head and cavity of the head are exposed to the terminus of several coolant flow lines through the head so that the disc is brought into contact with flowing coolant. The fluid coolant is delivered by a compressor at elevated pressure and is a flow of cooled gas after dehydration. Rapid flow of heat into cooled support at the base prevent deterioration of the diamond layer while allowing use of higher temperature braze metals.

Abstract: A cutting element which has a metal carbide stud having a plurality of ridges formed in a reduced or full diameter hemispherical outer end portion of said metal carbide stud. The ridges extend outwardly beyond the outer end portion of the metal carbide stud. A layer of polycrystalline material, resistant to corrosive and abrasive materials, is disposed over the ridges and the outer end portion of the metal carbide stud to form a hemispherical cap.