Abstract: In some embodiments, the present disclosure includes a method of forming a body of an earth-boring downhole tool. A mold is formed that has at least one interior surface defining a mold cavity within the mold. The mold cavity has a shape corresponding to a shape of the body of the earth-boring downhole tool to be formed therein. At least one insert is formed that includes particles of hard-phase material and a binder material using an additive manufacturing process. The at least one insert is positioned within the mold cavity. Additional particles of hard-phase material are provided within the mold cavity, and the additional particles of hard-phase material are infiltrated with molten metal, thus sintering and/or infiltrating the at least one insert to form the body of the earth-boring downhole tool. The resulting body of the earth-boring downhole tool includes the sintered and/or infiltrated at least one insert.

Abstract: Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

Abstract: Methods for forming fixed-cutter earth-boring drill bits include retrieving a forged steel drill bit body from an inventory of substantially identical forged steel drill bit bodies including fixed blades and junk slots between the fixed blades. Cutter pockets are formed in the blades. Nozzle holes are formed in the drill bit body to provide fluid communication from an interior of the forged steel drill bit body to the junk slots. Additional methods include forging first and second steel drill bit bodies substantially identical in shape and configuration, forming first cutter pockets in the first steel drill bit body in a first configuration, and forming second cutter pockets in the second steel drill bit body in a second, different configuration.

Abstract: Methods of creating and heat-treating 3D-printed objects may involve creating an object utilizing a 3D printer. The object may be moved from the 3D printer to a heat-treatment apparatus. The object may be exposed to an elevated temperature and pressure may be applied to the object utilizing a pressure-transmission medium of the heat-treatment apparatus. The 3D printer and heat-treatment apparatus may in a unified process flow volume.

Abstract: A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness.

Abstract: Methods for forming fixed-cutter earth-boring drill bits include retrieving a forged steel drill bit body from an inventory of substantially identical forged steel drill bit bodies including fixed blades and junk slots between the fixed blades. Cutter pockets are formed in the blades. Nozzle holes are formed in the drill bit body to provide fluid communication from an interior of the forged steel drill bit body to the junk slots. Additional methods include forging first and second steel drill bit bodies substantially identical in shape and configuration, forming first cutter pockets in the first steel drill bit body in a first configuration, and forming second cutter pockets in the second steel drill bit body in a second, different configuration.

Abstract: Methods for forming fixed-cutter earth-boring drill bits include retrieving a forged steel drill bit body from an inventory of substantially identical forged steel drill bit bodies including fixed blades and junk slots between the fixed blades. Cutter pockets are formed in the blades. Nozzle holes are formed in the drill bit body to provide fluid communication from an interior of the forged steel drill bit body to the junk slots. Additional methods include forging first and second steel drill bit bodies substantially identical in shape and configuration, forming first cutter pockets in the first steel drill bit body in a first configuration, and forming second cutter pockets in the second steel drill bit body in a second, different configuration.

Abstract: Methods of creating and heat-treating 3D-printed objects may involve creating an object utilizing a 3D printer. The object may be moved from the 3D printer to a heat-treatment apparatus. The object may be exposed to an elevated temperature and pressure may be applied to the object utilizing a pressure-transmission medium of the heat-treatment apparatus. The 3D printer and heat-treatment apparatus may in a unified process flow volume.

Abstract: Expandable apparatus include a triggering element comprising an at least partially corrodible composite material. Methods are used to trigger expandable apparatus using such a triggering element and to form such triggering elements for use with expandable apparatus.

Abstract: In some embodiments, systems for creating and heat-treating 3D-printed objects may include a 3D printer configured to create the object. A heat-treatment apparatus may be operatively connected to the 3D printer. The heat-treatment apparatus may be configured to expose the object to an elevated temperature to heat-treat the object. A pressure-transmission medium of the heat-treatment apparatus may be configured to apply pressure to the object during heat treatment. The 3D printer and heat-treatment apparatus may be incorporated into a unified process flow volume. Methods of creating and heat-treating 3D-printed objects may involve creating an object utilizing a 3D printer. The object may be moved from the 3D printer to a heat-treatment apparatus. The object may be exposed to an elevated temperature and pressure may be applied to the object utilizing a pressure-transmission medium of the heat-treatment apparatus. The 3D printer and heat-treatment apparatus may in a unified process flow volume.

Abstract: Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

Abstract: In some embodiments, the present disclosure includes a method of forming a body of an earth-boring downhole tool. A mold is formed that has at least one interior surface defining a mold cavity within the mold. The mold cavity has a shape corresponding to a shape of the body of the earth-boring downhole tool to be formed therein. At least one insert is formed that includes particles of hard-phase material and a binder material using an additive manufacturing process. The at least one insert is positioned within the mold cavity. Additional particles of hard-phase material are provided within the mold cavity, and the additional particles of hard-phase material are infiltrated with molten metal, thus sintering and/or infiltrating the at least one insert to form the body of the earth-boring downhole tool. The resulting body of the earth-boring downhole tool includes the sintered and/or infiltrated at least one insert.

Abstract: Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

Abstract: A method of forming at least a portion of an earth-boring tool using an electronic representation of at least one geometric feature of at least a component of an earth-boring tool stored in memory accessible by a processor operatively connected to a multi-axis positioning system, a direct metal deposition apparatus, and a material removal apparatus. The processor generates a deposition path for the direct metal deposition apparatus is based at least in part on the electronic representation of the at least one geometric feature of the at least a component of the earth-boring tool. The direct metal deposition tool is operated according to the generated deposition path to deposit metal material on an earth-boring tool component coupled to the multi-axis positioning system to at least partially form the at least one geometric feature of the earth-boring tool. Methods also include methods of repairing earth-boring tools.

Abstract: An article comprises a plurality of micro-sized or nano-sized galvanic cells, wherein the article has a seamless structure encompassing a plurality of empty spaces of different sizes, geometries, distributions, or a combination thereof, and one or more of the following properties of the article vary in different directions: tensile strength; compressive strength; electrical resistance; thermal conductance; modulus; or hardness.

Abstract: A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness.

Abstract: Methods for forming fixed-cutter earth-boring drill bits include retrieving a forged steel drill bit body from an inventory of substantially identical forged steel drill bit bodies including fixed blades and junk slots between the fixed blades. Cutter pockets are formed in the blades. Nozzle holes are formed in the drill bit body to provide fluid communication from an interior of the forged steel drill bit body to the junk slots. Additional methods include forging first and second steel drill bit bodies substantially identical in shape and configuration, forming first cutter pockets in the first steel drill bit body in a first configuration, and forming second cutter pockets in the second steel drill bit body in a second, different configuration.

Abstract: A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness.

Abstract: An earth-boring tool includes a tool body having an aperture therein defining a nozzle port, a nozzle or nozzle assembly disposed in the nozzle port, and a shape memory material disposed adjacent a surface of at least one component of the nozzle or nozzle assembly. The shape memory material retains at least one component of the nozzle or nozzle assembly by a threadless connection. The threadless connection includes mechanical interference between the shape memory material, the at least one component of the nozzle or nozzle assembly, and the tool body or another component of the nozzle or nozzle assembly. The shape memory material is formulated and configured to transform from a first phase and a first shape upon heating and to transform from a second phase and a second shape upon cooling.

Abstract: A method of forming an earth-boring tool includes forming a tool body including at least one inverted cutting element pocket, at least a portion of the at least one inverted cutting element pocket having a profile substantially matching a profile of an actual cutting element to be secured within a cutting element pocket to be formed by subsequently machining the at least one inverted cutting element pocket. Hardfacing material may be applied to portions of the tool body. The actual cutting element pocket is formed by removing material of the tool body within the at least one inverted cutting element pocket subsequent to applying the hardfacing material to portions of the tool body. A cutting element is affixed within the actual cutting element pocket.