EARTH-BORING TOOLS HAVING GAUGE CONFIGURATIONS FOR REDUCED CARBON FOOTPRINT, AND RELATED METHODS

Abstract

A method of manufacturing an earth-boring tool to reduce a carbon footprint of the earth-boring tool includes calculating an amount of CO2 associated with forming a drill bit. The method additionally includes redesigning the drill bit to reduce the amount of CO2 associated with forming the drill bit. The method may further include forming the redesigned drill bit. Related drill bits with reduced carbon footprints are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/267,713, filed Feb. 8, 2022, the disclosure of which is hereby incorporated herein in its entirety by this reference.

TECHNICAL FIELD

The disclosure, in various embodiments, relates generally to earth-boring tools, such as drill bits, having radially and axially extending blades. More particularly, the disclosure relates to drill bits and related methods of manufacturing drill bits that reduce the CO₂ emissions resulting from manufacturing the drill bits, while maintaining drill bit performance.

BACKGROUND

The recent emphasis on the environment and sustainability has incentivized organizations to take stock of their environmental impact. For example, companies that manufacture articles for oil and gas exploration and production, such as earth-boring tools, may track the carbon footprint of the articles they manufacture. The term “carbon footprint,” as used herein, means the amount of CO₂ and other carbon compounds emitted to the environment due to the consumption of fossil fuels for energy to obtain and process raw materials, as well as CO₂ and other carbon compounds emitted due to the consumption of fossil fuels for energy to process the raw materials into components of the article of manufacture (e.g., earth-boring tools).

Earth-boring tools, such as rotary drill bits, are commonly used for drilling boreholes or wellbores in earth formations for oil and gas exploration and production. One type of rotary drill bit is the fixed-cutter bit (often referred to as a “drag” bit). The design of a given drill bit may be tailored based on the drilling application. For example, one factor to consider in designing a drill bit is the physical properties and characteristics of the earth formation to be drilled. Another factor to consider is the intended wellbore trajectory and whether the intended wellbore involves directional drilling. The term “directional drilling,” as used herein, means both the process of directing a drill bit along some desired trajectory having non-linear portions through an earth formation to a predetermined target location to form a borehole, such as the process of directing a drill bit along a predefined trajectory in a direction other than directly vertically into an earth formation in a direction substantially parallel to the gravitational field of the earth to either a known or unknown target laterally offset from the drilling rig. One factor to consider in drill bit design, particularly for directional drilling, may be if there is a process to reduce the carbon footprint of the drill bit while maintaining performance in terms of bit longevity and directional stability.

BRIEF SUMMARY

In some embodiments, a method of manufacturing an earth-boring tool to reduce a carbon footprint of the earth-boring tool includes calculating an amount of CO₂ associated with forming a drill bit. The method additionally includes redesigning the drill bit to reduce the amount of CO₂ associated with forming the drill bit. The method may further include forming the redesigned drill bit.

In additional embodiments, a drill bit comprises a plurality of blades, cutting elements, an ultra abrasion-resistant (UAR) material, and diamond inserts. The plurality of blades extend radially outward from a longitudinal axis of the drill bit along a face region of the drill bit and extend axially along a gauge region of the drill bit. The cutting elements are coupled to the plurality of blades. The ultra abrasion-resistant material is on at least a portion of a blade of the plurality of blades in the gauge region. The diamond inserts comprise diamond material and are coupled to the blade in the gauge region. A combined mass of the diamond material is less than about 0.5% of a total mass of the drill bit.

In further embodiments, a method of manufacturing an earth-boring tool comprises positioning ultra abrasion-resistant material and diamond inserts comprising diamond material within a casting mold corresponding to a portion of a blade of a drill bit to be formed. The method additionally includes positioning displacements of cutting elements within the casting mold corresponding to a face region of the drill bit to be formed. The method further includes forming the drill bit comprising ultra abrasion-resistant material on at least the portion of the blade within the gauge region of the drill bit. The drill bit comprises from about 1.5 wt % to about 90.0 wt % ultra abrasion-resistant material. A combined mass of the diamond material is less than about 0.5% of a total mass of the drill bit.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a an earth-boring tool, according to embodiments of the disclosure;

FIG. 2 is a flow chart of a method of manufacturing an earth-boring tool to reduce a carbon footprint of the earth-boring tool, according to embodiments of the disclosure;

FIGS. 3A-3B are tables showing unitized amounts of CO₂ per kilogram of material attributable to the raw material (FIG. 3A) and attributable to different types of processes (FIG. 3B) to form earth-boring tools, according to embodiments of the disclosure;

FIGS. 4A-4P are simplified front views of a blade in a gauge region of an earth-boring tool, according to embodiments of the disclosure;

FIGS. 5A-5D are simplified cross-sectional side views of a blade in a gauge region of an earth-boring tool, according to embodiments of the disclosure; and

FIG. 6 is another method of manufacturing an earth-boring tool, according to embodiments of the disclosure.

DETAILED DESCRIPTION

The illustrations presented herein are not meant to be actual views of any particular earth-boring tool, drill bit, or component thereof, but are merely idealized representations, which are employed to describe embodiments of the present disclosure. For clarity in description, various features and elements common among the embodiments may be referenced with the same or similar reference numerals.

As used herein, the terms “longitudinal,” “longitudinally,” “axial,” or “axially” refers to a direction parallel to a longitudinal axis (e.g., rotational axis) of the drill bit described herein. For example, a “longitudinal dimension” or “axial dimension” is a dimension measured in a direction substantially parallel to the longitudinal axis of the drill bit described herein.

As used herein, the terms “radial” or “radially” refers to a direction transverse to a longitudinal axis of the drill bit described herein and, more particularly, refers to a direction as it relates to a radius of the drill bit described herein. For example, as described in further detail below, a “radial dimension” is a dimension measured in a direction substantially transverse (e.g., perpendicular) to the longitudinal axis of the drill bit as described herein.

As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, at least 99.9% met, or even 100% met.

As used herein, the term “about” in reference to a numerical value for a particular parameter is inclusive of the numerical value and a degree of variance from the numerical value that one of ordinary skill in the art would understand is within acceptable tolerances for the particular parameter. For example, “about” in reference to a numerical value may include additional numerical values within a range of from 90.0 percent to 110.0 percent of the numerical value, such as within a range of from 95.0 percent to 105.0 percent of the numerical value, within a range of from 97.5 percent to 102.5 percent of the numerical value, within a range of from 99.0 percent to 101.0 percent of the numerical value, within a range of from 99.5 percent to 100.5 percent of the numerical value, or within a range of from 99.9 percent to 100.1 percent of the numerical value.

As used herein, the terms “comprising,” “including,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps, but also include the more restrictive terms “consisting of” and “consisting essentially of” and grammatical equivalents thereof.

As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features and methods usable in combination therewith should or must be excluded.

As used herein, the term “configured” refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.

As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

As used herein, the term “earth-boring tool” means and includes any tool used to remove formation material and to form a bore (e.g., a borehole) through an earth formation by way of the removal of the formation material. Earth-boring tools include, for example, rotary drill bits (e.g., fixed-cutter or “drag” bits and roller cone or “rock” bits), hybrid bits including both fixed cutters and roller elements, coring bits, percussion bits, bi-center bits, reamers (including expandable reamers and fixed-wing reamers), and other so-called “hole-opening” tools.

As used herein, the term “cutting element” means and includes an element separately formed from and mounted to an earth-boring tool that is configured and positioned on the earth-boring tool to engage an earth (e.g., subterranean) formation to remove formation material therefrom during operation of the earth-boring tool to form or enlarge a borehole in the formation. State of the art cutting elements are formed as polycrystalline compacts of superabrasive material, such as diamond, cubic born nitride and diamond-like carbon materials.

As used herein, the term “diamond insert” means and includes an element separately formed from and mounted to an earth-boring tool that is configured and positioned on the earth-boring tool to inhibit the formation from rubbing against and wearing the bit body. By way of example in context of drill bits, diamond inserts may protect a gauge region of the drill bit from wear. As a non-limiting example, diamond inserts may be substantially free of sharp edges configured to effectively cut or otherwise remove formation material from the sidewall of the borehole with which the diamond inserts may contact during drilling operations. State of the art diamond inserts are formed as thermally stable polycrystalline compacts, generally of diamond. Thermal stability is conventionally achieved by removal (i.e., leaching) of cobalt or other Group VIII elements used as catalysts to form the diamond compact.

As used herein, the term “superabrasive material” means and includes any material having a Knoop hardness value of about 3,000 Kgf/mm² (29,420 MPa) or more such as, but not limited to, natural and synthetic diamond, cubic boron nitride and diamond-like carbon materials.

As used herein, the term “polycrystalline material” means and includes any material comprising a plurality of grains or crystals of the material that are bonded directly together by inter-granular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.

As used herein, the term “polycrystalline compact” means and includes any structure comprising a polycrystalline material formed by a process that involves application of pressure (e.g., compaction) to the precursor material or materials used to form the polycrystalline material.

FIG. 1 is a perspective view of an example drill bit 100 that may be modified, specifically in gauge region 106, according to embodiments of the disclosure. The drill bit 100 includes a bit body 102 having a longitudinal axis 101 about which the drill bit 100 rotates in operation. The bit body 102 comprises a plurality of blades 104 extending radially outward from the longitudinal axis 101 toward a gauge region 106 of the blade 104 and extending axially along the gauge region 106. Outer surfaces of the blades 104 may define at least a portion of a face region 108 and the gauge region 106 of the drill bit 100.

Forming the drill bit 100 involves processing a variety of raw materials, such as, for example, graphite, silicon carbide, diamond material, carbon steel, tungsten carbide, nitrile, silicones and rubbers, and stainless steel. The raw materials may be processed into components, such as the bit body 102, the nozzles 109, the shank 111, the cutting elements 110, and the diamond inserts 123 that are combined to form the resulting drill bit 100. Extraction of materials, processing of materials and fabrication of materials into components of drill bit 100 all involve production of carbon emissions.

In some embodiments, the bit body 102 may be formed from a particle-matrix composite material. For example, raw materials, such as graphite may be machined to form a crown mold for the bit body 102. The crown mold may include the general geometry of the bit body 102 to be formed from the crown mold, such as recesses for the blades 104. Graphite may also be used to form displacements in the shapes of cutting elements 110, and nozzles 109 that may be placed into the mold before a casting process to form pockets and openings within the resulting bit body 102. Diamond inserts 123 may be placed on the interior of the crown mold and infiltrated into the bit body 102 as described below.

The bit body 102 of the drill bit 100 is typically secured to a hardened steel shank 111 having an American Petroleum Institute (API) thread connection for attaching the drill bit 100 to a drill string. The drill string includes tubular pipe and equipment segments coupled end to end between the drill bit and other drilling equipment at the surface. Equipment such as a rotary table or top drive may be used for rotating the drill string and the drill bit 100 within the borehole. Alternatively, the shank 111 of the drill bit 100 may be coupled directly to the drive shaft of a down-hole motor, which then may be used to rotate the drill bit 100, alone or in conjunction with a rotary table or top drive.

The drill bit 100 may include nozzles 109 that provide a continuous fluid passageway from the shank 111 to the face region 108 of the drill bit 100. For example, the shank 111 may include a large central fluid passageway that extends partially through the bit body 102, and then the central fluid passageway branches into smaller channels that extend to the nozzles 109.

A row of cutting elements 110 may be mounted to each blade 104 of the drill bit 100. For example, cutting element pockets may be formed in the blades 104, and the cutting elements 110 may be positioned in the cutting element pockets and bonded (e.g., brazed, bonded, etc.) to the blades 104. The cutting elements 110 may comprise, for example, a polycrystalline compact in the form of a layer of diamond material, referred to in the art as a polycrystalline table, that is provided on (e.g., formed on or subsequently attached to) a supporting substrate with an interface therebetween. In some embodiments, the cutting elements 110 may comprise polycrystalline diamond compact (PDC) cutting elements each including a volume of superabrasive material, such as polycrystalline diamond material, supported on a ceramic-metal composite material substrate. Though the cutting elements 110 in the embodiment depicted in FIG. 1 are cylindrical or disc-shaped, the cutting elements 110 may have any desirable shape, such as a dome, cone, chisel, etc.

In operation, the drill bit 100 may be rotated about the longitudinal axis 101. As the bit 100 is rotated under applied “weight on bit” (WOB), the cutting elements 110 may engage a subterranean formation mounted in the face region 108 of the bit such that the cutting elements 110 exceed a compressive strength of the subterranean formation and penetrate the formation to remove formation material therefrom in a shearing cutting action. In addition, drilling fluid may circulate through the center of the drillstring, through the drill bit 100, exit through the nozzles 109, and transport any removed formation material to the top of the wellbore.

The gauge region 106 of each blade 104 may be an axially extending region of each blade 104. The gauge region 106 may be defined by a rotationally leading edge 112 opposite a rotationally trailing edge 114 and an uphole edge 116 opposite a downhole edge 118. The uphole edge 116 is adjacent to a crown chamfer 107 of the bit 100 proximal to a shank 111 of the bit 100 and distal from the face region 108 of the bit 100. As used herein, the terms “downhole” and “uphole” refer to locations within the gauge region relative to portions of the drill bit 100 such as the face region 108 of the bit 100 that engage the bottom of a wellbore to remove formation material. The uphole edge 116 is located closer to (e.g., proximate to, adjacent to) to the shank 111 of the bit 100 or to an associated drill string or bottom hole assembly as compared to the downhole edge 118 that is located closer to (e.g., proximate to, adjacent to) the face region 108 of the drill bit 100.

The gauge region 106 of each blade 104 may be divided (e.g., trisected) into a first, second, and a third portion including an uphole portion 120, a central portion 121, and a downhole portion 122, respectively. The uphole portion 120 may be located proximate to the uphole edge 116 of the gauge region 106, the downhole portion 122 may be located proximate to the downhole edge 118 of the gauge region 106, and the central portion 121 may be interposed between the uphole portion 120 and the downhole portion 122.

The materials and geometries of the uphole portion 120, the central portion 121, and the downhole portion 122 may be modified based on the design of the drill bit (shown and described below with reference to FIGS. 4A-5D). For example, at least a portion of the gauge region 106 (e.g., the uphole portion 120 and the central portion 121) may be radially recessed relative to another portion of the gauge region 106 (e.g., the downhole portion 122) and/or relative to the outer rotational diameter of the drill bit 100, which is defined by the radially outermost edge (or surface) of the drill bit 100. Additionally, at least a portion of the gauge region 106 (e.g., the uphole portion 120 and the central portion 121) may include a wear-resistant (e.g., abrasion-resistant) material on an outer surface (shown and described below with reference to FIGS. 4A-4E).

One or more diamond inserts 123 (i.e., thermally stable diamond products, or “TSP”) may be mounted on (i.e., infiltrated within) at least a portion of a blade 104 in the gauge region 106. The diamond inserts 123 may improve the wear resistance of the drill bit 100, within the gauge region 106. For example, as shown in FIG. 1, diamond inserts 123 may be mounted on each blade 104 within the uphole portion 120, the central portion 121, and the downhole portion 122 of the gauge region 106. The diamond inserts 123 may exhibit shapes, such as flat-ended or dome-ended cylinders, which may be substantially free of sharp edges configured to effectively cut or otherwise remove formation material from the sidewall of the borehole with which the diamond inserts may contact during drilling operations. The diamond inserts 123 may protect the gage region 106 from wear during drilling operations without being designed to remove formation material, in contrast to the cutting elements 110. Wear-resistance of the diamond inserts 123, particularly those employed in directional drilling such as drill bit 102, and particularly on the uphole portion 120 and to a lesser extent downhole portion 122 of gauge region 106 when drill bit 102 is steered away from a linear path to build a curved path, is significant to maintaining bit performance and longevity.

In some embodiments, at least a portion (e.g., the uphole portion 120, the central portion 121, and the downhole portion 122) of one or more blades 104 may be substantially free of diamond inserts 123. The number and configuration of the diamond inserts 123 may be modified (i.e., reduced or eliminated) based on the design of the drill bit (shown and described below with reference to FIGS. 4A-5D).

In forming the bit body 102 of a matrix type drill bit 100 modified in accordance with embodiments of the disclosure, portions of the crown mold interior surface corresponding to surfaces of the resulting bit body 102 that may be more exposed to abrasion during drilling, such as gauge region 106 of blades 104 may be lined with an ultra-abrasion-resistant (UAR) material, such as spherical cast tungsten carbide. For example, portions of the crown mold corresponding to one or more of the uphole portion 120, the central portion 121, and the downhole portion 122 of the blades 104 in the gauge region 106 may be lined with ultra abrasion-resistant material. An example of a suitable ultra abrasion-resistant material is spherical cast tungsten carbide material in powder form is that commercially available from Oerlikon Metco AG and sold under the tradename WOKA™. The ultra abrasion-resistant material (e.g., spherical cast tungsten carbide material) powder may be added lining one or more portions of the crown mold such that the resulting bit body or the drill bit comprises about 1.0 wt % to about 10.0 wt % ultra abrasion-resistant material (e.g., spherical cast tungsten carbide material). The use of such UAR materials may allow for the reduction in number of diamond inserts 123, or even elimination of diamond inserts 123, in gauge region 106 while maintaining bit performance and longevity.

The remainder of the crown mold may be filled with one or more particulate abrasion-resistant core materials, such as tungsten carbide, nickel, nickel alloys, other tough and ductile materials, or combinations of any of the foregoing materials. In some embodiments, the core material used to fill the crown mold comprises an ultra-abrasion-resistant (UAR) material powder, such as spherical cast tungsten carbide material powder. Thus, ultra abrasion-resistant material (e.g., spherical cast tungsten carbide) powder may be added to the crown mold such that the resulting drill bit comprises from about 1 wt % to about 90 wt % ultra abrasion-resistant material (e.g., spherical cast tungsten carbide material). Steel blanks at blade locations and for connection to a separately formed steel bit shank may be embedded within the particulate material volume, and then an infiltrant material (often referred to as a “binder” material), such as copper, or copper-nickel alloy may be liquefied to infiltrate and bind the material particles upon solidification to form the bit body 102.

In some other embodiments, the bit body 102 of the drill bit 100 as modified according to the present disclosure may be formed from steel. After forming the bit body 102, an abrasion-resistant material, such as iron, steel, stainless steel, titanium, titanium alloys, nickel, nickel alloys, tungsten carbide, other tough and ductile materials, or combinations of any of the foregoing materials may be selectively added to the surface of the bit body 102, such as by flame-spraying, brazing, high velocity oxygen fuel (HVOF) coating, or additive manufacturing processes, such as powder bed fusion, or direct energy deposition. In some embodiments, an ultra abrasion-resistant (UAR) material, such as spherical cast tungsten carbide, may be flame-sprayed onto to surfaces of the bit body 102, including the uphole portion 120, central portion 121, and downhole portion 122 of the blades 104 in the gauge region 106. An example of a suitable spherical cast tungsten carbide material suitable for flame-spraying is that commercially available from Oerlikon Metco AG and sold under the trade name WOKA™. The resulting drill bit 100 may include from about 1.0 wt % to about 10.0 wt % spherical cast tungsten carbide material. For example, the drill bit 100 may comprise from about 0.5 kg to about 3.0 kg of spherical cast tungsten carbide material.

After forming the bit body 102, the nozzles 109 may be secured within central openings of the bit body 102, and the cutting elements 110 may be secured to the bit body 102. As noted above, each of the processes to form the drill bit 100 uses energy, and certain processes use more energy than others. The energy consumed by forming the drill bit 100 and other drill bits results in generation of carbon dioxide (CO₂). Accordingly, the drill bit 100 and each earth-boring tool formed may be considered to have a carbon footprint associated with their formation.

FIG. 2 is a flow chart of a method 200 of manufacturing an earth-boring tool (e.g., the drill bit 100) to reduce a carbon footprint of the earth-boring tool, according to embodiments of the disclosure.

Referring now to FIG. 2, the method 200 may include calculating an amount of CO₂ associated with forming a conventional drill bit, as shown in act 202. The amount of CO₂ associated with forming a conventional drill bit may take into account a first amount of CO₂ attributable to the raw materials used to form a drill bit, and a second amount of CO₂ attributable to energy consumed by each process used to form the drill bit. The amount of CO₂ associated with forming a drill bit may take into account the CO₂ associated attributable to energy consumed from material formation and removal processes, such as casting and machining (e.g., milling and turning), and may also take into account CO₂ attributable to energy consumed from assembling process, such as welding and brazing.

The CO₂ attributable to the raw materials may include CO₂ resulting from energy consumed to process precursor materials into the raw materials, such as graphite, silicon carbide, diamond material, carbon steel, tungsten carbide, nitrile, silicones and rubbers, and stainless steel.

The CO₂ associated with each raw material used to form a drill bit may be calculated on a unitized basis. For example, the total mass of each respective raw material for forming the drill bit may be determined. The total mass of each respective raw material may be determined by measuring the volume and using the density, or by weighing the total amount of each respective material. Then, the total quantity of CO₂ resulting from each respective raw material used to form the drill bit may also be determined. Afterwards, the total quantity of CO₂ resulting from each raw material may be divided by the total mass of the respective raw material used to form the drill bit.

By way of example, the total mass of polycrystalline diamond material that will be used in the drill bit in the form of cutting elements and diamond inserts is measured. Next, the amount of CO₂ (in kilograms) resulting from forming the precursor materials into diamond material is determined. Then, the total quantity of CO₂ (in kg) from forming the diamond material is divided by the total mass (in kg) of the diamond material used in the drill bit. Accordingly, a unitized amount (kg of CO₂/kg of diamond material) may be determined. Determining unitized amounts of CO₂ (in kg) per kilogram of each raw material used to form the drill may facilitate reducing the carbon footprint of the drill bit.

FIG. 3A shows unitized amounts of CO₂ (in kg) per kilogram of select materials to form drill bit. Referring now to FIG. 3A, the amount of CO₂ generated per kilogram of one raw material can be directly compared to the CO₂ generated per kilogram of other raw materials. Comparing the unitized amounts of CO₂ per kilogram of each raw material may make it easy to identify the materials that have the largest impact on the carbon footprint of the drill bit. For example, the amount of CO₂ per kilogram of diamond material is much, by orders of magnitude, greater than the amount of CO₂ per kilogram of any other material.

Continuing with reference to FIG. 2, the amount of CO₂ associated with forming the drill bit may also take into account a second amount of CO₂ attributable to energy consumed by each process used to form the drill bit. For example, the second amount of CO₂ may include CO₂ resulting from processing the raw materials (e.g., into components) to form the drill bit. Forming the drill bit may involve independently forming drill bit components from raw materials that may be subsequently combined to form the drill bit. The CO₂ attributable to each process may include CO₂ resulting from energy consumed to form polycrystalline compact cutting elements, diamond inserts, a bit shank, and other components to form the drill bit. For example, polycrystalline compact cutting elements may be formed from polycrystalline material subjected to a high pressure high temperature (HPHT) process. Similarly, diamond material may be undergo to HPHT process to form diamond inserts. Additional examples may include forging the steel shank, machining graphite into the shape of a casting mold for the drill bit, and machining graphite into the shapes of cutting elements displacement and nozzle displacements that are placed into the casting mold before a casting process to form the drill bit. Furthermore, cutting elements may be secured into cutting pockets of the bit body of the drill bit following the casting process.

The CO₂ associated with each process to form a drill bit may be calculated on a unitized basis. For example, the total mass of material (e.g., raw material or components) that undergoes a certain type of process to form the drill bit may be determined. Then, the total quantity of CO₂ resulting from each specific process to form the drill bit may also be determined. Afterwards, the total quantity of CO₂ resulting from each type of process is divided by the total mass of either the type of raw material or type of component that undergoes the respective type of process to form the drill bit.

By way of example, the mass of the carbon steel that will used to create a forging for the shank of the bit body is measured. Next, the amount of CO₂ (in kilograms) resulting from forging the carbon steel is determined. Then, the total quantity of CO₂ (in kg) from forging the carbon steel blank is divided by the total mass (in kg) of the carbon steel that underwent the forging process. Accordingly, a unitized amount kg of CO₂/kg of carbon steel subjected to forging for the shank may be determined.

By way of another example, the mass of all of the diamond material used for diamond inserts in the bit design is measured. Next, the amount of CO₂ (in kilograms) resulting from processing the diamond material to form the diamond inserts is determined. Then, the total quantity of CO₂ (in kg) from the diamond inserts is divided by the total mass (in kg) of all of the diamond inserts used in the drill bit. Accordingly, a unitized amount (kg of CO₂/kg of diamond pressed to form cutting elements) may be determined. Determining unitized amounts of CO₂ (in kg) per kilogram of component(s) that undergoes each type of processing may facilitate reducing the carbon footprint of the drill bit.

FIG. 3B shows unitized amounts of CO₂ (in kg) per kilogram of material (e.g., raw material or component) for select processes used to form a drill bit. Referring now to FIG. 3B, the CO₂ generated per kilogram of component(s) that undergoes processing can be directly compared to the CO₂ generated per kilogram of component(s) that undergo different processes. Comparing the unitized amounts of CO₂ per kilogram of component(s) for each type of process may facilitate identifying the processes that have the largest impact on the carbon footprint of the drill bit. For example, the amount of CO₂ for pressing each kilogram of diamond material into diamond inserts or cutting elements is much greater, again by orders of magnitude, than the amount of CO₂ for processing any other material.

Continuing again with reference to FIG. 2, the method 200 may additionally include redesigning the drill bit to reduce the amount of CO₂ associated with forming the drill bit, as shown in act 204. After redesigning the drill bit to reduce the amount of CO₂ associated with forming the drill bit, the redesigned drill bit may be formed. Accordingly, the method 200 may additionally include forming the redesigned drill bit, as shown in act 206.

Certain raw materials and certain processes to form a drill bit may result in significantly more CO₂ than other raw materials or processes. The diamond raw material (FIG. 3A) and pressing the diamond into their components (FIG. 3B) each have a significant impact on the magnitude of emitted CO₂ associated with forming a drill bit. This may be in part due to the high pressure high temperature (HPHT) conditions required to form particulate diamond material consumes a large amount of energy. This may also be due to the high demand for energy to press the particulate diamond material into polycrystalline tables of cutting elements and diamond inserts to be placed in the bit body.

In some embodiments, redesigning the drill bit (e.g., the drill bit 100 of FIG. 1) to reduce the amount of CO₂ associated with forming the drill bit may involve reducing the quantity of diamond material in the drill bit. For example, diamond material may be removed from the drill bit until the combined mass of all of the diamond material is less than about 0.5% of the total mass of the drill bit. The diamond material used for diamond inserts may account for up to about 0.20% of the total mass of the drill bit, such as about 0.15% of the total mass of the drill bit, about 0.10% of the total mass of the drill bit, about 0.05% of the total mass of the drill bit, or even 0.00% of the total mass of the drill bit (in embodiments in which the diamond inserts are eliminated from the drill bit). The diamond material used for the cutting elements may account for up to about 0.30%, such as about 0.25% of the total mass of the drill bit, about 0.25% of the total mass of the drill bit, about 0.15% of the total mass of the drill bit, or about 0.10% of the total mass of the drill bit.

Reducing the quantity of diamond material may affect the properties (e.g., wear resistance, hardness, toughness, corrosion resistance, etc.) and/or performance of the resulting drill bit. Accordingly, certain aspects of the drill bit may also be redesigned to maintain or improve drill bit properties and/or performance, while reducing the amount of CO₂ associated with the drill bit. For example, one or more abrasion-resistant materials, such as spherical cast tungsten carbide, may be added to the surface of the bit body in place of diamond material. Additionally, certain areas of the drill bit may be redesigned to reduce or eliminate diamond material.

One area of the drill bit that may redesigned to reduce the amount of CO₂ associated with forming the drill bit is the gauge region. Drill bits generally include a number of diamond inserts mounted on blades within the gauge region. For example, an 8.5-inch drill bit with 4-inch gage pad and 5 blades may include up to about 250 diamond inserts within the gauge region.

FIGS. 4A-4P are simplified front views of a blade in a gauge region of an earth-boring tool, such as a matrix-type drill bit comprising the materials and processes referenced in FIGS. 3A and 3B. While only a single blade is shown for simplicity, it is understood that the earth-boring tool may include one or more additional blades that may be similar to the blade shown. In FIGS. 4A-4P and the associated description, functionally similar features (e.g., structures, materials) to those of the drill bit 100 of FIG. 1 are referred to with similar reference numerals in a 400 series. To avoid repetition, not all features shown in FIGS. 4A-4P are described in detail herein. Rather, unless described otherwise below, a feature as shown in FIGS. 4A-4P designated by a reference numeral that is a 300 increment of the reference numeral of a previously described feature will be understood to be substantially similar to the previously described feature.

FIG. 4A illustrates a blade 404 in the gauge region 406 of the earth-boring tool (e.g., drill bit) before being redesigned to reduce the CO₂ associated with forming the earth-boring tool. FIGS. 4B-4P illustrate different configurations of the blade 404′ in the gauge region 406 of the earth-boring tool after being redesigned to reduce to CO₂ associated with forming the earth-boring tool. Redesigning the blade 404 from what is shown in FIG. 4A to the blade 404′ shown in FIGS. 4B-4P may result in a CO₂ reduction associated with forming the redesigned earth-boring tool. For example, the CO₂ may be reduced by an amount up to about 75%, such as up to about 60%, up to about 50%, up to about 40%, up to about 30%, or up to about 15%.

Referring collectively to FIGS. 4B-4P, the number of diamond inserts 423 in the blade 404′ is less than the number of diamond inserts 423 in the blade 404 of FIG. 4A. Diamond inserts 423 may be removed until the combined mass of the diamond material from the diamond inserts 423 amounts to less than about 0.25% of the total mass of the drill bit, such as less than about 0.20% of the total mass of the drill bit, less than about 0.15% of the total mass of the drill bit, less than about 0.10% of the total mass of the drill bit, or less than about 0.05% of the total mass of the drill bit. Reducing the number of diamond inserts 423 in the blade 404′ may enable changing the positioning or spacing of the diamond inserts 423 on the blade 404′ to achieve desired wear resistance in targeted areas. For example, the diamond inserts 423 may be concentrated in certain areas (e.g., in an uphole portion 420, in a downhole portion 422, along a rotationally leading edge 412, along a rotationally trailing edge 414, or along an uphole edge 416) of the blade 404′ to achieve desired wear resistance in targeted areas. The diamond inserts 423 may also be arranged in patterns (e.g., rows, columns, shapes) to achieve desired wear resistance in certain areas. For example, the diamond inserts 423 may be arranged in columns offset from one another, in columns along the rotationally leading edge 412 or rotationally trailing edge 414, or in a triangular pattern along the uphole edge 416 and either the rotationally leading edge 412 or the rotationally leading edge 414. Additionally, the spacing between diamond inserts 423 may be modified to achieve desired wear resistance. For example, the diamond inserts 423 may be spaced from one another by a distance of from about 0.25 times of the diameter of the diamond insert 423 up to about 5 times the diameter of the diamond insert 423.

An abrasion-resistant material 426 may also be added to at least a portion of the blade 404′ in the gauge region 406 (e.g., the uphole portion 420) to achieve desired wear resistance. As non-limiting examples, the abrasion-resistant material 426 may include iron, steel, stainless steel, titanium, titanium alloys, nickel, nickel alloys, tungsten carbide, other tough and ductile materials, or combinations of any of the foregoing materials. In some embodiments, the abrasion-resistant material 426 comprises a UAR spherical cast tungsten carbide material. An example of a suitable spherical cast tungsten carbide material is that commercially available from Oerlikon Metco AG and sold under the tradename WOKA™.

Referring now to FIG. 4A, the blade 404 includes diamond inserts 423 in a first portion (uphole portion 420), second portion (central portion 421), and third portion (downhole portion 422) of the gauge region 406. The blade 404 includes about 47 diamond inserts 423, and the diamond inserts 423 occupy a substantial percentage (about 80%) of the surface area of the blade 404 within the gauge region. While the following CO₂ calculations were performed using an 8.5-inch outer diameter drill bit, with 5 blades, 4-inch gage pads, and 235 diamond inserts, the disclosure is not so limited. Similar calculations and methods to those described below may apply to any drill bit.

Referring now to FIG. 4B, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423. An outer surface of the central portion 421 may optionally be recessed relative to outer surfaces of the uphole portion 420 and the downhole portion 422. The blade 404′ includes about 18 diamond inserts arranged in three offset columns, and the diamond inserts 423 occupy a smaller percentage (about 35%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420 and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4B may result in a CO₂ reduction within a range of from about 14% to about 28% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4C, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423 and may optionally be recessed relative to the uphole portion 420 and the downhole portion 422. The blade 404′ includes about 12 diamond inserts arranged in two offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 20%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420 and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4C may result in a CO₂ reduction of within a range of from about 18% to about 36% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4D, the blade 404′ in the gauge region 406 is free of diamond inserts 423. The abrasion-resistant material 426 is included on the uphole portion 420 and the downhole portion 422. An outer surface of the central portion 421 may optionally be recessed relative to outer surfaces of the uphole portion 420 and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4D may result in a CO₂ reduction within a range of from about 25% to about 49% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4E, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423. The blade 404′ includes about 18 diamond inserts arranged in three offset columns, and the diamond inserts 423 occupy a smaller percentage (about 35%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420, the central portion 421, and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4E may result in a CO₂ reduction within a range of from about 18% to about 36% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4F, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423. The blade 404′ includes about 12 diamond inserts arranged in two offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 20%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420, the central portion 421, and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4F may result in a CO₂ reduction within a range of from about 18% to about 36% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4G, the blade 404′ in the gauge region 406 is free of diamond inserts 423. The abrasion-resistant material 426 is included on the first portion (uphole portion 420), the second portion (central portion 421) and the third portion (downhole portion 422). Forming a drill bit using the configuration of the blade 404′ of FIG. 4G may result in a CO₂ reduction within a range of from about 25% to about 49% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4H, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 9 diamond inserts arranged in three offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 18%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420. Forming a drill bit using the configuration of the blade 404′ of FIG. 4H may result in a CO₂ reduction within a range of from about 19% to about 38% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4I, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 6 diamond inserts arranged in two offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420. Forming a drill bit using the configuration of the blade 404′ of FIG. 4I may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4J, the blade 404′ in the gauge region 406 is free of diamond inserts 423. The abrasion-resistant material 426 is included on the first portion (uphole portion 420). Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. Forming a drill bit using the configuration of the blade 404′ of FIG. 4J may result in a CO₂ reduction within a range of from about 25% to about 49% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4K, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 9 diamond inserts arranged in three offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 18%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420, the central portion 421, and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4K may result in a CO₂ reduction within a range of from about 19% to about 38% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4L, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 6 diamond inserts arranged in two offset columns, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420, the central portion 421, and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4L may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4M, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423. An outer surface of the central portion 421 may optionally be recessed relative to outer surfaces of the upper portion 420 and the downhole portion 422. The blade 404′ includes about 6 diamond inserts arranged in a column along the rotationally leading edge 412 of the blade 404′, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420 and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4M may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4N, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420), and the third portion (downhole portion 422) of the gauge region 406. The second portion (central portion 421) of the gauge region 406 is free of the diamond inserts 423. An outer surface of the central portion 421 may optionally be recessed relative to outer surfaces of the upper portion 420 and the downhole portion 422. The blade 404′ includes about 6 diamond inserts arranged in a column along the rotationally trailing edge 414 of the blade 404′, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420 and the downhole portion 422. Forming a drill bit using the configuration of the blade 404′ of FIG. 4N may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4O, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 6 diamond inserts arranged in a triangle pattern along the uphole edge 416 and the rotationally leading edge 412 of the blade 404′, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420. Forming a drill bit using the configuration of the blade 404′ of FIG. 4O may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

Referring now to FIG. 4P, the blade 404′ includes diamond inserts 423 within the first portion (uphole portion 420) of the gauge region 406. The second portion (central portion 421) and third portion (downhole portion 422) of the gauge region 406 are free of the diamond inserts 423. Outer surfaces of the central portion 421 and the downhole portion 422 may optionally be recessed relative to an outer surface of the uphole portion 420. The blade 404′ includes about 6 diamond inserts arranged in a triangle pattern along the downhole edge 418 and the rotationally leading edge 412 of the blade 404′, and the diamond inserts 423 occupy a relatively small percentage (about 10%) of the surface area of the blade 404′ within the gauge region 406. The abrasion-resistant material 426 is included on the uphole portion 420. Forming a drill bit using the configuration of the blade 404′ of FIG. 4P may result in a CO₂ reduction within a range of from about 20% to about 40% compared to forming a drill bit using the configuration of the blade 404 of FIG. 4A.

As previously discussed, diamond material, such as in diamond inserts, may have a significant impact on the CO₂ associated with forming drill bits. Accordingly, redesigning drill bits to reduce CO₂ associated with forming the drill bits may involve recessing one or more portions (e.g., the uphole portion, the central portion, and/or the downhole portion) of the blades and reducing the number of diamond inserts by eliminating diamond inserts from the recessed portion(s) of the blades. Recessing one or more portions of blades within the gauge region of a drill bit may inhibit the recessed portion(s) from rubbing against the formation during the drilling process. Accordingly, the wear resistance of the recessed portion(s) of the blades may be less than the wear resistance of other portions (e.g., non-recessed portions) of the blades. Even within the gauge region, certain parts of the blades (e.g., the uphole portions) may experience increased wear compared to other portions (e.g., the central portions and downhole portions) of the blade because of processes such as directional drilling. Thus, even when the uphole portions of the blades are recessed relative to the remainder of the blades in the gauge region, diamond inserts may still be positioned within the uphole portions of the blades because of increased wear that occurs during directional drilling.

FIGS. 5A-5D are simplified cross-sectional side views of a blade (e.g., the blade 104, 404′) in the gauge region of the earth-boring tool. For simplicity, FIGS. 5A-5D show at most a single diamond insert within each portion of the blade (e.g., the uphole portion, the central portion, and the downhole portion) within the gauge region. However, it is understood that the earth boring may include any number of diamond inserts (including no diamond inserts), and may also include multiple diamond inserts within each portion of the (e.g., the uphole portion, the central portion, and the downhole portion) within the gauge region. In FIGS. 5A-5D and the associated description, functionally similar features (e.g., structures, materials) to those of the drill bit 100 of FIG. 1 are referred to with similar reference numerals in a 500-series. To avoid repetition, not all features shown in FIGS. 5A-5D are described in detail herein. Rather, unless described otherwise below, a feature as shown in FIGS. 5A-5D designated by a reference numeral that is a 400 increment of the reference numeral of a previously described feature will be understood to be substantially similar to the previously described feature.

FIG. 5A illustrates a simplified cross-section of a blade 504 of a drill bit (e.g., the drill bit 100) before being redesigned to reduce the CO₂ associated with forming the earth-boring tool. FIGS. 5B-5D illustrate different configurations of the blade 504′ of the earth-boring tool after being redesigned to reduce to CO₂ associated with forming the earth-boring tool. Recessing portions (e.g., an uphole portion 520, central portion 521, and/or downhole portion 522) of the blade 504 shown in FIG. 5A to achieve the blade 504′ shown in FIGS. 5B-5D may enable desired performance or wear-resistance of the resulting earth-boring tool.

Referring collectively to FIGS. 5A-5D, the blade 504, 504′ includes a gauge trimmer 517 mounted at a downhole edge 518 of the gauge region 506. The gauge trimmer 517 is a cutting element that defines an outer rotational diameter 503 of the drill bit. Diamond inserts 523 within the gauge region may be substantially coplanar with the respective portion (e.g., uphole portion 520, central portion 521, or downhole portion 522) of the blade 504, 504′ on which the diamond inserts 523 are mounted. Additional cutting elements may be included within the face region 508 (as shown in FIG. 1).

As shown in FIGS. 5B-5C, an outer surface of the blade 504 in the gauge region 506 may be recessed relative to the outer rotational diameter 103 of the drill bit. For example, the uphole portion 520, the central portion 521, and the downhole portion 522 may be recessed relative to the outer rotational diameter 103 of the drill bit by a radial distance d520, d521, d522, respectively. The radial distance d520, d521, d522, may each be within in a range of from about 0.1 mm to about 5 mm, such as from about 0.15 mm to about 3 mm, such as from about 0.5 mm to about 2 mm. As non-limiting examples, the radial distance d520, d521, d522, may be about 0.5 mm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, or about 3 mm. Additionally, the outer surface of the blade 504 in each portion of the gauge region may be recessed relative to one another. For example, d520 may be about 1 mm, d521 may be about 2 mm, and d522 may be about 3 mm. Furthermore, two radial distances (e.g., d520, d522) may be different than the third radial distance (e.g., d521). For example, the radial distances d520 and d522 may each be about 1 mm, and the radial distance d521 may be about 3 mm.

Referring now to FIG. 5A, the uphole portion 520, the central portion 521, and the downhole portion 522 of the blade 504 in the gauge region 506 are radially aligned with one another. For example, the radial distances d520, d521, d522 are all the same value. The blade 504 includes one or more diamond inserts 523 within each portion of the gauge region 506, including the uphole portion 520, the central portion 521, and the downhole portion 522.

Referring now to FIG. 5B, the uphole portion 520 and the downhole portion 522 of the blade 504′ in the gauge region 506 are radially aligned with one another, and the central portion 521 is recessed relative to the uphole portion 520 and the downhole portion 522. For example, the radial distances d520 and d522 are the same value, and are less than the radial distance d521. As illustrated in FIG. 5B, the blade 504′ may include one or more diamond inserts 523 on the uphole portion 520, and optionally on the downhole portion 522, and the central portion 521 may be free of diamond inserts 523. In some embodiments, one or more diamond inserts 523 may be located in the uphole portion 520, and each of the central portion 521 and the downhole portion 522 may be free of diamond inserts.

Referring now to FIG. 5C, the uphole portion 520 of the blade 504′ is recessed relative to the central portion 521, which is recessed relative to the downhole portion 522. For example, the radial distance d520 is greater than the radial distance d521, which is greater than the radial distance d522. The blade 504′ includes one or more diamond inserts 523 on the uphole portion 520, and each of the central portion 521 and the downhole portion 522 may be free of diamond inserts 523.

Referring now to FIG. 5D, the central portion 521 and the downhole portion 522 of the blade 504′ may each be recessed relative to the uphole portion 520 of the blade 504′. For example, the radial distance d520 is less than the radial distance d521, which is the same as the radial distance d522. The blade 504′ may be free of diamond inserts 523.

In all of the above instances illustrated in FIGS. 5B-5D, an abrasion-resistant material may also be added to at least a portion of the blade in the gauge region 506 (e.g., the uphole portion 520, the central portion 521, and/or the downhole portion 522) to achieve desired wear resistance. As non-limiting examples, the abrasion-resistant material may include iron, steel, stainless steel, titanium, titanium alloys, nickel, nickel alloys, tungsten carbide, other tough and ductile materials, or combinations of any of the foregoing materials. In some embodiments, the abrasion-resistant material comprises a UAR spherical cast tungsten carbide material. An example of a suitable spherical cast tungsten carbide material is that commercially available from Oerlikon Metco AG and sold under the trade name WOKA™.

Furthermore, the diamond inserts 523 may be replaced by or supplemented with other elements that provide additional abrasion resistance to the gauge region 506 of the blades. For example, in some embodiments, the diamond inserts 523 may be replaced by or supplemented with impregnated diamond inserts from hot isostatic pressing (HIP), tungsten carbide inserts (TCIs), or impregnating the matrix material with superabrasive material, such as natural or synthetic diamond grit.

FIG. 6 illustrates a flow chart of a method 600 of manufacturing an earth-boring tool, according to embodiments of the disclosure. Referring now to FIG. 6, the method 600 may include positioning ultra abrasion-resistant (UAR) material, and optionally positioning diamond inserts comprising diamond material, within a casting mold for a matrix type drill bit corresponding to a portion of a blade within a gauge region of a drill be to be formed, as shown in act 602.

The method 600 may also include positioning displacements of cutting elements within the casting mold corresponding to a face region of the drill bit to be formed therein, as shown in act 604.

The method 600 may additionally include forming the drill bit comprising the ultra abrasion-resistant (UAR) material in the gauge region, as shown in act 606. The drill bit may comprise from about 1.0 wt % to about 10.0 wt % ultra abrasion-resistant material. In some embodiments, the drill bit may comprise up to about 90 wt % ultra abrasion-resistant material. Additionally, a combined mass of the diamond material is less than about 0.5% of a total mass of the drill bit. In some embodiments, forming the drill bit comprises flame-spraying spherical cast tungsten carbide material on the at least a portion of the blade within the gauge region of the drill bit.

The method 600 may further include positioning spherical cast tungsten carbide particles within the casting mold corresponding to the gauge region of the drill bit to be formed therein.

While the disclosed structures and methods are susceptible to various modifications and alternative forms in implementation thereof, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the present disclosure is not limited to the particular forms disclosed. Rather, the present invention encompasses all modifications, combinations, equivalents, variations, and alternatives falling within the scope of the present disclosure as defined by the following appended claims and their legal equivalents.

Claims

1. A method of manufacturing an earth-boring tool to reduce a carbon footprint of the earth-boring tool, the method comprising:

calculating an amount of CO2 associated with forming a drill bit;

redesigning the drill bit to reduce the amount of CO2 associated with forming the drill; and

forming the redesigned drill bit.

2. The method of claim 1, wherein calculating an amount of CO2 associated with forming a drill bit comprises:

calculating a first amount of CO2 resulting from raw materials to be used in forming the drill bit; and

calculating a second amount of CO2 resulting from processing the raw materials to form the drill bit.

3. The method of claim 1, wherein calculating an amount of CO2 associated with forming a drill bit comprises calculating a unitized amount of CO2 per kilogram of each raw material to be used in forming the drill bit.

4. The method of claim 1, wherein calculating an amount of CO2 associated with forming a drill bit comprises calculating a unitized amount of CO2 per kilogram of material that undergoes a certain type of process to form the drill bit.

5. The method of claim 1, wherein redesigning the drill bit to reduce the amount of CO2 associated with forming the drill bit comprises reducing the amount of CO2 associated with forming the drill bit by a quantity within a range of from about 10% to about 50%.

6. The method of claim 1, wherein redesigning the drill bit to reduce the amount of CO2 associated with forming the drill bit comprises reducing an amount of diamond material in the drill bit.

7. The method of claim 1, wherein redesigning the drill bit to reduce the amount of CO2 associated with forming the drill bit comprises redesigning a gauge region of the drill bit.

8. The method of claim 7, wherein redesigning a gauge region of the drill bit comprises reducing a number of diamond inserts within the gauge region of the drill bit.

9. The method of claim 8, wherein redesigning the gauge region of the drill bit comprises increasing spacing between the diamond inserts.

10. The method of claim 8, wherein redesigning the gauge region of the drill bit comprises eliminating diamond inserts from one or more portions of a blade in the gauge region of the drill bit.

11. The method of claim 1, wherein forming the redesigned drill bit comprises forming a spherical cast tungsten carbide material on at least a portion of a gauge region of the redesigned drill bit.

12. A drill bit, comprising:

a longitudinal axis;

a plurality of blades extending radially outward from a longitudinal axis of the drill bit along a face region of the drill bit and extending axially along a gauge region of the drill bit;

cutting elements coupled to the plurality of blades;

an ultra abrasion-resistant material on at least a portion of a blade of the plurality of blades in the gauge region; and

diamond inserts comprising diamond material coupled to the blade in the gauge region,

wherein a combined mass of the diamond material is less than about 0.5% of a total mass of the drill bit.

13. The earth-boring tool of claim 12, wherein the at least a portion of the blade comprises an uphole portion of the blade.

14. The earth-boring tool of claim 12, wherein the at least a portion of the blade comprises an uphole portion of the blade and a downhole portion of the blade, the uphole portion of the blade separated from the downhole portion of the blade by a central portion of the blade.

15. The earth-boring tool of claim 12, wherein the diamond inserts are coupled to an uphole portion of the blade.

16. The earth-boring tool of claim 12, wherein another portion of the blade is radially recessed relative to the at least a portion of the blade.

17. The earth-boring tool of claim 12, wherein the diamond inserts are arranged in a pattern along a leading edge of the blade in the gauge region.

18. A method of manufacturing an earth-boring tool, the method comprising:

positioning ultra abrasion-resistant material and diamond inserts comprising diamond material within a casting mold corresponding to a portion of a blade within a gauge region of a drill bit to be formed;

positioning displacements of cutting elements within the casting mold corresponding to a face region of the drill bit to be formed; and

forming a drill bit comprising the diamond inserts and the ultra abrasion-resistant material, the ultra abrasion-resistant material on a surface of at least the portion of the blade within a gauge region of the drill bit, the drill bit comprising from about 1.0 wt % to about 90.0 wt % ultra abrasion-resistant material, wherein a combined mass of the diamond material is less than about 0.5% of a total mass of the drill bit.

19. The method of claim 18, wherein positioning ultra abrasion-resistant material within the casting mold comprises positioning spherical cast tungsten carbide particles within the casting mold.

20. The method of claim 18, wherein forming the drill bit comprises flame-spraying spherical cast tungsten carbide material on the at least a portion of the blade within the gauge region of the drill bit.