Abstract: A metal matrix composite tool that includes a hard composite portion comprising a reinforcement material infiltrated with a binder material, wherein the reinforcement material comprises a refractory metal component dispersed with reinforcing particles, wherein a surface roughness of the reinforcing particles is at least two times greater than the refractory metal component, wherein the refractory metal component has a failure strain of at least 0.05 and a shear modulus of 200 GPa or less, and wherein the reinforcing particles have a failure strain of 0.01 or less but at least five times less than the failure strain of the refractory metal component, and the reinforcing particles have a shear modulus of greater than 200 GPa and at least two times greater than the shear modulus of the refractory metal component. The reinforcing particles may comprise an intermetallic, a boride, a carbide, a nitride, an oxide, a ceramic, and/or a diamond.

Abstract: An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold. An infiltration chamber is defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. One or more thermal elements are positioned within at least one of the mold and the funnel, and the one or more thermal elements are in thermal communication with the infiltration chamber.

Abstract: An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold and having an inner wall, an outer wall, and a cavity defined between the inner and outer walls. An infiltration chamber is defined at least partially by the mold and the funnel. The inner wall faces the infiltration chamber and the outer wall forms at least a portion of an outer periphery of the mold assembly.

Abstract: Forming a precipitation hardened composite material having reinforcing particles and precipitated intermetallic particles dispersed in the binder material may involve heat treating the hard composite material at a temperature above a solvus line for the binder material and below a melting point of the binder material and quenching the hard composite material to a temperature below the solvus line of the binder material. At least some of the precipitated intermetallic particles in the precipitation hardened composite material may have at least one dimension less than 1 micron. Such precipitated intermetallic particles may optionally be grown to larger sizes by heat treating the precipitation hardened composite material at a temperature below the solvus line of the binder material.

Abstract: A drill bit may include a matrix bit body and a plurality of cutting elements coupled to an exterior portion of the matrix bit body, wherein the matrix bit body includes matrix particles and precipitated intermetallic particles dispersed in a binder, at least some of the matrix particles having a diameter of 50 microns or greater, and at least some of the precipitated intermetallic particles having at least one dimension of 1 micron to 30 microns.

Abstract: Zonal heating and cooling during the production of matrix drill bits may be achieved with a system that includes a cavity defined within a mold assembly having a central axis; reinforcing particles and a binder material disposed within the cavity; and a plurality of induction coils about a periphery of the mold assembly, each induction coil being spaced from each other along the height of the mold assembly, wherein a first induction coil of the plurality of induction coils is arranged proximal to a portion of mold assembly containing a portion of the reinforcing particles and a second induction coil of the plurality of induction coils is arranged proximal to a portion of the mold assembly containing a portion of the binder material.

Abstract: A wellbore tool may be formed, at least in part, by a fiber-reinforced hard composite portion that comprises reinforcing particles and reinforcing fibers dispersed in a binder, wherein the reinforcing fibers have an aspect ratio ranging from 1 to 15 times a critical aspect ratio (Ac), wherein Ac=?f/(2Tc), ?f is an ultimate tensile strength of the reinforcing fibers, and Tc is an interfacial shear bond strength between the reinforcing fiber and the binder or a yield stress of the binder, whichever is lower.