Abstract: A metal-matrix composite includes a reinforced composite material including reinforcement material dispersed in a binder material. The reinforcement material includes a metallic component dispersed with reinforcing particles and at least 25 percent of the metallic component has a particle size of 50 microns or less.

Abstract: An example drill bit for subterranean drilling operations includes a drill bit body with a blade. The drill bit may further include a cutting element and an alloy affixing the cutting element to the blade. The alloy may include a particulate phase, such as ceramic material or an intermetallic material, that increases the strength of the alloy without significantly affecting the melting point of the alloy.

Abstract: An example insulation enclosure includes a support structure having a top end, a bottom end, and an opening defined at the bottom end for receiving a mold within an interior of the support structure, and a thermal mass arranged at the top end of the support structure to thermally communicate with a top of the mold and resist heat flow from the top of the mold in an axial direction.

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: A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.

Abstract: An example mold assembly system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.

Abstract: Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.

Abstract: An example insulation enclosure includes a support structure having a top end, a top wall provided at the top end, a bottom end, and an opening defined at the bottom end for receiving a mold within an interior of the support structure. Rigid insulation material may be supported by the support structure and extending between the top and bottom ends and across the top end. The rigid insulation material may extend between the top and bottom ends and consist of one or more sidewall insulation loops that extend along a circumference of the insulation enclosure.

Abstract: A method for fabricating an infiltrated metal-matrix composite (MMC) tool includes positioning at least one boundary form within an infiltration chamber of a mold assembly and thereby segregating the infiltration chamber into at least a first zone and a second zone. Reinforcement materials are deposited into the infiltration chamber and include a first composition loaded into the first zone and a second composition loaded into the second zone. The first and second compositions are then infiltrated with at least one binder material to provide the infiltrated MMC tool with differing mechanical, chemical, physical, thermal, atomic, magnetic, or electrical properties between the first and second zones.

Abstract: A mold assembly system includes a mold assembly that defines an infiltration chamber used for forming an infiltrated metal-matrix composite (MMC) tool. Reinforcement materials are deposited within the infiltration chamber, and a binder material is used to infiltrate the reinforcement materials. At least one preformed mesh is positioned within the infiltration chamber and embedded within the reinforcement materials. The at least one preformed mesh includes a porous body and provides skeletal reinforcement to the infiltrated MMC tool following infiltration.

Abstract: A fixed-cutter drill bit is provided that includes a metal-matrix composite body having at least one metal-matrix composite blade. Cutters are disposed on the blades. A ductile insert is partially disposed within the body and has an exposed surface. The ductile insert has a greater ductility than the metal-matrix composite thereby alleviating stresses imposed on the metal-matrix composite during manufacture of the bit or drilling.

Abstract: A mold assembly system includes a mold assembly that defines an infiltration chamber used for forming an infiltrated metal-matrix composite (MMC) tool, and at least one boundary form positioned within the infiltration chamber and segregating the infiltration chamber into at least a first zone and a second zone. Reinforcement materials are deposited within the infiltration chamber and include a first composition loaded into the first zone and a second composition loaded into the second zone. At least one binder material infiltrates the first and second compositions, wherein infiltration of the first and second compositions results in differing mechanical, chemical, physical, thermal, atomic, magnetic, or electrical properties between the first and second zones in the infiltrated MMC tool.

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 system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.

Abstract: A low surface friction body for a drill bit includes a matrix drill bit body. The body includes a particulate phase having a friction-reducing additive, and a binding material that bonds the particulate phase using a suitable manufacturing process such as selective laser sintering. The particulate phase may include tungsten carbide, the friction-reducing additive may be polytetrafluoroethylene, and the binder material may be copper or cobalt. The friction-reducing additive is distributed throughout at least a portion of the drill bit body that includes the surface that will come into contact with drill cuttings and drilling fluid during operation. The molecular properties of the friction-reducing additive result in a drill bit body having a surface that is resistant to sticking even after enduring chipping and other types of wear.

Abstract: A mold transfer assembly includes a transfer housing providing an interior defined by one or more sidewalls and a top. The transfer housing is sized to receive and encapsulate a mold as the mold is moved between a furnace and a thermal heat sink. An arm is coupled to the transfer housing to move the transfer housing and the mold encapsulated within the transfer housing between the furnace and a thermal heat sink. The transfer housing exhibits one or more thermal properties to control a thermal profile of the mold.

Abstract: An example mold assembly for fabricating an infiltrated downhole tool includes a mold defining 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. A thermal mass is positioned within the infiltration chamber above the infiltrated downhole tool for imparting heat to the infiltrated downhole tool following an infiltration process.

Abstract: An example cooling system for a mold assembly includes a quench plate that defines one or more discharge ports and one or more recuperation ports. A fluid is circulated from the one or more discharge ports to the one or more recuperation ports to cool the mold assembly. A blocking ring is positioned on the quench plate and defines a central aperture for receiving a bottom of the mold assembly. An insulation enclosure having an interior for receiving the mold assembly is positioned on the blocking ring. The blocking ring prevents vapor generated by the fluid contacting the bottom of the mold assembly from migrating into the interior of the insulation enclosure.

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.