Specific Or Diverse Material Patents (Class 175/425)
  • Publication number: 20110180324
    Abstract: In one aspect of the present invention, a drilling assembly comprises a drill bit comprising a bit body and a cutting surface. A formation engaging element protrudes from the cutting surface and is configured to engage a formation. At least one compliant member is disposed intermediate the bit body and formation engaging element and is configured to provide compliancy in a lateral direction for the formation engaging element.
    Type: Application
    Filed: March 31, 2011
    Publication date: July 28, 2011
    Inventors: David R. Hall, Francis Leany, Scott Woolston, Daniel Manwill
  • Publication number: 20110174548
    Abstract: Downhole tools are provided with a topographical pattern, and anti-balling material is provided over the topographical pattern. The topographical pattern may be defined by at least one of a plurality of recesses extending into a surface of a body of the tool and a plurality of protrusions protruding from the surface. Downhole tools include an insert disposed within a recess in a body, and the insert comprises an anti-balling material having a composition selected to reduce accumulation of formation cuttings on the tools when the tools are used to form or service a wellbore. Downhole tools include anti-balling material disposed over a porous mass provided over the surfaces of the tools. Methods of forming downhole tools include providing anti-balling material over features on and/or in a surface of a body of a tool. Methods of repairing downhole tools include removing an insert therefrom and disposing a replacement insert therein.
    Type: Application
    Filed: January 13, 2011
    Publication date: July 21, 2011
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Suresh G. Patel, Chaitanya K. Vempati, Steven R. Radford, Timothy K. Marvel, Bruce Stauffer, George I. Butler
  • Patent number: 7980333
    Abstract: An earth boring drill bit comprising a milled cutter having rows of hardfacing guides on the cutter. Hardfacing is applied between adjacent hardfacing guides to form a hardfacing web that serves as a cutting element. The hardfacing web defines an interface between the hardfacing web and the hardfacing guide. The hardfacing web may extend past the crest of the hardfacing guides or end along the hardfacing guides flanks. Projecting hardfacing is provided on the interface to form trimmers.
    Type: Grant
    Filed: April 7, 2009
    Date of Patent: July 19, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Robert J. Buske, James L. Overstreet
  • Patent number: 7975785
    Abstract: Diamond-impregnated cutting tools including fibers and drilling systems incorporating such tools are described. The cutting tools contain a diamond-impregnated cutting portion that contains fibers made from carbon, glass, ceramic, polymer, and the like. The fibers may be used to both control the tensile strength and the erosion rate of the matrix to optimize the cutting performance of the tools. Additionally, the fibers may also 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. Using the fibers allows the cutting tools to last longer and make them safer and more economical because they need to be replaced less often.
    Type: Grant
    Filed: November 24, 2008
    Date of Patent: July 12, 2011
    Assignee: Longyear TM, Inc.
    Inventors: Kristian S. Drivdahl, Michael D. Rupp
  • Patent number: 7954569
    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, optionally, 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: April 28, 2005
    Date of Patent: June 7, 2011
    Assignees: TDY Industries, Inc., Baker Hughes Incorporated
    Inventors: Prakash K. Mirchandani, Jimmy W. Eason, James J. Oakes, James C. Westhoff, Gabriel B. Collins, John H. Stevens, Steven G. Caldwell, Alfred J. Mosco
  • Publication number: 20110120781
    Abstract: A drill bit may include a bit body having a plurality of blades extending radially therefrom, the bit body comprising a continuous infiltration binder and a plurality of carbide particles dispersed in the continuous infiltration binder, wherein at least a portion of the plurality of carbide particles and at least a portion of the continuous infiltration binder form a first carbide matrix region, wherein the plurality of carbide particles forming the first carbide matrix region have an average grain sizes of less than about 44 microns; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.
    Type: Application
    Filed: November 18, 2010
    Publication date: May 26, 2011
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Gregory T. Lockwood, Madapusi K. Keshavan, Anthony Griffo
  • Publication number: 20110114394
    Abstract: Methods for manufacturing a matrix tool body comprising placing a first matrix material within a first region of a mold cavity proximate a surface of the mold. A second matrix material may be placed within a second region of the mold cavity positioned inwardly of the first matrix material. The first matrix material and the second matrix material comprise a plurality of hard particles. The plurality of hard particles of the second matrix material have a median particle size that is less than the median particle size of the first matrix material. The plurality of hard particles of the first matrix material and the second matrix material are infiltrated with an infiltration binder to form the tool body. Also included are tool bodies having one or more regions proximate a surface of the tool body comprising an erosion resistant matrix material and/or a wear resistant matrix material.
    Type: Application
    Filed: November 18, 2010
    Publication date: May 19, 2011
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Gregory T. Lockwood, Youhe Zhang, Yuri Burhan
  • Publication number: 20110079446
    Abstract: Methods for welding a fixed-cutter bit body to a shank of an earth-boring bit are disclosed. An interface may be formed between the fixed-cutter bit body and the shank, and the interface may be friction stir welded. In some embodiments, the fixed-cutter bit body and the shank may overlap proximate to an exterior surface of the earth-boring bit. Methods for welding at least two portions of a bit body of a roller cone bit are also disclosed. An interface may formed between the at least two portions of the bit body of the roller cone bit and the interface may be friction stir welded. Earth-boring rotary drill bits formed using such methods are also disclosed.
    Type: Application
    Filed: October 1, 2010
    Publication date: April 7, 2011
    Applicant: BAKER HUGHES INCORPORATED
    Inventor: James A. Oxford
  • Publication number: 20110073378
    Abstract: A hardfacing composition for downhole well tools, such as earth boring bits, contains sintered ultrahard particles. The ultrahard particles consist of tungsten carbide grains, cobalt and vanadium. The ultrahard particles are dispersed within a matrix metal of iron, nickel or alloys thereof. The composition may also have sintered tungsten carbide particles of a larger size than the ultrahard particles. The ultrahard particles have a greater hardness than the sintered tungsten carbide particles. The ultrahard particles and the sintered tungsten carbide particles may be in a spherical pellet form. Other hard metal particles may be in the composition.
    Type: Application
    Filed: September 29, 2010
    Publication date: March 31, 2011
    Applicant: Baker Hughes Incorporated
    Inventor: James L. Overstreet
  • Patent number: 7913779
    Abstract: Rotary drill bits for drilling subterranean formations include a bit body and at least one cutting structure disposed on a face thereof. The bit body includes a crown region comprising a particle-matrix composite material that includes a plurality of boron carbide particles dispersed throughout an aluminum or aluminum-based alloy matrix material. In some embodiments, the matrix material may include a continuous solid solution phase and a discontinuous precipitate phase. Methods of manufacturing rotary drill bits for drilling subterranean formations include infiltrating a plurality of boron carbide particles with a molten aluminum or aluminum-based material. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.
    Type: Grant
    Filed: September 29, 2006
    Date of Patent: March 29, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Heeman Choe, John H. Stevens, James C. Westhoff, Jimmy W. Eason, James L. Overstreet
  • Publication number: 20110067924
    Abstract: Implementations of the present invention include impregnated drill bits having a plurality of relatively large abrasive cutting media, such as polycrystalline diamonds, embedded therein. According to some implementations of the present invention, the relatively large abrasive cutting media can be dispersed in an unorganized arrangement throughout at least a portion of the crown. Additionally, one or more implementations can include a second plurality of relatively small abrasive cutting media. Implementations of the present invention also include drilling systems including impregnated drill bits having a plurality of relatively large abrasive cutting media embedded therein, methods of using such impregnated drill bits, and methods of forming such impregnated drill bits.
    Type: Application
    Filed: September 17, 2010
    Publication date: March 24, 2011
    Applicant: LONGYEAR TM, INC.
    Inventors: Christian M. Lambert, Michael D. Rupp
  • Patent number: 7905301
    Abstract: An earth boring bit formed from an alloy comprising a low carbon content and high molybdenum content is disclosed herein. The molybdenum content is greater than about 0.8% to about 1.15% by weight of the alloy. The carbon content may range up to about 0.16% by weight of the alloy. The alloy may further comprise alloy further comprises manganese, phosphorus, sulfur, silicon, nickel, chromium, copper, aluminum, vanadium, and calcium; with the balance being iron. The alloy experiences a relatively flattened hardenability curve and low martinsite formation.
    Type: Grant
    Filed: July 2, 2008
    Date of Patent: March 15, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Carmel Z. El Hakam, Eric C. Sullivan, John F. Bradford, III, Don Q. Nguyen
  • Patent number: 7900720
    Abstract: In one aspect of the present invention, a section of a drill string has a drill bit with a body intermediate a shank and a working face, the working face having at least one cutting element. A jack element is disposed within the drill bit body and has a distal end substantially protruding from the working face. A drive shaft is in communication with the jack element and a rotary source. The drive shaft has a first portion secured within a bore of a tool string component in the tool string and a second portion secured within a bore of the drill bit. The first and second portions of the drive shaft are connected at a pin and box connection wherein the first and second portions are automatically connected as the tool string component is mechanically coupled to the drill bit.
    Type: Grant
    Filed: December 14, 2007
    Date of Patent: March 8, 2011
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, David Lundgreen, Paula Turner, Daryl Wise, Nathan Nelson, Andrew Pilgrim, Robert Myler
  • Publication number: 20110031028
    Abstract: A hardmetal composite used as wear-resistant surfaces and inlays in earth-engaging equipment includes more than one hardphase. At least one hardphase has a high average particle size, for example, from 100 ?m to 2000 ?m. The hardphases vary in terms of particle size, hardness, and binder content, and at least one hardphase includes a particulate constituent capable of plastic deformation that comprises at least 1% residual porosity.
    Type: Application
    Filed: August 6, 2009
    Publication date: February 10, 2011
    Inventors: Harold Sreshta, Eric F. Drake, Douglas B. Caraway
  • Patent number: 7878275
    Abstract: A drill bit that includes 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; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades is disclosed.
    Type: Grant
    Filed: May 15, 2008
    Date of Patent: February 1, 2011
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Youhe Zhang, Yuelin Shen
  • Patent number: 7878274
    Abstract: An earth boring drill bit comprising a milled cutter having rows of teeth hardfacing guides on the cutter. Hardfacing is applied between adjacent teeth hardfacing guides to form a cutting element. The hardfacing may extend past the crest of the teeth hardfacing guides or end along the teeth hardfacing guides flanks.
    Type: Grant
    Filed: September 26, 2008
    Date of Patent: February 1, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Robert J. Buske, James L. Overstreet
  • Publication number: 20110005837
    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: September 21, 2010
    Publication date: January 13, 2011
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Carl Hoffmaster, Shelton W. Alsup, Michael G. Azar, Thomas W. Oldham, Stuart R. Oliver, Sidney J. Isnor
  • Patent number: 7866417
    Abstract: An earth boring drill bit comprising a milled cutter having rows of teeth hardfacing guides on the cutter. Hardfacing is applied between adjacent teeth hardfacing guides to form a cutting element. The hardfacing may include an annular body with ridges that outwardly project from the body.
    Type: Grant
    Filed: October 21, 2008
    Date of Patent: January 11, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Robert J. Buske, James L. Overstreet
  • Publication number: 20110000718
    Abstract: A drill bit including a bit body and an upper portion, wherein the bit body and the upper portion are comprised of a matrix material, and wherein the upper portion includes a threaded connection comprised of a machineable matrix material is disclosed.
    Type: Application
    Filed: July 2, 2009
    Publication date: January 6, 2011
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Steve Bankes, Gary Chunn, Tommy Gene Ray, Darrell Vantreese, Kenneth Scholwinski
  • Publication number: 20100320005
    Abstract: In one aspect, an impregnated drill bit is provided having at least one insert positioned within at least one of the plurality of blades such that the insert spans more than 75% of the height of the blade and at least a portion of the blade has a blade height of at least 40 mm. In another aspect, an impregnated drill bit is provided having a plurality of blades with at least a portion of at least one blade having a blade height of at least 60 mm. Also provided are methods of manufacturing such impregnated drill bits.
    Type: Application
    Filed: June 22, 2010
    Publication date: December 23, 2010
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Yuri Burhan, Gregory T. Lockwood, Jonan Fulencheck, Michael G. Azar
  • Publication number: 20100307837
    Abstract: A casing end tool has a bowl-like (or cup-like) body defined by a wall having an outer convex surface and an inner concave surface opposite of the outer convex surface. The bowl-like body has a center axis. The inner concave surface is non-axisymmetric with respect to the center axis, while the outer convex surface is axisymmetric with respect to the center axis. The non-axisymmetric configuration is provided in one implementation through the presence of a set of raised boss or land structures formed on the inner concave surface.
    Type: Application
    Filed: June 3, 2010
    Publication date: December 9, 2010
    Applicant: Varel International, Ind., L.P.
    Inventors: William W. King, Michael Reese, Steven W. Drews, Ian Alastair Kirk
  • Publication number: 20100307838
    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 5, 2009
    Publication date: December 9, 2010
    Applicant: Baker Hughes Incorporated
    Inventors: John H. Stevens, Jimmy W. Eason
  • Patent number: 7841428
    Abstract: Methods of manufacturing polycrystalline diamond are disclosed. More particularly, a mixture including diamond and fullerenes may be provided. Further, the mixture may be exposed to a high pressure, high temperature sintering process. In addition, a volume of polycrystalline diamond bonded to a substrate may be formed by providing a mixture including diamond and fullerenes and exposing the mixture to a high pressure, high temperature sintering process. A drill bit for drilling a subterranean formation is disclosed. Further, polycrystalline diamond compacts are disclosed including polycrystalline diamond bonded to a substrate, wherein the polycrystalline diamond includes less than about 1% by weight or is substantially free of non-fullerenes, non-diamond carbon. Polycrystalline diamond exhibiting an increased diamond volume fraction due to the presence of fullerenes during manufacture relative to polycrystalline diamond formed without fullerenes is disclosed.
    Type: Grant
    Filed: February 10, 2006
    Date of Patent: November 30, 2010
    Assignee: US Synthetic Corporation
    Inventor: Kenneth E. Bertagnolli
  • Patent number: 7832506
    Abstract: Cutting elements offering increased toughness and thermal fatigue resistance can be formed of a wear resistant material having coarse grains disposed in a binder matrix with a binder content of at least about 18% by weight. The coarse grains include grains of at least one selected from the group of a transition metal carbide, a transition metal boride, and transition metal nitride. The binder content and coarse grain size may be selected to provide a Rockwell A hardness of at least about 75 Ra or a wear number of at least about 1.5.
    Type: Grant
    Filed: March 31, 2008
    Date of Patent: November 16, 2010
    Assignee: Smith International, Inc.
    Inventors: Dah-Ben Liang, Gary R. Portwood, James C. Minikus, Amardeep Singh, Jonathan Bitler
  • Publication number: 20100276208
    Abstract: A high thermal conductivity hardmetal composition comprising tungsten carbide in a nickel based matrix binder is disclosed. The hardmetal has at least 50 wt % tungsten carbide, the tungsten carbide being composed of at least 50 vol % of spherical particles. The binder material is composed of at least 98.5 wt % of components selected from the group consisting of nickel, boron, and silica, and the binder flux of boron plus silica content ranges from between 3.5 to 10.0 wt % of the binder material.
    Type: Application
    Filed: April 29, 2009
    Publication date: November 4, 2010
    Inventor: Jiinjen Albert Sue
  • Patent number: 7823665
    Abstract: A method and apparatus for milling an item in a wellbore. The method and apparatus including providing a milling tool having one or more blades which are geometrically configured to resist deflection by distributing cutting forces in multiple directions.
    Type: Grant
    Filed: August 7, 2007
    Date of Patent: November 2, 2010
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Michael Sullivan, Thomas M. Redlinger, Hubert E. Halford, Thomas F. Bailey
  • Patent number: 7823664
    Abstract: An earth boring bit has a steel body having at least one leg with a depending bearing pin. A cone having cutting elements is rotatably mounted to the bearing pin. A ball plug weld is on the outer surface of the leg. A layer of hardfacing applied to part of the outer surface of the leg, the hardfacing having carbide particles in a matrix. A corrosion resistant coating containing at least 50% nickel is formed on parts of the outer surface of the leg that are free of the layer of hardfacing both above and below the ball plug weld.
    Type: Grant
    Filed: August 14, 2008
    Date of Patent: November 2, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: Alan J. Massey, David K. Luce, Eric Sullivan, John F. Bradford, III, Carmel Z. El Hakam, James L. Overstreet, Ajay V. Kulkarni
  • Publication number: 20100270086
    Abstract: Earth-boring drill bits include a bit body, an element having an attachment feature bonded to the bit body, and a shank assembly. Methods for assembling an earth-boring rotary drill bit include bonding a threaded element to the bit body of a drill bit and engaging the shank assembly to the threaded element. In additional embodiments, a nozzle assembly for an earth-boring rotary drill bit may include a cylindrical sleeve having a threaded surface and a threaded nozzle disposed at least partially in the cylindrical sleeve and engaged therewith. Methods of forming an earth-boring drill bit include providing a nozzle assembly including a tubular sleeve and nozzle at least partially within a nozzle port of a bit body.
    Type: Application
    Filed: April 23, 2009
    Publication date: October 28, 2010
    Inventors: Oliver Matthews, III, David A. Stockey, Redd H. Smith
  • Patent number: 7810587
    Abstract: The invention relates to a drill bit containing tungsten carbide powder having powder particles which have a core of cast tungsten carbide and a shell of tungsten monocarbide.
    Type: Grant
    Filed: April 9, 2009
    Date of Patent: October 12, 2010
    Assignee: H.C. Starck GmbH
    Inventors: Christian Gerk, Klause-Dieter Wernicke
  • Publication number: 20100252327
    Abstract: A drill bit is disclosed that in one aspect includes a cutting device on a selected section of the drill bit, which cutting device is configured to cut formation on the high side of a wellbore during drilling of the wellbore. In one aspect, the cutting device comprises a cutting element disposed on a substantially non-rotating member placed around the selected section. In another aspect, the selected section may be a gage section of the drill bit.
    Type: Application
    Filed: December 23, 2009
    Publication date: October 7, 2010
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Chad J. Beuershausen, Thorsten Schwefe, Britney E. Meckfessel, Trung Q. Huynh
  • Patent number: 7802495
    Abstract: Methods of forming earth-boring rotary drill bits include providing a bit body, providing a shank that is configured for attachment to a drill string, and attaching the shank to the bit body. Providing a bit body includes providing a green powder component having a first region having a first composition and a second region having a second, different composition, and at least partially sintering the green powder component. Other methods include providing a powder mixture, pressing the powder mixture to form a green component, and sintering the green component to a final density. A shank is provided that includes an aperture, and a feature is machined in a surface of the bit body. The aperture is aligned with the feature, and a retaining member is inserted through the aperture. An earth-boring bit includes a bit body comprising a particle-matrix composite material including a plurality of hard particles dispersed throughout a matrix material. A shank is attached to the bit body using a retaining member.
    Type: Grant
    Filed: November 10, 2005
    Date of Patent: September 28, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: James A. Oxford, Jimmy W. Eason, Redd H. Smith, John H. Stevens, Nicholas J. Lyons
  • Publication number: 20100236834
    Abstract: A hardfacing composition comprising an iron-based binder alloy; and a carbide phase comprising a sintered carbide and a cast tungsten carbide, wherein the cast carbide is present in a quantity of at least 22% by weight, based on the total weight of the carbide phase, and the cast carbide comprises particles having sizes in the range of from 30 to 60 mesh. Also provided is a hardfacing composition comprising an iron-based binder alloy; and a carbide phase comprising a super dense sintered carbide and one or more additional carbide materials, wherein the super dense sintered carbide is present in a quantity of at least 10 percent by weight (% w), based on the total weight of the carbide phase, and comprises particles having sizes in the range of from 16 to 40 mesh. Included are methods of manufacturing such hardfacing compositions and downhole tools having such improved hardfacing compositions applied thereon.
    Type: Application
    Filed: March 22, 2010
    Publication date: September 23, 2010
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Sike Xia, Zhou Yong
  • Publication number: 20100230173
    Abstract: A carbide composite material that includes a continuous ductile phase; and at least one discrete carbide region surrounded by the continuous ductile phase, each discrete carbide region may comprise an integrally bridged plurality of cast and/or sintered carbide particles, and each discrete region may have a nodular particle morphology.
    Type: Application
    Filed: March 12, 2010
    Publication date: September 16, 2010
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Sike Xia, Zhou Yong
  • Publication number: 20100224418
    Abstract: A multi-layer precursor material for use in forming hardfacing on a tool including hard particles, metal particles and a polymer. Methods of forming a multi-layer precursor film. Methods of using a precursor material to form hardfacing on a tool, including brazing a precursor material onto a surface of the tool. Intermediate structures for use in forming earth-boring tools including a precursor material covering an internal surface of a body of the tools. Methods of forming earth-boring tools include forming a body having a fluid passageway extending therethrough and covering a surface of the body with a hardfacing material. The surface of the body may be located in a region susceptible to erosion when fluid is caused to flow through the fluid passageway.
    Type: Application
    Filed: March 4, 2009
    Publication date: September 9, 2010
    Applicant: Baker Hughes Incorporated
    Inventors: Jimmy W. Eason, Travis E. Puzz
  • Patent number: 7784381
    Abstract: A matrix drill bit and method of manufacturing a matrix bit body from a composite of matrix materials is disclosed. Two or more different types of matrix materials may be used to form a composite matrix bit body. A first matrix material may be selected to provide optimum fracture resistance (toughness) and optimum erosion, abrasion and wear resistance for portions of a matrix bit body such as cutter sockets, cutting structures, blades, junk slots and other portions of the bit body associated with engaging and removing formation materials. A second matrix material may be selected to provide desired infiltration of hot, liquid binder material with the first matrix material to form a solid, coherent, composite matrix bit body.
    Type: Grant
    Filed: January 18, 2008
    Date of Patent: August 31, 2010
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Ram L. Ladi, Gary Weaver, David A. Brown
  • Patent number: 7784567
    Abstract: Earth-boring rotary drill bits include bit bodies comprising a composite material including a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material. The bits further include a cutting structure disposed on a face of the bit body. In some embodiments, the bit bodies may include a plurality of regions having differing material compositions. For example, the bit bodies may include a first region comprising a plurality of hard phase regions or particles dispersed throughout a titanium or titanium-based alloy matrix material, and a second region comprising a titanium or a titanium-based alloy material. Methods for forming such drill bits include at least partially sintering a plurality of hard particles and a plurality of particles comprising titanium or a titanium-based alloy material to form a bit body comprising a particle-matrix composite material. A shank may be attached directly to the bit body.
    Type: Grant
    Filed: November 6, 2006
    Date of Patent: August 31, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: Heeman Choe, John H. Stevens, James L. Overstreet, James C. Westhoff, Jimmy W. Eason
  • Patent number: 7779937
    Abstract: An earth-boring bit has at least one steel tooth with a scoop-shaped profile. The scoop-shaped profile is formed by milling and hardfacing a tooth to have at least one flank with a concave profile. Additionally, the tooth may contain one flank with a concave profile and another with a convex profile. The centerline axis of the tooth may be moved to alter the angle between the flanks and the centerline to vary the manner in which the tooth engages the formation.
    Type: Grant
    Filed: July 21, 2008
    Date of Patent: August 24, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: David K. Luce, Robert J. Buske
  • Publication number: 20100193255
    Abstract: An earth-boring rotary drill bit includes a bit body, with a first region configured to carry a plurality of cutters for engaging a subterranean earth formation of a first particle-matrix composite material and a second region configured for attachment to a drill string of a second particle-matrix composite material having a second material composition, and an annular shank extending from the second region. Each of the first particle-matrix composite material and second particle-matrix composite material has a cast microstructure. A method of making an earth-boring rotary drill bit includes providing a plurality of hard particles in a mold to define a particle precursor; infiltrating the particle precursor sequentially with a plurality of molten matrix materials to form a corresponding plurality of layers, each comprising a particle-matrix mixture; and cooling the plurality of particle-matrix mixtures to solidify the matrix materials and form the bit body.
    Type: Application
    Filed: August 3, 2009
    Publication date: August 5, 2010
    Inventors: John H. Stevens, Jimmy W. Eason
  • Publication number: 20100193252
    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, optionally, 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: Application
    Filed: April 20, 2010
    Publication date: August 5, 2010
    Applicants: TDY INDUSTRIES, INC., BAKER HUGHES INCORPORATED
    Inventors: Prakash K. Mirchandani, Jimmy W. Eason, James J. Oakes, James C. Westhoff, Gabriel B. Collins, John H. Stevens, Steven G. Caldwell, Alfred J. Mosco
  • Patent number: 7735585
    Abstract: A hard material insert (1) for a drill (2, 2?) includes an axially central reinforcement (3) provided in the insert, and two diametrically opposite, radial arms (4) each having a cross-section tapering radially outwardly, opposite free side (8) and connection side (7), with the free and connection sides (8, 7) of one of the radial arms (4) being arranged alternatively to the free and connection sides of another of the radial arms (4), and a concave recess (6) provided on the connection side (7).
    Type: Grant
    Filed: August 20, 2007
    Date of Patent: June 15, 2010
    Assignee: Hilti Aktiengesellschaft
    Inventor: Olaf Koch
  • Publication number: 20100108401
    Abstract: The present invention relates to drill bits and methods of making drill bits. In one embodiment, a drill bit includes a bit body having at least one independent blade, in which the blade is attached to the bit body by way of a piece that is attached to a force absorbing material. In another embodiment, a drill bit includes an integrated blade, in which the blade is cut into segments allowing the segments of the blade to independently flex.
    Type: Application
    Filed: August 20, 2009
    Publication date: May 6, 2010
    Inventors: Curtis Clifford Lanning, Aaron Schen
  • Publication number: 20100108399
    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: Application
    Filed: October 30, 2008
    Publication date: May 6, 2010
    Inventors: Jimmy W. Eason, John H. Stevens, James L. Overstreet
  • Publication number: 20100101866
    Abstract: A hardfacing is provided to protect surfaces of drill bits and other downhole tools. The hardfacing may include tungsten carbide particles or pellets formed with an optimum weight percentage of binding material and dispersed within and bonded to a matrix deposit. The tungsten carbide particles may be formed by sintering or other appropriate techniques. The tungsten carbide particles may have generally spherical shapes, partially spherical shapes or non-spherical shapes.
    Type: Application
    Filed: January 3, 2008
    Publication date: April 29, 2010
    Inventor: Jay S. Bird
  • Patent number: 7703555
    Abstract: An abrasive wear-resistant material includes a matrix and sintered and cast tungsten carbide granules. A device for use in drilling subterranean formations includes a first structure secured to a second structure with a bonding material. An abrasive wear-resistant material covers the bonding material. The first structure may include a drill bit body and the second structure may include a cutting element. A method for applying an abrasive wear-resistant material to a drill bit includes providing a bit, mixing sintered and cast tungsten carbide granules in a matrix material to provide a pre-application material, heating the pre-application material to melt the matrix material, applying the pre-application material to the bit, and solidifying the material. A method for securing a cutting element to a bit body includes providing an abrasive wear-resistant material to a surface of a drill bit that covers a brazing alloy disposed between the cutting element and the bit body.
    Type: Grant
    Filed: August 30, 2006
    Date of Patent: April 27, 2010
    Assignee: Baker Hughes Incorporated
    Inventor: James L. Overstreet
  • Patent number: 7703556
    Abstract: Earth-boring rotary drill bits including a bit body attached to a shank assembly at a joint. In some embodiments, the joint may be configured to carry at least a portion of any tensile longitudinal and rotational load applied to the drill bit by mechanical interference at the joint. In additional embodiments, the joint may be configured to carry a selected portion of any tensile longitudinal load applied to the drill bit. Methods for attaching a shank assembly to a bit body of an earth-boring rotary drill bit include configuring a joint to carry at least a portion of any tensile longitudinal and rotational load applied to the drill bit by mechanical interference. Additional embodiments include configuring a joint to carry a selected portion of any tensile longitudinal load applied to the drill bit by mechanical interference.
    Type: Grant
    Filed: June 4, 2008
    Date of Patent: April 27, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, James L. Duggan, Anupam K. Singh
  • Patent number: 7695542
    Abstract: Fibers for diamond-impregnated cutting tools and their associated methods for manufacture and use are described. The cutting tools contain a diamond-impregnated cutting portion that contains fibers made from carbon, glass, ceramic, polymer, and the like. The fibers can be in any form, including chopped and milled fibers. The fibers may also be coated with metal, ceramic, or other performance-enhancing coatings. The fibers may be used to both control the tensile strength control the erosion rate of the matrix to optimize the cutting performance of the tools. Additionally, the fibers may also 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. And as the cutting portion erodes, the fibers may also increase the lubricity at the face of the cutting portion.
    Type: Grant
    Filed: November 30, 2007
    Date of Patent: April 13, 2010
    Assignee: Longyear TM, Inc.
    Inventors: Kristian S. Drivdahl, Michael D. Rupp
  • Publication number: 20100084198
    Abstract: A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a concave cutting face perpendicular to an axis of the body is disclosed. A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a non-planar cutting face perpendicular to an axis of the body, the cutting face including a circumferential concave portion, and an inner protrusion portion is also disclosed.
    Type: Application
    Filed: October 8, 2008
    Publication date: April 8, 2010
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Bala Durairajan, Carl M. Hoffmaster
  • Patent number: 7677338
    Abstract: Strategically placed hardfacing material near the shank end of a drill bit above the transition edges provides additional protection for compensator areas and the upper leg surfaces of drill bits during updrilling and/or backreaming operations. The strategically located hardfacing is typically passive in the normal drill mode, but active in the updrill drilling mode and/or back reaming. Alternative designs including other strategic material placement, the formation of hardfacing materials in tooth/wear design shapes, bimetallic gage, graded composite hardfacing materials, recesses or cavities at edges of the outer diameter, and various methods of applying the material also may be employed.
    Type: Grant
    Filed: March 14, 2007
    Date of Patent: March 16, 2010
    Inventors: James L. Overstreet, Robert J. Buske, Jeremy K. Morgan
  • Patent number: 7666244
    Abstract: A hardfacing composition for a drill bit, including a carbide phase comprising from about 50% to about 75% by weight of the hardfacing composition of a combination of 16 to 40 mesh cemented tungsten carbide and 80 to 200 mesh super dense tungsten carbide cobalt particles, wherein about 5% to about 50% by weight of the carbide phase comprises the super dense tungsten carbide cobalt particles, and a binder alloy including about 25% to about 50% by weight of the hardfacing composition.
    Type: Grant
    Filed: July 5, 2005
    Date of Patent: February 23, 2010
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Anthony Griffo, Dah-Ben Liang, Alysia C. White
  • Publication number: 20100038148
    Abstract: Machining and cutting tools including, but not limited to, rotary drill bits, mining tools, milling tools, wood shredders, reamers and wire dies formed with at least one substrate having a layer of polycrystalline diamond disposed thereon. The polycrystalline diamond layer may be generally described as a polycrystalline diamond compact (PDC) or PDC layer. The PDC may be formed by using an intermetallic aluminide catalyst. One example of such catalyst may include nickel aluminide used to form diamond to diamond bonds between adjacent diamond particles.
    Type: Application
    Filed: January 7, 2008
    Publication date: February 18, 2010
    Inventor: William W. King