Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a surface location that is subject to wear during operation of the bit. A bottom surface of a hard material plate is attached to a substantially conforming surface of the leg at the location subject to wear. The attachment of the conforming surfaces is made using a flowable material such as a brazing material.

Abstract: A drill tool includes a bit body, at least one bearing shaft extending from the bit body and a cone mounted for rotation on the bearing shaft. An outer bearing surface of the bearing shaft includes a non-loading zone. A first groove and a second groove are formed in the outer bearing surface at the non-loading zone. The first and second grooves are both circumferentially offset from each other and axially offset from each other. One or more of the grooves includes an opening for making a fluid connection to an internal lubricant channel within this bearing shaft. The circumferential and axial offsetting of the first and second grooves define a plurality of attenuation zones that function to restrict propagation of a cone pumping pressure pulse towards a sealing system of the drill tool.

Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a leading edge (at an outer surface or shoulder surface, for example) that is subject to wear during operation of the bit. A bottom surface of a hard material plate having an edge is attached to a conforming surface of the leg in a position where the edge of the hard material plate defines at least a portion of the leading edge of the leg. The attachment of the surfaces is made using a flowable material such as a brazing material.

Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a surface edge that is subject to wear during operation of the bit. A bottom surface of a hard material plate having an edge is attached to a conforming surface of the leg in a position where the edge of the hard material plate defines at least a portion of the surface edge of the leg. The attachment of the surfaces is made using a flowable material such as a brazing material.

Abstract: A PDC cutter includes a diamond table layer and an underlying substrate layer. A cap structure for the PDC cutter includes a first portion overlying, but not attached to, a front face of the diamond table layer and a second portion extending perpendicularly from the first portion which is overlying and attached to an outer peripheral surface of the underlying substrate layer.

Abstract: A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using capacitance measurements. The apparatus includes a capacitance measuring device having a positive and negative terminal, a leached component comprising a polycrystalline structure, a first wire, and a second wire. The leached component includes a first surface and an opposing second surface. The first wire electrically couples the positive terminal to one of the surfaces of the leached component and the second wire electrically couples the negative terminal to the other surface of the leached component. The capacitance is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure.

Abstract: A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using eddy current measurements. The apparatus includes an eddy current measuring device having at least one terminal, a leached component comprising a polycrystalline structure, a first wire, and a probe. The leached component includes a cutting surface and an opposing second surface. A portion of the polycrystalline structure extending inwardly from the cutting surface has at least a portion of a catalyst material removed from therein. The first wire electrically couples the terminal to the probe, which is placed in contact with the cutting surface. The eddy current is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure.

Abstract: A method for non-destructively characterizing one or more regions within a polycrystalline structure using capacitance and eddy current measurements. The eddy current measurements include at least one of an impedance amplitude and a phase shift angle. The capacitance is measured one or more times and compared to a first calibration curve to determine an estimated leaching depth within the polycrystalline structure. A first data scattering range is ascertained from the capacitance measurements to determine a relative porosity or the leaching quality within the polycrystalline structure. The eddy current is measured one or more times and compared to a second calibration curve to determine an estimated leaching depth within the polycrystalline structure. A second data scattering range is ascertained from the eddy current measurements to determine a relative porosity or the leaching quality within the polycrystalline structure.

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 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 method for forming pockets of a drill bit includes inserting a displacement plug in a cutter pocket defined by a substrate of a drill bit. A hardfacing material is applied to the substrate and the displacement plug using a plasma arc welding torch. The heat from the plasma arc welding torch reduces an oxide layer on the outer surface of the displacement plug, and the molten hardfacing material flows over the displacement plug and wets against the displacement plug. The displacement plug is then removed to reveal a final cutter pocket configured to receive a cutter compact. The cutter compact is secured to the final cutter pocket by brazing.

Abstract: Surface texturing is employed to modify the topography of one or more surfaces (radial or cylindrical) of the bearing system for a roller cone rock bit. The surface texturing results in a dimpled surface which retains additional lubricant helpful in reducing friction in the boundary and mixed lubrication regimes. Shot peening is disclosed as one method for texturing the desired surface.

Abstract: An acoustic emissions testing device includes a test cutter including a first surface, an acoustic sensor, an indenter coupled to the first surface, and a load. The load is exerted on the indenter, which transfers the load to the first surface. The acoustic sensor is communicably coupled to the test cutter and detects one or more acoustic events occurring therein. An acoustic emissions testing system includes a data recorder coupled to the testing device. The data recorder records the data from testing device. Based upon the data received, the toughness of the test cutter is objectively determined and can be ranked comparatively to the toughness of other test cutters. The load is ramped up to a peak load, held for a period of time, and then ramped down. Cutters from the same cutter type as the test cutters have similar toughness.

Abstract: A drill tool includes a bit body, at least one bearing shaft extending from the bit body, and a cone mounted for rotation on the bearing shaft. A first sealing system includes a first annular seal gland formed in a cylindrical surface of the cone and a seal ring retained within the first annular seal gland and compressed against a cylindrical surface of the bearing shaft. A second sealing system includes a second annular seal gland formed in a radial surface of the cone and a Belleville spring retained within the second annular seal gland and compressed against a radial surface surrounding the bearing shaft. A set of non-pressure compensated lubrication channels are configured to supply lubricant to an interstitial volume defined between the cone and bearing shaft, the lubricant retained within the interstitial volume by the first and second sealing systems, the lubrication channels further supporting open air circulation through the bearing when the sealing systems fail and lubricant is lost.

Abstract: Surface texturing is employed to modify the topography of one or more surfaces (radial or cylindrical) of the bearing system for a roller cone rock bit. The surface texturing results in a dimpled surface which retains additional lubricant helpful in reducing friction in the boundary and mixed lubrication regimes. Shot peening is disclosed as one method for texturing the desired surface.

Abstract: A rolling cone cutter for a roller cone earth-boring bit has a generally conical body. The generally conical body defines a plurality of lands and grooves. Each land supports a circumferential row of primary cutter elements. At least one of the plurality of lands has a land sidewall. The land sidewall defines a boundary of an adjacent groove. A plurality of protective inserts are disposed within the land sidewall. The protective inserts may reduce erosion of the land sidewall. One or more protective inserts may be disposed between a pair of primary cutters.

Abstract: A drill bit includes a bit head and a rotating bit cone. A sealing system for the drill bit includes a seal gland and a seal retained within the seal gland. The seal gland is defined by a radial cone surface, a head sealing surface and an opposed cone sealing surface. At least one of the head sealing surface and opposed cone sealing surface is not cylindrical (i.e., the surface is conical and not parallel to an axis of rotation for the cone). Additionally, the radial cone surface may be conical (i.e., the surface does not extend perpendicular to the axis of rotation of the cone). The seal is radially compressed between the head sealing surface and the opposed cone sealing surface. The use of one or more conical surfaces in the gland is provided to bias the compressed seal into a preferred dynamic sealing zone.

Abstract: A method and apparatus for testing the abrasive wear resistance of PDC cutters or other superhard materials. The method includes obtaining a first cutter having a first substrate and a first cutting table coupled thereto and obtaining a second cutter having a second substrate and a second cutting table coupled thereto. The method also includes positioning a surface of the first cutting table in contact with a surface of the second cutting table. The method also includes rotating at least one of the first cutters and the second cutters where at least a portion of the first and/or second cutting tables is removed. The method includes determining the amount of first and/or second cutting table removed. The apparatus includes a first holder coupled to the first cutter and a second holder coupled to the second cutter, where at least one holder rotates circumferentially.

Abstract: A method and apparatus for fabricating a cutter. The method includes obtaining a compact including a cutting surface, a bonding interface, and a sidewall extending from the perimeter of the cutting surface to the perimeter of the bonding interface. The method includes obtaining a substrate including a bonding surface, a mounting surface, and a substrate sidewall extending from the perimeter of the bonding surface to the perimeter of the mounting surface. At least a portion of the bonding interface is positioned adjacent at least a portion of the bonding surface. At least one of the substrate and the compact is rotated to produce a rotational differential therebetween. The temperature is increased on at least the bonding surface to a first temperature. The compact is coupled to the substrate to form the cutter. The apparatus includes a first holder coupled to the compact and a second holder coupled to the substrate.

Abstract: A drill bit includes a bit head and a rotating bit cone. A sealing system for the drill bit includes a seal gland and a seal retained within the seal gland. The seal gland is defined by a radial cone surface, a head sealing surface and an opposed cone sealing surface. At least one of the head sealing surface and opposed cone sealing surface is not cylindrical (i.e., the surface is conical and not parallel to an axis of rotation for the cone). Additionally, the radial cone surface may be conical (i.e., the surface does not extend perpendicular to the axis of rotation of the cone). The seal is radially compressed between the head sealing surface and the opposed cone sealing surface. The use of one or more conical surfaces in the gland is provided to bias the compressed seal into a preferred dynamic sealing zone.