Abstract: The present invention relates to a system and method for automated or “robotic” application of hardfacing to the surface of a steel-toothed cutter of a standard earth-boring rock bit or a hybrid-type rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter, particularly a hybrid rock bit cutter, beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction.

Abstract: Downhole tools are provided with a topographical pattern, and anti-balling material is provided over the topographical pattern. The topographical pattern may be defined by at least one of a plurality of recesses extending into a surface of a body of the tool and a plurality of protrusions protruding from the surface. Downhole tools include an insert disposed within a recess in a body, and the insert comprises an anti-balling material having a composition selected to reduce accumulation of formation cuttings on the tools when the tools are used to form or service a wellbore. Downhole tools include anti-balling material disposed over a porous mass provided over the surfaces of the tools. Methods of forming downhole tools include providing anti-balling material over features on and/or in a surface of a body of a tool. Methods of repairing downhole tools include removing an insert therefrom and disposing a replacement insert therein.

Abstract: In one aspect, an apparatus for use downhole is disclosed that in one configuration includes a downhole device configured to be in an active position and an inactive position and an actuation device that includes: a housing including an annular chamber configured to house a first fluid therein, a piston in the annular chamber configured to divide the annular chamber into a first section and a second section, the piston being coupled to a biasing member, a control unit configured to enable movement of the first fluid from the first section to the second section to supply a second fluid under pressure to the tool to move the tool into the active position and from the second section to the first section to stop the supply of the second fluid to the tool to cause the tool to move into the inactive position.

Abstract: Downhole tools are provided with a topographical pattern, and anti-balling material is provided over the topographical pattern. The topographical pattern may be defined by at least one of a plurality of recesses extending into a surface of a body of the tool and a plurality of protrusions protruding from the surface. Downhole tools include an insert disposed within a recess in a body, and the insert comprises an anti-balling material having a composition selected to reduce accumulation of formation cuttings on the tools when the tools are used to form or service a wellbore. Downhole tools include anti-balling material disposed over a porous mass provided over the surfaces of the tools. Methods of forming downhole tools include providing anti-balling material over features on and/or in a surface of a body of a tool. Methods of repairing downhole tools include removing an insert therefrom and disposing a replacement insert therein.

Abstract: An apparatus for use downhole is disclosed that, in one configuration includes a downhole tool configured to operate in an active position and an inactive position and an actuation device, which may include a control unit. The apparatus includes a telemetry unit that sends a first pattern recognition signal to the control unit to move the tool into the active position and a second pattern recognition signal to move the tool into the inactive position. The apparatus may be used for drilling a subterranean formation and include a tubular body and one or more extendable features, each positionally coupled to a track of the tubular body, and a drilling fluid flow path extending through a bore of the tubular body for conducting drilling fluid therethrough. A push sleeve is disposed within the tubular body and coupled to the one or more features.

Abstract: Walk characteristics of an earth-boring rotary drill bit may be predicted by measuring locations and orientations of cutting elements thereof and calculating the magnitude and direction of an imbalance force of the drill bit using the measurements obtained. The calculated imbalance force may be compared to the imbalance force of at least one other drill bit having a calculated imbalance force and observed walk characteristics. An earth-boring rotary drill bit may be designed by constructing a database including the magnitude and direction of a calculated imbalance force and observed walk characteristics for a number of drill bits. Desired walk characteristics are selected, the database is referenced, and the bit may be configured to exhibit an imbalance force selected to impart desired walk characteristics to the drill bit. Drill bits are configured to exhibit an imbalance force oriented in a predetermined direction relative to a blade of the drill bit.

Abstract: A roller cone bit is provided that includes a companion ring positioned exterior to a seal, wherein the companion ring includes a textured surface where the inner diameter of the companion ring contacts the bearing pin.

Abstract: A method of manufacturing a drill bit and several embodiments of a drill bit for drilling a well in an earth formation. In one embodiment, the drill bit comprises a diamond impregnated bit body with one or more thermally stable pins embedded therein. More specifically, the drill bit may include a diamond impregnated bit body having a plurality of blades, with one or more of the blades having a cone section, a nose section, a shoulder section, and a gage section; a plurality of diamond impregnated cutters extending from the blades; and one or more thermally stable polycrystalline diamond pins embedded within, and possibly extending from, at least some of the cutters. In some embodiments, each cutter includes an embedded pin. Alternatively, the pin or pins may be located in the cone, shoulder, nose, and/or gauge sections.

Abstract: The present invention relates to a system and method for automated or “robotic” application of hardfacing to the surface of a steel-toothed cutter of a standard earth-boring rock bit or a hybrid-type rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter, particularly a hybrid rock bit cutter, beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction.

Abstract: A roller cone bit is provided that includes a companion ring positioned exterior to a seal, wherein the companion ring includes a textured surface where the inner diameter of the companion ring contacts the bearing pin.

Abstract: An earth boring drill bit comprising: a bit body; a plurality of fixed blades extending downwardly from the bit body, each blade having a leading edge; a plurality of fixed-blade cutting elements arranged on the leading edge of the fixed blades; at least one rolling cutter mounted for rotation on the bit body; and wherein the rolling cutter is configured to act as a depth-of-cut limiter, thereby reducing the risk of damage to the fixed-blade cutting elements. The fixed-blade cutting elements may include thermally stable polycrystalline diamond wafers mounted on tungsten carbide substrates and/or a mosaic of geometrically-shaped thermally stable diamond elements cooperatively arranged and bonded to form a unitary cutting surface. The rolling cutter may be positioned, relative to the fixed blades, to also limit rate of penetration and/or exposure of the fixed-blade cutting elements.

Abstract: Walk characteristics of an earth-boring rotary drill bit may be predicted by measuring locations and orientations of cutting elements thereof and calculating the magnitude and direction of an imbalance force of the drill bit using the measurements obtained. The calculated imbalance force may be compared to the imbalance force of at least one other drill bit having a calculated imbalance force and observed walk characteristics. An earth-boring rotary drill bit may be designed by constructing a database including the magnitude and direction of a calculated imbalance force and observed walk characteristics for a number of drill bits. Desired walk characteristics are selected, the database is referenced, and the bit may be configured to exhibit an imbalance force selected to impart desired walk characteristics to the drill bit. Drill bits are configured to exhibit an imbalance force oriented in a predetermined direction relative to a blade of the drill bit.

Abstract: A turbine blade (18) for a gas turbine engine includes a machining datum and support tool interface (52). The datum and interface feature is a frustoconical depression residing in a blade outer shroud (36) and ideally aligned with an airfoil stacking line (40). The blade has a prefinished state in which the depression has a prefinished depth and a finished state in which the depression has a finished depth. The finished depth is smaller than the prefinished depth, but is nevertheless sufficient to act as a support feature during manufacturing operations. The utility of the depression, as both a datum and as a support feature, survives the original manufacturing operations so that the depression is useful for post-manufacturing inspection and repair.

Abstract: A turbine blade (18) for a gas turbine engine includes a machining datum (60) that extends radially from a pocket (54) in the outer shroud (36) of the blade. The datum is spaced from a sidewall (64) of the pocket so that the datum is peripherally continuous irrespective of whether the blade is in a prefinished state or in a completely finished state. Because the datum's peripheral continuity survives the original manufacturing process, the datum is available for use in post-manufacturing inspection and repair operations.