Abstract: Roller cone bits of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each project outwardly a distance therefrom. At least one of the cutting elements comprises a steel base portion that is integral with the cone and that projects a distance therefrom. A cutting element end portion is attached to the base portion and extends therefrom to form a tip of the cutting element. The base and end portions are permanently attached together when the cone and base are in a preexisting rigid state. The cutting element end portion is formed from a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: An energizer for a mechanical seal assembly for use in a drill bit is disclosed. The energizer is a composite of at least two resilient materials, one having a durometer hardness that is greater than the other. The material contacting a journal provides relatively high frictional forces so as to prevent the energizer from rotating in relation to adjacent components. The relatively softer resilient material provides the energizing force necessary to maintain a good dynamic seal between the metal seal rings. The energizer components may be separate components that engage one another upon assembly, or may be bonded together to form a ring prior to assembly into the drill bit.

Abstract: A cutting element for a drill bit that includes an outer support element having at least a bottom portion and a side portion; and an inner rotatable cutting element, a portion of which is disposed in the outer support element, wherin the inner rotatable cutting element includes a substrate and a diamond cutting face having a thickness of at least 0.050 inches disposed on an upper surface of the substrate; and wherein a distance from an upper surface of the diamond cutting face to a bearing surface between the inner rotatable cutting element and the outer support element ranges from 0 to about 0.300 inches is disclosed.

Abstract: Roller cone bits of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each project outwardly a distance therefrom. At least one of the cutting elements comprises a steel base portion that is integral with the cone and that projects a distance therefrom. A cutting element end portion is attached to the base portion and extends therefrom to form a tip of the cutting element. The base and end portions are permanently attached together when the cone and base are in a preexisting rigid state. The cutting element end portion is formed from a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: Disclosed is a seal assembly for dynamically sealing between rotatable members, such as employed to seal the rolling cone of a rock bit. One preferred assembly includes an energizer, first and second seal rings, and a cushioning ring having an L-shaped cross-section disposed about portions of one of the seal rings to seal and absorb impact loads and thereby protect the more-rigid seal rings.

Abstract: A rolling cone bit and a cutting insert for a rolling cone are disclosed. The insert includes an undulating cutting surface including a peak, and blades radiating therefrom. The cutting insert may include an ultrahard layer of diamond or other superabrasive material, wherein the outer cutting surface of the layer includes contours that generally correspond to the contours of the interface surface that is between the ultrahard layer and the substrate so as to reduce residual stresses and lessen the likelihood of spalling or delamination of the ultrahard material. The blades radiate from a central peak and may include a sharper and/or higher leading edge as compared to a trailing edge. Valleys between the blades may differ in depth, and the cutting surface may have an undulating perimeter.

Abstract: Roller cone bits include a steel bit body having a leg extending therefrom. A steel cone is disposed on the leg and includes steel cutting elements projecting outwardly therefrom. One of the cutting elements comprises a steel base integral with the cone and that projects therefrom. A cutting element end is attached to the base portion and extends to form a cutting element tip. The base and end portions are attached when the cone base are in a preexisting rigid state. The end portion comprises a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: Disclosed is a seal assembly for dynamically sealing between rotatable members, such as employed to seal the rolling cone of a rock bit. One preferred assembly includes an energizer, first and second seal rings, and a cushioning ring having an L-shaped cross-section disposed about portions of one of the seal rings to seal and absorb impact loads and thereby protect the more-rigid seal rings.

Abstract: An energizer for a mechanical seal assembly for use in a drill bit is disclosed. The energizer is a composite of at least two resilient materials, one having a durometer hardness that is greater than the other. The material contacting a journal provides relatively high frictional forces so as to prevent the energizer from rotating in relation to adjacent components. The relatively softer resilient material provides the energizing force necessary to maintain a good dynamic seal between the metal seal rings. The energizer components may be separate components that engage one another upon assembly, or may be bonded together to form a ring prior to assembly into the drill bit.

Abstract: Roller cone bits include a steel bit body having a leg extending therefrom. A steel cone is disposed on the leg and includes steel cutting elements projecting outwardly therefrom. One of the cutting elements comprises a steel base integral with the cone and that projects therefrom. A cutting element end is attached to the base portion and extends to form a cutting element tip. The base and end portions are attached when the cone base are in a preexisting rigid state. The end portion comprises a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.