Abstract: Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

Abstract: Hardfacing is used to protect wear surfaces of drill bits and other downhole tools. A hardfacing member can be formed by heating a metal matrix material, e.g., via a laser process, injecting a plurality of particles into the heated metal matrix material, disposing the mixture on at least a portion of a substrate thereby forming a hardfacing member having a particle-embedded metal matrix material, and attaching the hardfacing member to a main body.

Abstract: A pulsed power drilling (PPD) component includes a functional gradient of material from a first portion to a second portion of the PPD component. The functional gradient of material provides a greater wear resistance of the first portion relative to the second portion and a greater electrical conductivity or resistivity of the second portion relative to the first portion.

Abstract: Systems and methods for cold-spraying coatings on rotors in motor assemblies for improving reliability of motor assembly use downhole in wellbores is provided. For example, a motor assembly can include a stator positioned downhole in a wellbore and rotor coupled to the wellbore. The rotor can include a base material and a first coating deposited onto the base material via cold spraying for reducing damage to the rotor. The first coating may include sprayed particles that have a melting point temperature that is higher than a temperature of a gas used in the cold spraying. In some examples, the rotor may include a second coating deposited onto the first coating via cold spraying, high velocity oxygen fuel coating, or high velocity air fuel. The first coating may have a first hardness that is less than a second hardness of the second coating.

Abstract: A downhole motor or pump assembly that includes a stator and a rotor rotatable within the stator. The stator includes a tubular housing and an overlay deposited by cold spray onto an interior of the housing to form overlay lobes along a first length of the stator. The downhole motor or pump may be used to perform downhole operations.

Abstract: Systems and methods for cold-spraying coatings on rotors in motor assemblies for improving reliability of motor assembly use downhole in wellbores is provided. For example, a motor assembly can include a stator positioned downhole in a wellbore and rotor coupled to the wellbore. The rotor can include a base material and a first coating deposited onto the base material via cold spraying for reducing damage to the rotor. The first coating may include sprayed particles that have a melting point temperature that is higher than a temperature of a gas used in the cold spraying. In some examples, the rotor may include a second coating deposited onto the first coating via cold spraying, high velocity oxygen fuel coating, or high velocity air fuel. The first coating may have a first hardness that is less than a second hardness of the second coating.

Abstract: A pulsed power drilling (PPD) component includes a functional gradient of material from a first portion to a second portion of the PPD component. The functional gradient of material provides a greater wear resistance of the first portion relative to the second portion and a greater electrical conductivity or resistivity of the second portion relative to the first portion.

Abstract: A downhole motor or pump assembly that includes a stator and a rotor rotatable within the stator. The stator includes a tubular housing and an overlay deposited by cold spray onto an interior of the housing to form overlay lobes along a first length of the stator. The downhole motor or pump may be used to perform downhole operations.

Abstract: Drill collars may be constructed using solid-state welding processes. Solid-state welding produces robust drill collars with high fatigue lifespans and permits individual segments of the drill collar to be optimized based on their intended use. A drill collar may be formed of a first segment with a different material, density, modulus of elasticity and/or geometry than an adjacent second segment fused thereto. If a segment of a drill collar is damaged in use, the damaged segment may be removed and replaced, possibly without de-rating the drill collar. Methods of forming the solid-state welds may include friction welding adjacent segments to one another such that features in each segment are circumferentially aligned when the weld is formed. Supplemental energy sources may provide additional heat at the welded surfaces to ensure the segments are effectively fused.

Abstract: Drill collars may be constructed using solid-state welding processes. Solid-state welding produces robust drill collars with high fatigue lifespans and permits individual segments of the drill collar to be optimized based on their intended use. A drill collar may be formed of a first segment with a different material, density, modulus of elasticity and/or geometry than an adjacent second segment fused thereto. If a segment of a drill collar is damaged in use, the damaged segment may be removed and replaced, possibly without de-rating the drill collar. Methods of forming the solid-state welds may include friction welding adjacent segments to one another such that features in each segment are circumferentially aligned when the weld is formed. Supplemental energy sources may provide additional heat at the welded surfaces to ensure the segments are effectively fused.

Abstract: Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

Abstract: A system for causing wear to a material in representative downhole conditions is provided, and can include a housing with a chamber at least partially filled with a fluid, an abrasion device at least partially immersed in the fluid, a heat transfer element thermally coupled to a housing, an engagement arm coupled to the housing and a test sample attached to the engagement arm that can apply an engagement force to the test sample causing engagement of the test sample with the abrasion device. An actuation device can displace the abrasion device relative to the test sample, and cause wear of the test sample during a wear test in response to the engagement of the test sample with the abrasion device. A controller can control a thermal output of the heat transfer element to maintain the chamber within a temperature range that is representative of the downhole conditions.

Abstract: A system for causing wear to a material in representative downhole conditions is provided, and can include a housing with a chamber at least partially filled with a fluid, an abrasion device at least partially immersed in the fluid, a heat transfer element thermally coupled to a housing, an engagement arm coupled to the housing and a test sample attached to the engagement arm that can apply an engagement force to the test sample causing engagement of the test sample with the abrasion device. An actuation device can displace the abrasion device relative to the test sample, and cause wear of the test sample during a wear test in response to the engagement of the test sample with the abrasion device. A controller can control a thermal output of the heat transfer element to maintain the chamber within a temperature range that is representative of the downhole conditions.

Abstract: The present disclosure provides a system for improving wear resistance of a downhole tool component using a bonded diamond compact (BDC) construct. The BDC construct includes a BDC element and an encapsulation layer bonded to the BDC element. The encapsulation layer may fully encapsulate the BDC element. The downhole tool component may be a drill bit, push the bit pad, or mud motor beating assembly. The BDC construct may be disposed in a plug section of the downhole tool component. The encapsulation layer may form an insulating layer over the BDC element to protect the BDC element from thermal damage during hard-facing or brazing of the BDC construct to the downhole tool component.

Abstract: Hardfacing is used to protect wear surfaces of drill bits and other downhole tools. A hardfacing member can be formed by heating a metal matrix material, e.g., via a laser process, injecting a plurality of particles into the heated metal matrix material, disposing the mixture on at least a portion of a substrate thereby forming a hardfacing member having a particle-embedded metal matrix material, and attaching the hardfacing member to a main body.

Abstract: The present disclosure provides a system for improving wear resistance of a downhole tool component using a bonded diamond compact (BDC) construct. The BDC construct includes a BDC element and an encapsulation layer bonded to the BDC element. The encapsulation layer may fully encapsulate the BDC element. The downhole tool component may be a drill bit, push the bit pad, or mud motor beating assembly. The BDC construct may be disposed in a plug section of the downhole tool component. The encapsulation layer may form an insulating layer over the BDC element to protect the BDC element from thermal damage during hard-facing or brazing of the BDC construct to the downhole tool component.

Abstract: Downhole tools such as bearing assemblies and stabilizers are described for withstanding abrasive and erosive wear in operation. These stabilizers and bearing assemblies employ wear-resistant hard materials such as TSP, PCD, leached WC, and SCD composite materials. A bond between a braze material and wear tiles constructed of a hard phase material may include a non-planar interface with the braze material. Self-lubricating materials may be provided within the braze material or the hard material in some instances.

Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.