Abstract: Methods and apparatus for maintaining lubrication of rolling cone cutters mounted on journal pins. Embodiments comprise a rotating cone disposed on a journal pin and forming a journal gap there between. A cylindrical journal sleeve is disposed in the journal gap. The journal sleeve has a longitudinal gap forming opposing end portions, which are continuously contoured. A lubrication port is disposed in the journal pin and in fluid communication with a lubrication supply. The lubrication port has an outlet located in a recess in the journal gap. Each end of the recess comprises a transitioning surface extending between the bottom of the recess and the outer surface of the journal pin to prevent sharp transitions. In certain embodiments, the journal pin may comprise two or more lubrication ports, each located in a recess with transitioning surfaces.

Abstract: A shaped insert that includes a top portion, and a grip length, wherein the grip length is modified to have a non-uniform cross sectional area is disclosed. In another case, a shaped insert includes a top portion, and a grip length, wherein the grip length is modified such that the insert is non-cylindrical. In another case, a shaped insert includes a top portion, and a grip length, wherein the grip length is coated in a non-uniform manner.

Abstract: Annular seals of this invention comprise an elastomeric seal body that is configured to fit within a seal gland of a rock bit. The seal comprises a first seal surface, for providing a seal along a dynamic rotary surface formed between the seal body and one portion of the rock bit, and a second seal surface, for providing a seal between the seal body and another portion of the rock bit. The annular seal further comprises an extrusion prevention member that is positioned adjacent a surface of the seal body between the first and second seal surfaces. The extrusion prevention member can be integral, partially-attached, or independent of the seal body. The extrusion prevention member is preferably formed from a material having a hardness that is greater than that of the seal body. The member is positioned along the seal body at a location adjacent a groove, formed between opposed members of the rock bit, to act as a physical barrier to prevent the seal from being extruded therethrough.

Abstract: Rock bits comprising wear and fracture resistant surface of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each projecting outwardly a distance therefrom. At least a portion of the cone comprises a wear resistant surface formed from a wear resistant composite material. The wear resistant composite material is made by the process of combining powders selected from the group consisting of carbides, borides, nitrides, carbonitrides, refractory metals, cermets, Co, Fe, Ni, steel, and combinations thereof, to form a material mixture. The material mixture is applied onto a designated surface of the cone, in one form or another, when the cone is in a pre-existing rigid state. Depending on the particular application, the material mixture can be applied in as a slurry to the designated surface of the cone to form a coating thereon.

Abstract: Seals of this invention comprise an annular elastomeric ring-shaped body having a dynamic surface disposed along a first body portion, the dynamic surface comprising at least two surface elements that project outwardly therefrom to provide multiple barriers to fluid and debris migration thereacross when placed into contact with a rock bit rotary dynamic surface. The seal dynamic surface includes a recessed portion disposed between the surface elements, and a static seal surface disposed along a second body portion. At least one of the surface elements includes a wear surface that is formed from a material that is more wear resistant than materials that are used to form a remaining portion of the seal. A preferred wear surface is one formed from a composite material comprising a fabric of nonelastomeric polymeric material that is bonded together with an elastomeric material.

Abstract: Annular seals of this invention comprise an elastomeric seal body that is configured to fit within a seal gland of a rock bit. The seal comprises a first seal surface, for providing a seal along a dynamic rotary surface formed between the seal body and one portion of the rock bit, and a second seal surface, for providing a seal between the seal body and another portion of the rock bit. The annular seal further comprises an extrusion prevention member that is positioned adjacent a surface of the seal body between the first and second seal surfaces. The extrusion prevention member can be integral, partially-attached, or independent of the seal body. The extrusion prevention member is preferably formed from a material having a hardness that is greater than that of the seal body. The member is positioned along the seal body at a location adjacent a groove, formed between opposed members of the rock bit, to act as a physical barrier to prevent the seal from being extruded therethrough.

Abstract: Rock bits comprising wear and fracture resistant surface of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each projecting outwardly a distance therefrom. At least a portion of the cone comprises a wear resistant surface formed from a wear resistant composite material. The wear resistant composite material is made by the process of combining powders selected from the group consisting of carbides, borides, nitrides, carbonitrides, refractory metals, cermets, Co, Fe, Ni, steel, and combinations thereof, to form a material mixture. The material mixture is applied onto a designated surface of the cone, in one form or another, when the cone is in a pre-existing rigid state. Depending on the particular application, the material mixture can be applied in as a slurry to the designated surface of the cone to form a coating thereon.

Abstract: Composite constructions of this invention comprise an ordered microstructure made up of multiple structural units that can be the same or different, and that comprise at least a first structural phase and a second structural phase. The first structural phase comprises a hard material that is selected from the group consisting of cermet materials, PCD, PCBN and mixtures thereof. The second structural phase is in contact with the first phase and comprises a material that is different than that selected to form the first structural phase. Additionally, the second structural phase is in contact with at least a portion of the first structural phase. Composite constructions of this invention can also have a multi-layer structures comprising two or more layers, wherein at least one of the layers comprises a composite construction having an ordered microstructure made up of the multiple structural units described above.