Abstract: Methods of repairing earth-boring tools may involve providing wear-resistant material over a temporary displacement member to repair a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools may include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature may be configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools may include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Methods of depositing hardfacing material portions of earth-boring tools may involve supporting at least a portion of an earth-boring tool in a holder of a workpiece positioner, the holder being movable in at least a third plane. A location of a surface of the at least a portion of the earth-boring tool may be determined utilizing at least one sensor. The workpiece positioner, the sensor, and a torch positioner comprising a hardfacing torch movable in at least a first plane perpendicular to the third plane and a second plane parallel to the third plane may be controlled utilizing a programmable control system to cause the torch positioner to oscillate the hardfacing torch in the second plane while selectively causing the workpiece positioner to move the holder in the third plane and causing the torch to deposit hardfacing material on the surface.

Abstract: Methods of repairing earth-boring tools may involve providing wear-resistant material over a temporary displacement member to repair a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools may include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature may be configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools may include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Methods of repairing earth-boring tools may involve providing wear-resistant material over a temporary displacement member to repair a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools may include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature may be configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools may include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Methods of depositing hardfacing material portions of earth-boring tools may involve supporting at least a portion of an earth-boring tool in a holder of a workpiece positioner, the holder being movable in at least a third plane. A location of a surface of the at least a portion of the earth-boring tool may be determined utilizing at least one sensor. The workpiece positioner, the sensor, and a torch positioner comprising a hardfacing torch movable in at least a first plane perpendicular to the third plane and a second plane parallel to the third plane may be controlled utilizing a programmable control system to cause the torch positioner to oscillate the hardfacing torch in the second plane while selectively causing the workpiece positioner to move the holder in the third plane and causing the torch to deposit hardfacing material on the surface.

Abstract: Methods of repairing earth-boring tools may involve providing wear-resistant material over a temporary displacement member to repair a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools may include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature may be configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools may include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Methods for depositing hardfacing material on portions of drill bits comprise providing a vertically oriented plasma transfer arc torch secured to a positioner having controllable movement in a substantially vertical plane. A rolling cutter is secured to a chuck mounted on an articulated arm of a robot. A surface of a tooth of the rolling cutter is positioned in a substantially perpendicular relationship beneath the torch. The torch is oscillated along a substantially horizontal axis. The rolling cutter is moved with the articulated arm of the robot in a plane beneath the oscillating torch. A hardfacing material is deposited on the tooth of the rolling cutter.

Abstract: Methods of forming and repairing earth-boring tools include providing wear-resistant material over a temporary displacement member to form a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature is configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Hardfacing is applied on gage surfaces of bit blades, the leading and trailing edges of bit blades, and on carbide inserts. The gage surfaces contains natural diamonds, synthetic diamonds, thermally stable polycrystalline (TSP) diamonds and carbide inserts, and the hardfacing is applied over at least a portion of them. As primary cutters on the bit blades are worn down during drilling, the gage surfaces of the bit blades are also worn down. A hardfacing is applied to the worn gage surfaces of the bit blades, thereby allowing the drill bit to drill deeper and longer without requiring replacement.

Abstract: The present invention relates to a system and method for automated or “robotic” application of hardfacing to the surface of a steel-toothed cutter of a rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program selection, and welding program correction.

Abstract: Methods for depositing hardfacing material on portions of drill bits comprise providing a vertically oriented plasma transfer arc torch secured to a positioner having controllable movement in a substantially vertical plane. A rolling cutter is secured to a chuck mounted on an articulated arm of a robot. A surface of a tooth of the rolling cutter is positioned in a substantially perpendicular relationship beneath the torch. The torch is oscillated along a substantially horizontal axis. The rolling cutter is moved with the articulated arm of the robot in a plane beneath the oscillating torch. A hardfacing material is deposited on the tooth of the rolling cutter.

Abstract: A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit.

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.

Abstract: Earth-boring tools include at least one up-drill feature disposed on a transition surface so as to be passive during down drilling and active during up drilling and/or back reaming operations. Systems for down drilling and up drilling with drill bits comprising one or more up-drill features are also disclosed. Furthermore, methods for forming a borehole with an earth-boring tool including such up-drill features and for forming an earth-boring tool comprising such up-drill features are also disclosed.

Abstract: A rotary drill bit includes a bit body substantially formed of a particle-matrix composite material having an exterior surface and an abrasive wear-resistant material disposed on at least a portion of the exterior surface of the bit body. Methods for applying an abrasive wear-resistant material to a surface of a drill bit are also provided.

Abstract: An earth-boring bit has rotatable cones with rows of carbide elements installed thereon. A nose is symmetrically arranged on a cone axis of one of the cones. The nose has a central core that protrudes outward. A base joins supporting metal of the cone. A free end is opposite the base. Teeth are formed on the cone between the base and the free end, the teeth extending radially outward. A hard facing layer is located on the teeth. Intermediate hardfacings extend outward from the core between each of the teeth. The intermediate hardfacings may be lugs and preferably extend the same distance from the core as the teeth.

Abstract: Methods of forming and repairing earth-boring tools include providing wear-resistant material over a temporary displacement member to form a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature is configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools include a depth-of-cut control feature extending over a temporary displacement member.

Abstract: Earth-boring tools such as, for example, earth-boring rotary drill bits include erosion-resistant structures disposed proximate areas of intersection between faces of the tools and fluid nozzle recesses or fluid passageways extending through the tools to the face. In some embodiments, such an erosion-resistant structure may comprise a mass of hardfacing material. In additional embodiments, such an erosion-resistant structure comprises an erosion-resistant insert. Methods of forming such earth-boring tools include providing erosion-resistant structures proximate intersections between the faces of the tools and fluid nozzle recesses or fluid passageways extending through the tools. Methods of repairing earth-boring tools include providing an annular-shaped, erosion-resistant structure over an eroded surface of a body of a previously used earth-boring tool proximate an intersection between an outer face of the body and an inner surface of the body.

Abstract: A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit.

Abstract: The present invention relates to a system and method for automated or “robotic” application of hardfacing to the surface of a steel-toothed cutter of a rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program selection, and welding program correction.