Abstract: An earth boring drill bit having an alternate path to allow cuttings to be ejected or evacuated from the drill bit and up the bore hole is disclosed. The evacuation hole of the present disclosure allows larger sized cuttings to evacuate from the bit without having to be continually ground by rolling cone cutters until the cuttings are small enough to follow a path around the edge of the shirttail of the bit and up the borehole. A cuttings restrictor is disposed at the inlet of the evacuation hole. The cuttings restrictor ensures that only cuttings that are sized to move completely through the evacuation hole and exit the drill bit are allowed to enter the evacuation hole.

Abstract: A post manufacture method and apparatus for reducing residual stresses present within a component. The component includes a substrate, a polycrystalline structure coupled thereto, and residual stresses present therein. The method includes obtaining a component from a component category, determining a critical temperature and a critical time period for the component category at which the component becomes structurally impaired, determining a heat treatment temperature and a heat treatment time period based upon the critical temperature and the critical time period, and heating one or more remaining components from the component category to the heat treatment temperature for the heat treatment time period. The apparatus includes a heater defining a heating chamber and a molten bath positioned within the heating chamber. The components are placed within the pre-heated molten bath and isolated from oxygen during heating to the heat treatment temperature for the heat treatment time period.

Abstract: A sealing system includes a first gland in a cone and a second gland in a shaft region. A first ring is mounted in the first gland, a second ring is mounted in the second gland and a third ring is positioned between the first and second rings. The first and third rings present a pair of opposed metal seal faces. A biasing spring is configured to exert an axial force against the third ring so as to keep the metal seal faces in sealing contact. A third gland is formed between the second and third rings, with an o-ring sealing member installed within the third gland and compressed in a sealing relationship between the second and third rings. The third ring includes a sealing region supporting the metal seal face and a body region supporting the third gland, with the sealing region pivotally coupled to the body region.

Abstract: A substrate includes a surface having blind apertures formed therein. The blind apertures formed in the surface are preferably arranged in a regular and repeating pattern, such as with an array. A super-abrasive material fills each of the blind apertures. Each apertures hole has an opening with a cross-sectional dimension in the range of 1 mm to 15 mm. The super-abrasive material filling each of the plurality of blind apertures may be a polycrystalline diamond compact or an impregnated diamond material (such as formed by fused tungsten carbide impregnating randomly distributed diamond particles). The blind apertures may be formed in the substrate using electrical discharge machining.

Abstract: A sealing system includes a first gland in a cone and a first ring mounted in the first gland. A second ring is mounted to a shaft region. A third ring is positioned between the first and second rings. The first and third rings present a pair of metal seal faces. A second gland is formed between the second and third rings, with an o-ring sealing member installed within the third gland and radially compressed in a sealing relationship between the second and third rings. The second gland is sized to permit axial movement of the o-ring sealing member within the second gland in response to pressure changes. An energizer is configured to exert an axial force against the third ring so as to keep the metal seal faces in sealing contact. The axial force is applied at a radial position corresponding to a radial center the metal seal faces.

Abstract: A drill bit for drilling a hole in an earth formation includes a bit body and a blade extending from the bit body. The blade has a leading section, a top section, and a plurality of transition sections extending between the leading section and the top section. The drill bit further includes a plurality of cutters. Each cutter is positioned in a respective cutter pocket formed. Each cutter extends beyond the top section of the blade, and each transition section of the blade is between adjacent cutter pockets. The drill bit further includes a plurality of abrasion resistant inserts. Each abrasion resistant insert is positioned in a respective insert pocket formed in the blade. The plurality of abrasion resistant inserts are designed to cut into an earth formation. At least a portion of each abrasion resistant insert is disposed at a respective transition section of the blade.

Abstract: A short matrix drill bit is disclosed along with methods of manufacturing the same. The Short drill matrix bit includes a combination shank/blank bonded to a matrix. The combination shank/blank includes a blank portion and a shank portion, which are formed as a unitary component. The combination shank and blank may also include an outer layer formed along at least a portion of the combination shank/blank. In some instances, the outer layer is nickel plating, or some other suitable material, which facilitates wetting of the binder material used to form the matrix.

Abstract: A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.

Abstract: A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth.

Abstract: An apparatus and method for manufacturing a downhole tool. The cemented matrix material is formed from a metal powder, a shoulder powder, and a binder material, wherein the metal powder and/or the shoulder powder includes at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or powders of other suitable metals or alloys, or a combination of such mentioned powders.

Abstract: A fixed cutter bit for milling a frac plug includes a body and a face. The face includes a base surface and a plurality of cutter support structures extending from the base surface. Each cutter support structure has a peripheral portion and an inner portion disposed radially internal of the peripheral portion. At least one first-type cutter is supported by each peripheral portion; at least one second-type cutter is supported by each inner portion. The first type cutter is adapted to mill a harder material than the second-type cutter, and the first-type is different from the second-type.

Abstract: A hardfaced infiltrated matrix downhole tool and a method for hardfacing such items is provided. The hardfaced infiltrated matrix downhole tool includes a body, an intermediate base coat coupled to at least a portion of the surface of the body, and a hardfacing material coupled to at least a portion of the intermediate base coat. The body is composed of at least a carbide material and an infiltrating binder material. The intermediate base coat bonds to the surface of the body and to the hardfacing material. The method includes obtaining an infiltrated matrix downhole tool, applying and bonding the intermediate base coat to at least a portion of the surface of the infiltrated matrix downhole tool, and applying and bonding the hardfacing material to at least a portion of the intermediate base coat.

Abstract: A cleaned component having a polycrystalline structure, a method and apparatus for cleaning a leached component to form the cleaned component, and a method for determining the effectiveness of cleaning the leached component. The cleaned component includes a leached layer that has at least a portion of by-product materials removed. The by-product materials were deposited into the leached layer during a leaching process that formed the leached layer. The apparatus and method for cleaning includes a tank, a cleaning fluid placed within the tank, and at least a portion of the leached layer immersed into the cleaning fluid. Optionally, a transducer emits ultrasonic waves into the leached layer. The method for determining the effectiveness of cleaning includes cleaning the leached component to form the cleaned component, measuring one or more capacitance values of the cleaned component, repeating the cleaning and the measuring until achieving a stable lower limit capacitance value.

Abstract: A sealing system includes a first gland in a cone and a second gland in a shaft region. A first ring is mounted in the first gland, a second ring is mounted in the second gland and a third ring is positioned between the first and second rings. The first and third rings present a pair of metal seal faces. A third ring is mounted to the second ring through a set of mounting pins which permit axial movement of the third ring. A biasing spring is mounting in the second ring and configured to exert an axial force against the third ring so as to keep the metal seal faces in sealing contact. A third gland is formed between the second and third rings, with an o-ring sealing member installed within the third gland and compressed in a sealing relationship between the second and third rings.

Abstract: A coating that includes a polyisocyanate compound and at least one metal inclusion selected from the group consisting of tungsten and tungsten carbide. The metal inclusions range between about five percent by weight to about fifty percent by weight. A downhole tool that includes a body, a shank positioned at one end of the body, at least one cutter coupled to the body, and a coating coupled to at least a portion of one or more of the body or the shank. The coating includes a polyisocyanate compound and at least one metal inclusion selected from the group consisting of tungsten, tungsten carbide, and aluminum. The metal inclusions range between about five percent by weight to about fifty percent by weight. An intermediate coating is optionally disposed between at least a portion of the coating and at least one of the body or the shank.

Abstract: A disc cutter and a downhole tool including disc cutters therein. The disc cutter is disc-shaped and includes a lower portion and an upper portion. The lower portion is fabricated using a substrate material. At least a portion of the upper portion's perimeter is fabricated using at least one of polycrystalline diamond, synthetic diamond grit, natural diamond grit, and cubic boron nitride. According to certain exemplary embodiments, the disc cutter also includes an intermediate layer, which is fabricated from the substrate material, extending outwardly from at least a portion of the lower portion to a distal end positioned within the upper portion. In alternative exemplary embodiments, the disc cutter is disc-shaped and includes an inner portion made of substrate material, an outer portion made of at least one of polycrystalline diamond, synthetic diamond grit, natural diamond grit, and cubic boron nitride, and a channel extending orthogonally through the inner portion.

Abstract: A system and method of fabricating a percussion tool that includes a choke valve that is replaceable and/or maintainable without disassembly of the percussion tool. The flow tube includes inner and outer walls and at least one opening formed in the outer wall. The inner wall extends from a top end of the flow tube to a bottom end of the flow tube and defines a central channel therein. The outer wall extends from the top end towards the bottom end, surrounds a portion of the inner wall, and defines an outer channel with the inner wall. The choke is positioned at the top end over the central channel and regulate a fluid flow therethrough. A check valve is positioned in fluid communication with the choke.

Abstract: A choke assembly for controlling air flow into a piston of a percussion tool for downhole drilling includes a choke and a choke adapter. The choke comprises a choke body and a choke opening in the choke body for fluid to flow therethrough. The choke further includes one or more arm slots formed into the choke body between an inner wall of the choke body and an outer wall of the choke body. The one or more arm slots are designed to receive one or more arms of a choke change tool. The choke adapter has an adapter opening extending through the choke adapter. The choke is sized to fit in the adapter opening. The choke is removable from the choke adapter after the choke is inserted into the adapter opening.

Abstract: A system and method of fabricating a percussion tool that includes one or more coatings applied onto a piston, casing, and/or flow tube. The percussion tool includes a piston positioned in sliding contact within a casing. The piston includes an inner wall and an outer wall, where the inner wall defines a passageway extending longitudinally therethrough. The outer wall is positioned in close fitting relationship with an internal surface of the casing. One or more coatings are disposed on at least one of the casing's internal surface and/or the piston's outer wall. A flow tube may be placed through the passageway such that an outer wall of the flow tube is in a close fitting relationship with the piston's inner wall. One or more coatings can be disposed on at least one of the piston's inner wall and/or the flow tube's outer wall.

Abstract: An apparatus, system, and method of fabricating a percussion tool that includes a flow tube. The flow tube includes upper and lower portions, inner and outer walls, and at least one opening formed in the outer wall. The upper portion extends from a top end towards a bottom end. The lower portion extends from the upper portion to the bottom end. The inner wall extends from the top end to the bottom end and defines a central channel therein. The outer wall extends from the top end towards the bottom end, surrounds a portion of the inner wall and defines an outer channel with the inner wall. The opening is fluidly communicable with a first conduit formed within a piston, which surrounds a portion of the flow tube, when in an up position and is fluidly communicable with a second conduit formed within the piston when in a down position.