Abstract: A steering pad apparatus for a rotary steerable system is provided. The steering pad apparatus comprises a base comprising one or more base lugs, each of the base lugs defining a respective axial hole therein. The apparatus further comprises a steering pad hingedly coupled to the base, the steering pad comprising one or more pad lugs, each said pad lug defining a respective axial hole therein. The one or more pad lugs are coupled to the one or more base lugs such that each of the one or more pad lugs is adjacent to at least one of the one or more base lugs. The apparatus further comprises, for each adjacent base lug and pad lug, a respective one or more bushings received in at least one of: the hole of the pad lug; and the hole of the base lug.

Abstract: Hardfacing is used to protect wear surfaces of drill bits and other downhole tools. A hardfacing member can be formed by heating a metal matrix material, e.g., via a laser process, injecting a plurality of particles into the heated metal matrix material, disposing the mixture on at least a portion of a substrate thereby forming a hardfacing member having a particle-embedded metal matrix material, and attaching the hardfacing member to a main body.

Abstract: A steering head for steering a drill string may include a pad pusher including a steering pad and a piston. The steering pad may have a pivot axis, and be rotatable about the pivot axis between retracted and extended positions. The pad pusher may further include a motion restrictor to restrict rotation about the pivot axis. The steering head may further include a housing having a motion restrictor disposed at a position corresponding to the pad pusher motion restrictor. The pad pusher motion restrictor may be engageable with the housing motion restrictor to restrict motion of the steering pad relative to the housing.

Abstract: A rotary steerable tool for steering a drill string may include a tool collar extending along a longitudinal axis of the tool, a pad pusher, a pad retention housing, and a piston liner. The pad pusher may be rotatable about a pivot axis thereof between retracted and extended positions relative to the tool collar, for steering the drill string. The piston liner may be coupled to the pad retention housing and have a piston channel that defines a curved profile. The piston liner may provide sealing contact against a perimeter of the piston upon pivoting of the pad pusher through the piston channel along the curved profile, relative to the piston liner.

Abstract: A rotary steerable tool for steering a drill string can include a tool collar, a plurality of pad pushers, and a plurality of fasteners. The pad pushers can each be positionable within a respective cavity of the tool collar. Each pad pusher can be coupled to a pad retention housing that has an engagement hole and a through hole spaced apart from the engagement hole. The pad pushers can be interconnected by a plurality of fasteners. Each fastener can extend between adjacent pad retention housings to interconnect the plurality of pad pushers around the tool collar.

Abstract: A steering pad apparatus for a rotary steerable system is provided. The steering pad apparatus comprises a base comprising one or more base lugs, each of the base lugs defining a respective axial hole therein. The apparatus further comprises a steering pad hingedly coupled to the base, the steering pad comprising one or more pad lugs, each said pad lug defining a respective axial hole therein. The one or more pad lugs are coupled to the one or more base lugs such that each of the one or more pad lugs is adjacent to at least one of the one or more base lugs. The apparatus further comprises, for each adjacent base lug and pad lug, a respective one or more bushings received in at least one of: the hole of the pad lug; and the hole of the base lug.

Abstract: The present disclosure provides a system for improving wear resistance of a downhole tool component using a bonded diamond compact (BDC) construct. The BDC construct includes a BDC element and an encapsulation layer bonded to the BDC element. The encapsulation layer may fully encapsulate the BDC element. The downhole tool component may be a drill bit, push the bit pad, or mud motor beating assembly. The BDC construct may be disposed in a plug section of the downhole tool component. The encapsulation layer may form an insulating layer over the BDC element to protect the BDC element from thermal damage during hard-facing or brazing of the BDC construct to the downhole tool component.

Abstract: Rotary steerable drilling systems are subjected to harsh environments including high temperature and pressure. A metallic seal ring prevents or limits erosive wear by limiting the velocity of the fluid that traversers from the high pressure side of the metallic seal ring to the low pressure side of the metallic seal ring to a value that can be sustained by the material of the metallic seal ring. A metallic seal ring is capable of withstand the wear and tear of drilling mud or other fluids used for downhole drilling operations. A metallic seal ring includes a mating configuration that creates a seal as the metallic seal ring is contracted when or a tension is applied when disposed or positioned in the piston bore. The metallic seal ring maintains an adequate seal to protect the components of a pad assembly over the life or specified duration of a downhole drilling operation.

Abstract: A steering head for steering a drill string may include a pad pusher including a steering pad and a piston. The steering pad may have a pivot axis, and be rotatable about the pivot axis between retracted and extended positions. The pad pusher may further include a motion restrictor to restrict rotation about the pivot axis. The steering head may further include a housing having a motion restrictor disposed at a position corresponding to the pad pusher motion restrictor. The pad pusher motion restrictor may be engageable with the housing motion restrictor to restrict motion of the steering pad relative to the housing.

Abstract: Hardfacing is used to protect wear surfaces of drill bits and other downhole tools. A hardfacing member can be formed by heating a metal matrix material, e.g., via a laser process, injecting a plurality of particles into the heated metal matrix material, disposing the mixture on at least a portion of a substrate thereby forming a hardfacing member having a particle-embedded metal matrix material, and attaching the hardfacing member to a main body.

Abstract: A rotary steerable tool for steering a drill string can include a tool collar, a plurality of pad pushers, and a plurality of fasteners. The pad pushers can each be positionable within a respective cavity of the tool collar. Each pad pusher can be coupled to a pad retention housing that has an engagement hole and a through hole spaced apart from the engagement hole. The pad pushers can be interconnected by a plurality of fasteners. Each fastener can extend between adjacent pad retention housings to interconnect the plurality of pad pushers around the tool collar.

Abstract: A rotary steerable tool for steering a drill string may include a tool collar extending along a longitudinal axis of the tool, a pad pusher, a pad retention housing, and a piston liner. The pad pusher may be rotatable about a pivot axis thereof between retracted and extended positions relative to the tool collar, for steering the drill string. The piston liner may be coupled to the pad retention housing and have a piston channel that defines a curved profile. The piston liner may provide sealing contact against a perimeter of the piston upon pivoting of the pad pusher through the piston channel along the curved profile, relative to the piston liner.

Abstract: The present disclosure provides a system for improving wear resistance of a downhole tool component using a bonded diamond compact (BDC) construct. The BDC construct includes a BDC element and an encapsulation layer bonded to the BDC element. The encapsulation layer may fully encapsulate the BDC element. The downhole tool component may be a drill bit, push the bit pad, or mud motor beating assembly. The BDC construct may be disposed in a plug section of the downhole tool component. The encapsulation layer may form an insulating layer over the BDC element to protect the BDC element from thermal damage during hard-facing or brazing of the BDC construct to the downhole tool component.

Abstract: Rotary steerable drilling systems are subjected to harsh environments including high temperature and pressure. A metallic seal ring prevents or limits erosive wear by limiting the velocity of the fluid that traversers from the high pressure side of the metallic seal ring to the low pressure side of the metallic seal ring to a value that can be sustained by the material of the metallic seal ring. A metallic seal ring is capable of withstand the wear and tear of drilling mud or other fluids used for downhole drilling operations. A metallic seal ring includes a mating configuration that creates a seal as the metallic seal ring is contracted when or a tension is applied when disposed or positioned in the piston bore. The metallic seal ring maintains an adequate seal to protect the components of a pad assembly over the life or specified duration of a downhole drilling operation.