Specific Or Diverse Material Patents (Class 175/425)
  • Patent number: 8365845
    Abstract: In one aspect of the present invention, a high impact resistant tool comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface, the body comprising a substantially pointed geometry with an apex, the apex comprising a curved surface that joins a leading side and a trailing side of the body at a first and second transitions respectively, an apex width between the first and second transitions is less than a third of a width of the substrate, and the body also comprises a body thickness from the apex to the interface greater than a third of the width of the substrate.
    Type: Grant
    Filed: October 5, 2011
    Date of Patent: February 5, 2013
    Inventors: David R. Hall, Ronald B. Crockett, Casey Webb, Michael Beazer
  • Patent number: 8365846
    Abstract: A front face of a diamond table mounted to a substrate is processed to introduce a material which comingles with or semi-alloys with or partially displaces interstitial catalyst binder in a thermal channel to a desired depth. The material is selected to be less thermally expandable than the catalyst binder and/or more thermally conductive than the catalyst binder and/or having a lower heat capacity than the catalyst binder.
    Type: Grant
    Filed: March 2, 2010
    Date of Patent: February 5, 2013
    Assignee: Varel International, Ind., L.P.
    Inventors: Alfazazi Dourfaye, Michael R. Reese, William W. King
  • Publication number: 20130028672
    Abstract: An article includes a working portion including cemented carbide, and a heat sink portion in thermal communication with the working portion. The heat sink portion includes a heat sink material having a thermal conductivity greater than a thermal conductivity of the cemented carbide. Also disclosed are methods of making an article including a working portion comprising cemented carbide, and a heat sink portion in thermal communication with the working portion and including a heat sink material having a thermal conductivity that is greater than a thermal conductivity of the cemented carbide. The heat sink portion conducts heat from the working portion.
    Type: Application
    Filed: October 1, 2012
    Publication date: January 31, 2013
    Applicant: TDY INDUSTRIES, LLC
    Inventor: TDY Industries, LLC
  • Publication number: 20130025941
    Abstract: A method for forming a coating upon a wellbore tool includes forming a pattern of features supported by a body and forming a coating over the pattern of features. Forming the pattern of features includes forming a first feature and forming a second feature spaced from the first feature by a first width at a first elevation and by a second width at a second elevation, the second width being different than the first width, and the first elevation being further from an interior region of the body than the second elevation. Also disclosed is a wellbore tool comprising a coating covering a pattern of features and a method of utilizing a wellbore tool in a subterranean formation, the method including forming a pattern of features, forming a coating over the pattern, and disposing the wellbore tool in a borehole.
    Type: Application
    Filed: July 28, 2011
    Publication date: January 31, 2013
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Sunil Kumar, Hendrik John
  • Patent number: 8360169
    Abstract: One aspect of the instant disclosure relates to a subterranean drilling assembly comprising a subterranean drill bit and a sub apparatus coupled to the drill bit. Further, the sub apparatus may include at least one cooling system configured to cool at least a portion of the drill bit. For example, the sub apparatus may include at least one cooling system comprising a plurality of refrigeration coils or at least one thermoelectric device. In another embodiment a subterranean drill bit may include at least one cooling system positioned at least partially within the subterranean drill bit. Also, a sub apparatus or subterranean drill bit may be configured to cool drilling fluid communicated through at least one bore of a subterranean drill bit and avoiding cooling drilling fluid communicated through at least another bore of the subterranean drill bit. Methods of operating a subterranean drill bit are disclosed.
    Type: Grant
    Filed: February 13, 2012
    Date of Patent: January 29, 2013
    Assignee: US Synthetic Corporation
    Inventors: Kenneth E. Bertagnolli, Scott M. Schmidt
  • Publication number: 20130020136
    Abstract: A hardmetal composition comprises tungsten carbide in an amount greater than 50 weight percent of the hardmetal composition. In addition, the hardmetal composition comprises a binder material consisting of at least 90 weight percent nickel, a binder flux between 3.5 to 10.0 weight percent chosen from the group consisting of boron and silicon, and less than 1.0 weight percent other components.
    Type: Application
    Filed: January 24, 2012
    Publication date: January 24, 2013
    Applicant: REEDHYCALOG, L.P.
    Inventors: Jiinjen Albert Sue, Harold Sreshta, Rajagopala Pillai
  • Patent number: 8347990
    Abstract: A drill bit may include a bit body having a plurality of blades extending radially therefrom, the bit body comprising a first matrix region and a second matrix region, wherein the first matrix region is formed from a moldable matrix material having carbide particles with a unimodal particle size distribution; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.
    Type: Grant
    Filed: November 18, 2009
    Date of Patent: January 8, 2013
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Youhe Zhang, Yuelin Shen
  • Patent number: 8322465
    Abstract: An earth-boring bit part such as, for example, a bit body, roller cone, or mud nozzle includes a hybrid cemented carbide composite. The hybrid cemented carbide includes a cemented carbide dispersed phase, and a cemented carbide continuous phase. A method of manufacture also is disclosed.
    Type: Grant
    Filed: August 22, 2008
    Date of Patent: December 4, 2012
    Assignee: TDY Industries, LLC
    Inventor: Prakash K. Mirchandani
  • Publication number: 20120298425
    Abstract: An apparatus and method for manufacturing a downhole tool that reduces failures occurring along a bondline between a cemented matrix coupled around a blank. The cemented matrix material is formed from a powder and a binder material. The blank includes an internal blank component and a coating coupled around at least a portion of the surface of the internal blank component. The internal blank component includes a top portion and a bottom portion. The internal blank component is substantially cylindrically shaped and defines a channel extending through the top portion and the bottom portion. The coating is a metal in some exemplary embodiments. The coating reduces the migration of the binder material into the blank thereby allowing the control of intermetallic compounds thickness within the bondline.
    Type: Application
    Filed: May 21, 2012
    Publication date: November 29, 2012
    Applicant: Varel Europe S.A.S
    Inventors: Bruno Cuillier De Maindreville, Williams Gomez
  • Publication number: 20120298426
    Abstract: A multi-layer film for use in forming a layer of hardfacing on a surface of a tool includes a first layer and a second layer covering at least a portion of a surface of the first layer. The layers each include a polymer material and a plurality of particles dispersed throughout the polymer material. An intermediate structure includes a body of an earth-boring tool, a first material layer disposed over a surface of the body, and a second material layer disposed over the first material layer. A method of applying hardfacing includes providing a first material layer on a surface of a body of an earth-boring tool, providing a second material layer adjacent the first material layer, heating the body and removing the polymer material from the body of the earth-boring tool, and heating the body higher temperature to form a layer of hardfacing material.
    Type: Application
    Filed: August 6, 2012
    Publication date: November 29, 2012
    Applicant: Baker Hughes Incorporated
    Inventors: Jimmy W. Eason, Travis E. Puzz
  • Patent number: 8317893
    Abstract: Methods, systems, and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.
    Type: Grant
    Filed: June 10, 2011
    Date of Patent: November 27, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: John H. Stevens, Jimmy W. Eason
  • Publication number: 20120285293
    Abstract: A composite sintered powder metal article including a first region including a cemented hard particle material such as, for example, cemented carbide. The article includes a second region including: a metallic material selected from a steel, nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a molybdenum alloy, cobalt, a cobalt alloy, tungsten, a tungsten alloy; and from 0 up to 30 percent by volume of hard particles. The first region is metallurgically bonded to the second region, and each of the first region and the second region has a thickness of greater than 100 microns. The second region comprises at least one mechanical attachment feature so that the composite sintered powder metal article can be attached to another article. The article comprises one of an earth boring article, a metalcutting tool, a metalforming tool, a woodworking tool, and a wear article.
    Type: Application
    Filed: July 26, 2012
    Publication date: November 15, 2012
    Applicant: TDY INDUSTRIES, LLC
    Inventors: Prakash K. Mirchandani, Morris E. Chandler
  • Patent number: 8309018
    Abstract: Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material.
    Type: Grant
    Filed: June 30, 2010
    Date of Patent: November 13, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, John H. Stevens, James L. Duggan, Nicholas J. Lyons, Jimmy W. Eason, Jared D. Gladney, James A. Oxford, Benjamin J. Chrest
  • Patent number: 8276691
    Abstract: Embodiments relate to rotary drill bits that employ superabrasive cutting elements including a diamond-silicon carbide composite table. In an embodiment, a rotary drill bit includes a bit body configured to engage a subterranean formation. The bit body includes a plurality of blades. The rotary drill bit further includes a plurality of superabrasive cutting elements. Each of the superabrasive cutting elements is attached to a corresponding one of the cutting blades. At least one of the superabrasive cutting elements includes a substrate and a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including a matrix comprising nanometer-sized silicon carbide grains and micrometer-sized diamond grains dispersed through the matrix.
    Type: Grant
    Filed: March 27, 2012
    Date of Patent: October 2, 2012
    Assignee: US Synthetic Corporation
    Inventors: Jiang Qian, Kenneth E. Bertagnolli, Michael A. Vail, Jason Wiggins, Jim I. Dewberry, David P. Miess
  • Patent number: 8268452
    Abstract: Methods for forming earth-boring tools include providing a metal or metal alloy bonding agent at an interface between a first element and a second element and sintering the first element, the second element, and the boding agent to form a bond between the first element and the second element at the interface. The methods may be used, for example, to bond together portions of a body of an earth-boring tool (which may facilitate, for example, the formation of cutting element pockets) or to bond cutting elements to a body of an earth-boring tool (e.g., a bit body of a fixed-cutter earth-boring drill bit or a cone of a roller cone earth-boring drill bit). At least partially formed earth-boring tools include a metal or metal alloy bonding agent at an interface between two or more elements, at least one of which may comprise a green or brown structure.
    Type: Grant
    Filed: July 31, 2007
    Date of Patent: September 18, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Nicholas J. Lyons, Jimmy W. Eason, Redd H. Smith, John H. Stevens
  • Patent number: 8267203
    Abstract: Earth-boring drill bits include a bit body, an erosion-resistant extension, and a shank. The erosion-resistant extension includes a generally tubular body, and an erosion-resistant material lining the generally tubular body within a fluid passageway. The erosion-resistant material lining the generally tubular body within the fluid passageway exhibits an erosion resistance greater than an erosion resistance exhibited by a material of the generally tubular body. Methods of forming an erosion-resistant extension include lining at least a portion of a wall of a generally tubular body within a fluid passageway extending through the generally tubular body with an erosion-resistant material.
    Type: Grant
    Filed: August 7, 2009
    Date of Patent: September 18, 2012
    Assignee: Baker Hughes Incorporated
    Inventor: James Andy Oxford
  • Publication number: 20120228036
    Abstract: Fibers for diamond-impregnated cutting tools and their associated methods for manufacture and use are described. A matrix is formed that contains fibers made from carbon, glass, ceramic, polymer, and the like. The matrix is then sintered to form a cutting portion of a drill bit. The type and concentration of the fibers can be modified to control the tensile strength and the erosion rate of the matrix to optimize the cutting performance of the tools. Additionally, the fibers may be added to the cutting section to weaken the structure and allow higher modulus binders to be used for the cutting tools at a lower cost, allowing the amount of fibers to be tailored to retain the diamonds in the cutting portion for the desired amount. As the cutting portion erodes, the fibers may also increase the lubricity at the face of the cutting portion.
    Type: Application
    Filed: May 22, 2012
    Publication date: September 13, 2012
    Applicant: Longyear TM, Inc.
    Inventors: KRISTIAN S. DRIVDAHL, Michael D. Rupp
  • Patent number: 8245797
    Abstract: An earth-boring tool includes a bit body having a face on which two different types of cutters are disposed, the first type being cutting elements suitable for drilling at least one subterranean formation and the second type suitable for drilling through at least one elastomeric component of a casing string, as well as a casing shoe and cement. Methods of drilling with an earth-boring tool include engaging and drilling an elastomeric component using at least one abrasive cutting structure.
    Type: Grant
    Filed: October 23, 2009
    Date of Patent: August 21, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Chad T. Jurica, Scott F. Donald, Adam R. Williams
  • Patent number: 8225886
    Abstract: An article of manufacture includes a cemented carbide piece and a joining phase that binds the cemented carbide piece into the article. The joining phase includes inorganic particles and a matrix material. The matrix material is a metal and a metallic alloy. The melting temperature of the inorganic particles is higher than the melting temperature of the matrix material. A method includes infiltrating the space between the inorganic particles and the cemented carbide piece with a molten metal or metal alloy followed by solidification of the metal or metal alloy to form an article of manufacture.
    Type: Grant
    Filed: August 11, 2011
    Date of Patent: July 24, 2012
    Assignee: TDY Industries, LLC
    Inventors: Prakash K. Mirchandani, Michale E. Waller, Morris E. Chandler, Heath C. Coleman
  • Patent number: 8225890
    Abstract: Control of the carbide volume in the matrix in an impregnated bit is accomplished by coating the hard particles in the matrix to space them further apart to increase the soft binder percentage in a controllable manner. The softer binder due to lower volume content of hard particles allows more rapid matrix wear in the softer formations to allow more diamond grit to cut better before getting flat spots and to be replaced faster with additional diamond grit further into the matrix as the higher content of the softer binder and the softer coating on the hard particles in the matrix promotes more effective cutting with more frequent emergence of diamond grit on the bit face as cutting progresses.
    Type: Grant
    Filed: April 21, 2009
    Date of Patent: July 24, 2012
    Assignee: Baker Hughes Incorporated
    Inventor: Dan E. Scott
  • Patent number: 8220566
    Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of at least partially carburized monotungsten carbide and ditungsten carbide eutectic particles dispersed throughout a matrix material. In some embodiments, the particles are at least substantially fully carburized monotungsten carbide and ditungsten carbide eutectic particles. In further embodiments, the particles are generally spherical or at least substantially spherical. Methods of forming such particles include exposing a plurality of monotungsten carbide and ditungsten carbide eutectic particles to a gas containing carbon. Methods of manufacturing such tools include providing a plurality of at least partially carburized monotungsten carbide and ditungsten carbide eutectic particles or at least substantially completely carburized monotungsten carbide and ditungsten carbide eutectic particles within a matrix material.
    Type: Grant
    Filed: October 30, 2008
    Date of Patent: July 17, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Jimmy W. Eason, John H. Stevens, James L. Overstreet
  • Patent number: 8210288
    Abstract: A rotary drill bit with cutting elements operable to control depth of cut and rate of penetration during formation of a wellbore are provided. Respective sets of secondary cutting elements and primary cutting elements may also be disposed on exterior portions of a rotary drill bit. A number of blades may extend from exterior portions of the drill bit with a number of cutting elements disposed on exterior portions of each blade. Each cutting element may include a substrate with a cutting surface disposed thereon. A respective protector may extend from the cutting surface of one or more cutting elements to limit depth of penetration of the associated cutting element into adjacent portions of a downhole formation and/or to control rate of penetration of an associated rotary drill bit.
    Type: Grant
    Filed: January 30, 2008
    Date of Patent: July 3, 2012
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Shilin Chen, William W. King
  • Patent number: 8210287
    Abstract: A core drill bit includes an elongate hollow cylindrical body having opposite first and second ends with an end section having an end face defining an annular non-planar surface. The cutting head includes a plurality of circumferentially spaced apart cutting segments, the cutting segments being electrical welded to the non-planar surface whereby raised portions of the surface melt during the welding to affix the cutting segments with the face of the tool body.
    Type: Grant
    Filed: January 4, 2010
    Date of Patent: July 3, 2012
    Assignee: Diamond Products, Limited
    Inventors: Karl H. Moller, Andrew L. Jedick, Thomas G. Ruffner
  • Publication number: 20120160562
    Abstract: An earth removal member with features for facilitating drill-through is provided for drilling with casing or liner applications. In one embodiment, the casing bit includes a tubular body; a nose attached to one end of the tubular body, wherein the nose includes a blade support and comprises a drillable material; a blade attached to the blade support using mating profiles; cutters disposed along the blade; and a nozzle disposed in the nose.
    Type: Application
    Filed: December 21, 2011
    Publication date: June 28, 2012
    Inventors: Sharp Ugwuocha, Steven Rae
  • Patent number: 8201648
    Abstract: An earth-boring rotary drill bit includes a bit body configured to carry one or more cutters for engaging a subterranean earth formation, the bit body comprising a particle-matrix composite material having a plurality of hard particles dispersed throughout a matrix material, the matrix material comprising a shape memory alloy. The matrix material comprises a metal alloy configured to undergo a reversible phase transformation between an austenitic phase and a martensitic phase. The matrix material may include an Ni-based alloy, Cu-based alloy, Co-based alloy, Fe-based alloy or Ti-based alloy.
    Type: Grant
    Filed: January 29, 2009
    Date of Patent: June 19, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Heeman Choe, John Stevens, Eric Sullivan
  • Publication number: 20120125694
    Abstract: The present invention includes a matrix powder system comprising one or more polycrystalline carbides, binderless carbides, or a combination thereof, a composite comprising the matrix powder system and a metal bond phase, a matrix bit body for a drill bit for oil and gas drilling made of this composite material, and a drill bit for oil and gas drilling comprising the matrix bit body and at least one cutter. The polycrystalline and/or binderless carbides may comprise carbides of W, Ti, V, Cr, Nb, Mo, Ta, Hf, Zr, or a combination thereof. The binderless carbides have less than 3 wt. % binder and the binderless and/or polycrystalline carbides may have a grain size of ?15 ?m and a hardness of ?1900 HV (0.5 kgf). Additional ceramic components and/or metals may also be present in the matrix powder system. Alternatively, the composite material may be present on only a portion of the matrix bit body surface.
    Type: Application
    Filed: November 24, 2010
    Publication date: May 24, 2012
    Applicant: KENNAMETAL INC.
    Inventors: Xin Deng, Debangshu Banerjee, Michael Wilfert
  • Patent number: 8182778
    Abstract: The invention relates to boron carbide and to a method for making the same, as well as to a super-abrasive material and a machine device including said boron carbide. The boron carbide of the invention has the following formula BC5 and has a diamond-type cubic structure with a mesh parameter a=3.635±0.006 &angst. The boron carbide of the invention can particularly be used in the field of machining.
    Type: Grant
    Filed: April 9, 2008
    Date of Patent: May 22, 2012
    Assignees: Centre National de la Recherche Scientifique, Universite Pierre et Marie Curie (Paris 6), European Synchrotron Radiation Facility
    Inventors: Yann Le Godec, Mohamed Mezouar, Denis Andrault, Vladimir Solozhenko, Oleksandr Kurakevych
  • Patent number: 8172914
    Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one of carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and at least one melting point-reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.
    Type: Grant
    Filed: August 15, 2008
    Date of Patent: May 8, 2012
    Assignees: Baker Hughes Incorporated, TDY Industries, Inc.
    Inventors: Prakash K. Mirchandani, Jimmy W. Eason, James J. Oakes, James C. Westhoff, Gabriel B. Collins
  • Publication number: 20120103691
    Abstract: Methods of coupling a bearing assembly to a downhole tool include forming at least a portion of a downhole component from a diamond-enhanced material, applying a metal material to a surface of the downhole component using an ultrasonic molten metal process, and coupling at least a portion of the surface of the downhole component to at least another component of the downhole tool. Downhole tools include at least one component of a bearing assembly that is configured to move relative to a portion of the downhole tool. The at least one bearing component comprises a diamond-enhanced material and is coupled to a portion of the downhole tool by an ultrasonic molten metal process.
    Type: Application
    Filed: October 27, 2011
    Publication date: May 3, 2012
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Redd H. Smith, James Andy Oxford, Alan J. Massey
  • Publication number: 20120103696
    Abstract: A polycrystalline compact comprises a plurality of grains of hard material and a plurality of nanoparticles disposed in interstitial spaces between the plurality of grains of hard material. The plurality of nanoparticles has a thermal conductivity less than a thermal conductivity of the plurality of grains of hard material. An earth-boring tool comprises such a polycrystalline compact. A method of forming a polycrystalline compact comprises combining a plurality of hard particles and a plurality of nanoparticles to form a mixture and sintering the mixture to form a polycrystalline hard material comprising a plurality of interbonded grains of hard material. A method of forming a cutting element comprises infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of nanoparticles. The plurality of nanoparticles have a lower thermal conductivity than the interbonded grains of hard material.
    Type: Application
    Filed: October 19, 2011
    Publication date: May 3, 2012
    Applicant: BAKER HUGHES INCORPORATED
    Inventor: Anthony A. DiGiovanni
  • Patent number: 8147790
    Abstract: Embodiments of the invention relate to methods of fabricating polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding by carbon pumping, and PCD and polycrystalline diamond compacts formed by such methods. In an embodiment of a method of fabricating PCD, a plurality of diamond crystals and a metal-solvent catalyst may be provided. The diamond crystals and metal-solvent catalyst may be subjected to a first pressure-temperature condition during which carbon is dissolved in the metal-solvent catalyst. After subjecting the diamond crystals and metal-solvent catalyst to the first pressure-temperature condition, the diamond crystals and metal-solvent catalyst may be subjected to a second pressure-temperature condition at which diamond is stable.
    Type: Grant
    Filed: June 9, 2009
    Date of Patent: April 3, 2012
    Assignee: US Synthetic Corporation
    Inventors: Michael A. Vail, Kenneth E. Bertagnolli
  • Patent number: 8141656
    Abstract: One aspect of the instant disclosure relates to a subterranean drilling assembly comprising a subterranean drill bit and a sub apparatus coupled to the drill bit. Further, the sub apparatus may include at least one cooling system configured to cool at least a portion of the drill bit. For example, the sub apparatus may include at least one cooling system comprising a plurality of refrigeration coils or at least one thermoelectric device. In another embodiment a subterranean drill bit may include at least one cooling system positioned at least partially within the subterranean drill bit. Also, a sub apparatus or subterranean drill bit may be configured to cool drilling fluid communicated through at least one bore of a subterranean drill bit and avoiding cooling drilling fluid communicated through at least another bore of the subterranean drill bit. Methods of operating a subterranean drill bit are disclosed.
    Type: Grant
    Filed: January 14, 2009
    Date of Patent: March 27, 2012
    Assignee: US Synthetic Corporation
    Inventors: Kenneth E. Bertagnolli, Scott M. Schmidt
  • Publication number: 20120067651
    Abstract: A hardfacing composition comprising a carbide phase and a matrix phase, The carbide phase comprises mono-tungsten carbide in a quantity of greater than 50 percent by weight, based on the total weight of the carbide phase. The matrix phase comprises iron and nickel. The nickel is present in a quantity in the range of from 0.5 to 20 percent by weight, based on the total weight of the matrix phase. Also included are methods of applying such hardfacing compositions to a downhole tool and downhole tools having such hardfacing compositions applied thereon.
    Type: Application
    Filed: September 15, 2011
    Publication date: March 22, 2012
    Applicant: Smith International, Inc.
    Inventors: Sike Xia, Yong Zhou
  • Patent number: 8109350
    Abstract: A polycrystalline abrasive composite cutter, including a tool body with a top cutting surface and a flank surface. The composite cutter, joined to a substrate, constitute a shear cutter for a PDC bit, roller-cone bit insert, or other tool that can be highly useful for petroleum drilling or other applications. The body of the polycrystalline abrasive composite cutter includes a plurality of polycrystalline abrasive layers (90) and a plurality of arresting layers (100). The polycrystalline abrasive layers (90) and the arresting layers (100) are arranged to alternate throughout the tool body in a direction normal to the top cutting surface (92) and in a direction normal to a flank surface (94).
    Type: Grant
    Filed: January 26, 2007
    Date of Patent: February 7, 2012
    Assignee: University of Utah Research Foundation
    Inventors: Zhigang Z. Fang, Stephen C. Johnson, Haibo Zhang
  • Patent number: 8109349
    Abstract: In one aspect of the invention, a high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches thickness from the apex to a central region of the cemented metal carbide substrate.
    Type: Grant
    Filed: February 12, 2007
    Date of Patent: February 7, 2012
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, Ronald B. Crockett, John D. Bailey, Jeff Jepson, Scott Dahlgren
  • Publication number: 20120024604
    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.
    Type: Application
    Filed: August 2, 2011
    Publication date: February 2, 2012
    Inventors: Carl Hoffmaster, Shelton W. Alsup, Michael G. Azar, Thomas W. Oldham, Stuart R. Oliver, Sidney J. Isnor
  • Patent number: 8104550
    Abstract: Earth-boring tools include wear-resistant materials disposed in at least one recess formed in an exterior surface of a body thereof. Exposed surfaces of the wear-resistant material are substantially level with exterior surfaces of the body adjacent the wear-resistant material. In some embodiments, recesses may be formed in formation-engaging surfaces of blades of earth-boring rotary tools, adjacent one or more inserts secured to bodies of earth-boring tools, or adjacent one or more cutting elements secured to bodies of earth-boring tools. Methods of forming earth-boring tools include filling one or more recesses formed in an exterior surface of a body with wear-resistant material and causing exposed surfaces of the wear-resistant material to be substantially level with the exterior surface of the body.
    Type: Grant
    Filed: September 28, 2007
    Date of Patent: January 31, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: James L. Overstreet, Michael L. Doster, Mark E. Morris, Kenneth E. Gilmore, Robert M. Welch, Danielle V. Roberts
  • Patent number: 8100201
    Abstract: A rotary drill bit (10) is provided for drilling a hole in a subsurface formation. The bit body (12) includes a plurality of axially extending ribs (16a, b, c and d) and a flow channel between adjacent ribs. A plurality of cutting elements are fixedly mounting on a respective one of the plurality of ribs. A plurality of flow nozzles (20a, b, c and d) direct fluid to a respective one of the plurality of cutting elements to clean and cool the cutting elements.
    Type: Grant
    Filed: July 24, 2009
    Date of Patent: January 24, 2012
    Assignee: BlueFire Equipment Corporation
    Inventor: Anatoli Borissov
  • Publication number: 20120012403
    Abstract: A MAX-phase material is provided for a cutting tool and other applications.
    Type: Application
    Filed: July 13, 2011
    Publication date: January 19, 2012
    Inventor: L. Pierre de Rochemont
  • Publication number: 20110308864
    Abstract: A drill bit is disclosed that includes a matrix bit body having a lower end face for engaging a rock formation, the end face having a plurality of raised impregnated ribs extending from the face of the bit body and separated by a plurality of channels therebetween, and at least one of the plurality of ribs having a leading or trailing portion thereof comprising the same the matrix material as the bit body forming a continuous body matrix.
    Type: Application
    Filed: August 30, 2011
    Publication date: December 22, 2011
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Gregory T. Lockwood, Jonan Fulenchek
  • Patent number: 8079429
    Abstract: Geometric compensation techniques are used to improve the accuracy by which features may be located on drill bits formed using particle compaction and sintering processes. In some embodiments, a positional error to be exhibited by at least one feature in a less than fully sintered bit body upon fully sintering the bit body is predicted and the at least one feature is formed on the less than fully sintered bit body at a location at least partially determined by the predicted positional error. In other embodiments, bit bodies of earth-boring rotary drill bits are designed to include a design drilling profile and a less than fully sintered bit body is formed including a drilling profile having a shape differing from a shape of the design drilling profile. Less than fully sintered bit bodies of earth-boring rotary drill bits are formed using such methods.
    Type: Grant
    Filed: June 4, 2008
    Date of Patent: December 20, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, John H. Stevens, James L. Duggan, Nicholas J. Lyons, Jimmy W. Eason, Oliver Matthews, III
  • Publication number: 20110303465
    Abstract: Impregnated drilling tools include elongated structures that provide enhanced properties. The drilling tools contain a diamond-impregnated cutting section that contains elongated structures made from carbon, glass, ceramic, and the like. The elongated structures can comprise tubes, fibers, or rods. In one or more implementations the elongated structures are nano-sized. The elongated structures can control the tensile strength and/or the erosion rate of the drilling tools to optimize the cutting performance of the tools. Additionally, the elongated structures may also weaken the cutting section in one or more implementations; thereby, allowing higher strength binders to be used. Such higher modulus binders can cost less and allow for tailoring of the cutting section to retain the diamonds for the desired amount of time. As the cutting section erodes, the elongated structures may also increase the lubricity at the face of the cutting section.
    Type: Application
    Filed: August 24, 2011
    Publication date: December 15, 2011
    Applicant: LONGYEAR TM, INC.
    Inventors: Michael D. Rupp, Cody A. Pearce, Christian M. Lambert, Kristian S. Drivdahl
  • Patent number: 8074750
    Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC-SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC-SiC material, and the ABC-SiC material may be toughened to increase a fracture toughness exhibited by the ABC-SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.
    Type: Grant
    Filed: September 3, 2010
    Date of Patent: December 13, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Heeman Choe, John H. Stevens, James L. Overstreet, Jimmy W. Eason, James C. Westhoff
  • Patent number: 8056652
    Abstract: A hardfacing composition for a drill bit that includes an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy is disclosed. Drill bits having hardfacing compositions that include an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy are also disclosed.
    Type: Grant
    Filed: June 5, 2008
    Date of Patent: November 15, 2011
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Guodong Zhan
  • Publication number: 20110259647
    Abstract: Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.
    Type: Application
    Filed: June 10, 2011
    Publication date: October 27, 2011
    Applicant: Baker Hughes Incorporated
    Inventors: John H. Stevens, Jimmy W. Eason
  • Patent number: 8028774
    Abstract: A high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches from the apex to a central region of the cemented metal carbide substrate. The diamond material comprises a 1 to 5 percent concentration of binding agents by weight.
    Type: Grant
    Filed: November 25, 2009
    Date of Patent: October 4, 2011
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, Ronald B. Crockett, Jeff Jepson, Scott Dahlgren, John Bailey
  • Patent number: 8025112
    Abstract: An article of manufacture includes a cemented carbide piece and a joining phase that binds the cemented carbide piece into the article. The joining phase includes inorganic particles and a matrix material. The matrix material is a metal and a metallic alloy. The melting temperature of the inorganic particles is higher than the melting temperature of the matrix material. A method includes infiltrating the space between the inorganic particles and the cemented carbide piece with a molten metal or metal alloy followed by solidification of the metal or metal alloy to form an article of manufacture.
    Type: Grant
    Filed: August 22, 2008
    Date of Patent: September 27, 2011
    Assignee: TDY Industries, Inc.
    Inventors: Prakash K. Mirchandani, Morris E. Chandler, Michale E. Waller, Heath C. Coleman
  • Patent number: 8016057
    Abstract: Subterranean drill bits having good erosion resistance, strength, toughness, and thermal stability are disclosed. The drill bits comprise a bit body carrying at least one cutting element and having an infiltrated metal matrix. The infiltrated metal matrix comprises a matrix powder composition bound together by an infiltrant. The matrix powder mixture includes cast tungsten carbide powder having a particle size of ?30 (600 micron) +140 mesh (106 micron), a second component powder consisting of one or more other types of tungsten carbide particles, and a metal powder.
    Type: Grant
    Filed: June 19, 2009
    Date of Patent: September 13, 2011
    Assignee: Kennametal Inc.
    Inventors: Xin Deng, Jonathan W. Bitler
  • Patent number: 8016056
    Abstract: A cutting tool that includes at least one tungsten carbide cutting element disposed on a support, wherein at least one tungsten carbide cutting element has at least one localized region having a material property different from the remaining region, wherein the at least one localized region having a different material property is prepared by a method including determining at least one localized region needing a variation in a material property different from the remaining region; coating a portion of a surface of the at least one tungsten carbide cutting element with a refractory material such that a surface corresponding to the localized region is left uncoated; and treating the coated cutting element with a selected agent to diffuse the selected agent into the localized region is disclosed.
    Type: Grant
    Filed: June 29, 2006
    Date of Patent: September 13, 2011
    Assignee: Sandvik Intellectual Property AB
    Inventors: Ramamurthy K. Viswanadham, Dah-Ben Liang, Gregory T. Lockwood
  • Patent number: 8007922
    Abstract: An article includes a working portion including cemented carbide, and a heat sink portion in thermal communication with the working portion. The heat sink portion includes a heat sink material having a thermal conductivity greater than a thermal conductivity of the cemented carbide. Also disclosed are methods of making an article including a working portion comprising cemented carbide, and a heat sink portion in thermal communication with the working portion and including a heat sink material having a thermal conductivity that is greater than a thermal conductivity of the cemented carbide. The heat sink portion conducts heat from the working portion.
    Type: Grant
    Filed: October 25, 2007
    Date of Patent: August 30, 2011
    Assignee: TDY Industries, Inc
    Inventors: Prakash K. Mirchandani, Alfred J. Mosco, Eric W. Olsen, Steven G. Caldwell