Abstract: A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed.

Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.

Abstract: Thermally-stable polycrystalline diamond materials of this invention comprise a first phase including a plurality of bonded together diamond crystals, and a second phase including a reaction product formed between a binder/catalyst material and a material reactive with the binder/catalyst material. The reaction product is disposed within interstitial regions of the polycrystalline diamond material that exists between the bonded diamond crystals. The first and second phases are formed during a single high pressure/high temperature process condition. The reaction product has a coefficient of thermal expansion that is relatively closer to that of the bonded together diamond crystals than that of the binder/catalyst material, thereby providing an improved degree of thermal stability to the polycrystalline diamond material.

Abstract: A drill bit that includes a bit body formed from a matrix powder and at least one cutting element for engaging a formation, wherein the matrix powder included (a) stoichiometric tungsten carbide particles, (b) cemented tungsten carbide particles, and (c) cast tungsten carbide particles, and wherein after formation with the matrix powder, the bit has an erosion rate of less than 0.001 in/hr, a toughness of greater than 20 ksi(in0.5), and a transverse rupture strength of greater than 140 ksi is disclosed.

Abstract: Thermally-stable polycrystalline diamond materials of this invention comprise a first phase including a plurality of bonded together diamond crystals, and a second phase including a reaction product formed between a binder/catalyst material and a material reactive with the binder/catalyst material. The reaction product is disposed within interstitial regions of the polycrystalline diamond material that exists between the bonded diamond crystals. The first and second phases are formed during a single high pressure/high temperature process condition. The reaction product has a coefficient of thermal expansion that is relatively closer to that of the bonded together diamond crystals than that of the binder/catalyst material, thereby providing an improved degree of thermal stability to the polycrystalline diamond material.

Abstract: The invention provides a fixed cutter drill bit for drilling through unconsolidated, highly abrasive formations. The bit includes a bit body having a cutting face and a side portion. The bit body comprising carbide matrix material. A plurality of blades azimuthally spaced about the cutting face and a plurality of cutters disposed along the blades. At least one gage pad is disposed along a side of the bit body and includes wear resistant gage elements formed of a material more wear resistant than the matrix material forming a portion of the gage pad. The wear resistant elements have a rounded surface and are embedded in gage pad material proximal a leading edge of the gage pad to provide a rounded wear-resistant edge or surface proximal the leading edge.

Abstract: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

Abstract: Drill bit reinforcing members or blanks of this invention are formed from high-strength steels having a carbon content less than about 0.3 percent by weight, a yield strength of at least 55,000 psi, a tensile strength of at least 80,000 psi, a toughness of at least 40 CVN-L, Ft-lb, and a rate of expansion percentage change less than about 0.0025%/° F. during austenitic to ferritic phase transformation. In one embodiment, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.5 to 1.5 percent by weight manganese, up to about 0.8 percent by weight chromium, 0.05 to 4 percent by weight nickel, and 0.02 to 0.8 percent by weight molybdenum. In another example, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.9 to 1.5 percent by weight manganese, 0.1 to 0.5 percent by weight silicon, and one or more microalloying element selected from the group consisting of vanadium, niobium, titanium, zirconium, aluminum and mixtures thereof.

Abstract: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

Abstract: An insert for a drill bit that includes diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less is disclosed. A method of forming a diamond-impregnated cutting structure, that includes loading a plurality of substantially uniformly coated diamond particles into a mold cavity, pre-compacting the substantially uniformly coated diamond particles using a cold-press cycle, and heating the compacted, substantially uniformly coated diamond particles with a matrix material to form the diamond impregnated cutting structure is also disclosed.

Abstract: A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed.

Abstract: The invention provides a fixed cutter drill bit for drilling through unconsolidated, highly abrasive formations. The bit includes a bit body having a cutting face and a side portion. The bit body comprising carbide matrix material. A plurality of blades azimuthally spaced about the cutting face and a plurality of cutters disposed along the blades. At least one gage pad is disposed along a side of the bit body and includes wear resistant gage elements formed of a material more wear resistant than the matrix material forming a portion of the gage pad. The wear resistant elements have a rounded surface and are embedded in gage pad material proximal a leading edge of the gage pad to provide a rounded wear-resistant edge or surface proximal the leading edge.

Abstract: A new composition for forming a matrix body which includes spherical sintered tungsten carbide and an infiltration binder including one or more metals or alloys is disclosed. In some embodiments, the composition may include a Group VIIIB metal selected from one of Ni, Co, Fe, and alloys thereof. Moreover, the composition may also include cast tungsten carbide. In addition, the composition may also include carburized tungsten carbide.

Abstract: The disclosure provides an improved method for manufacturing a drill bit. The method includes applying a hardfacing material to the drill bit, forming a cutter pocket within the drill bit with plunge EDM, and inserting a cutting element into the cutter pocket.

Abstract: Drill bit reinforcing members or blanks of this invention are formed from high-strength steels having a carbon content less than about 0.3 percent by weight, a yield strength of at least 55,000 psi, a tensile strength of at least 80,000 psi, a toughness of at least 40 CVN-L, Ft-lb, and a rate of expansion percentage change less than about 0.0025%/° F. during austenitic to ferritic phase transformation. In one embodiment, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.5 to 1.5 percent by weight manganese, up to about 0.8 percent by weight chromium, 0.05 to 4 percent by weight nickel, and 0.02 to 0.8 percent by weight molybdenum. In another example, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.9 to 1.5 percent by weight manganese, 0.1 to 0.5 percent by weight silicon, and one or more microalloying element selected from the group consisting of vanadium, niobium, titanium, zirconium, aluminum and mixtures thereof.

Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.

Abstract: A structural matrix drill bit body having different binder materials in different spatial locations as well as a method for forming the same, is provided. The different binder materials provide different functional properties to the different spatial locations of the drill bit body. The method for forming such a structural matrix body includes providing a matrix material within a mold, then infiltrating the matrix material with at least two binder materials which provide different functional properties in combination with the material. The arrangement is then heated and the heating process causes the different binder materials to infiltrate different spatial locations of the drill bit body.

Abstract: In one embodiment, a method of increasing a durability of a drill bit having a bit body with at least one blade disposed thereon, at least one cutter pocket disposed on the blade, and at least one cutter disposed in the cutter pocket is disclosed. The method includes brazing the at least one cutter to the at least one cutter pocket so that a braze material disposed between the at least one cutter pocket and the at least one cutter comprises an exposed surface, and overlaying at least a portion of the exposed surface with a hardfacing material, wherein the hardfacing material includes a binder having a melting point selected to avoid damaging the cutter.

Abstract: Drill bit reinforcing members or blanks of this invention are formed from high-strength steels having a carbon content less than about 0.3 percent by weight, a yield strength of at least 55,000 psi, a tensile strength of at least 80,000 psi, a toughness of at least 40 CVN-L, Ft-lb, and a rate of expansion percentage change less than about 0.0025%/° F. during austenitic to ferritic phase transformation. In one embodiment, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.5 to 1.5 percent by weight manganese, up to about 0.8 percent by weight chromium, 0.05 to 4 percent by weight nickel, and 0.02 to 0.8 percent by weight molybdenum. In another example, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.9 to 1.5 percent by weight manganese, 0.1 to 0.5 percent by weight silicon, and one or more microalloying element selected from the group consisting of vanadium, niobium, titanium, zirconium, aluminum and mixtures thereof.

Abstract: A new composition for forming a matrix body which includes spherical sintered tungsten carbide and an infiltration binder including one or more metals or alloys is disclosed. In some embodiments, the composition may include a Group VIIIB metal selected from one of Ni, Co, Fe, and alloys thereof. Moreover, the composition may also include cast tungsten carbide. In addition, the composition may also include carburized tungsten carbide.