Abstract: A method of forming a tooth rock bit is disclosed. In one embodiment, the method includes attaching the at least one cutting element to a surface of a cone, and depositing a hard facing layer on at least one cutting element prior to the attaching.

Abstract: A multi-stage diffuser nozzle for use as a drill bit nozzle jet includes a flow restriction portion upstream of a fluidic distributor portion, and also preferably includes a transition region between these two. The flow restrictor communicates with the interior fluid plenum of a drill bit and is used to limit or restrict the total flow of drilling fluid by having a relatively small cross-sectional area for fluid flow. The fluidic distributor communicates with the flow restrictor and reduces the exit flow velocities of the drilling fluid as the drilling fluid is ejected from the nozzle by providing a relatively larger cross-sectional area for fluid flow. The fluidic distributor also directs the flow paths of the drilling fluid to locations such as cone surfaces that are prone to bit balling. The transition region is an area that dampens fluid pressure oscillations in the drilling fluid.

Abstract: A roller cone drill bit is disclosed which includes a bit body adapted to be coupled to a drill string, a bearing journal depending from the bit body and a single roller cone rotatably attached to the journal. The roller cone has a plurality of inserts disposed thereon. In one aspect, the inserts have an extension length of at least 0.6 inches. A roller cone drill bit is disclosed, including a bit body, a bearing journal depending from the bit body, and a single roller cone rotatably attached to the journal. The roller cone has a plurality of inserts disposed thereon. In another aspect, the inserts are arranged such that at most about 20 percent of the inserts are crossed substantially at centerlines thereof by any single plane which contains the axis of the cone axis 10 and which crosses at least two of the inserts.

Abstract: Self relieving seals of this invention comprise an elastomeric seal body having a first sealing surface and a second sealing surface for contact with respective drill bit sealing surfaces. The seal includes a pair of external surfaces that each extend along the seal body between the first and second sealing surfaces. The seal includes one or more relief ports that are disposed through the seal body and that have openings through each of the seal body external surfaces. The relief port can be specially configured, e.g., have different diameter sections of constant or variable dimensions, to provide a degree of control over pressure equalization through the seal body when the seal is loaded within the drill bit. The seal may include an element, e.g., solid, tubular, or porous, disposed within the relief port to provide a further desired degree of control over pressure equalization through the seal when the seal is loaded within the drill bit.

Abstract: A roller cone drill bit is disclosed which includes a bit body adapted to be coupled to a drill string, a bearing journal depending from the bit body and a single roller cone rotatably attached to the journal. The roller cone has a plurality of inserts disposed thereon. In one aspect, the inserts have an extension length of at least 0.6 inches. A roller cone drill bit is disclosed, including a bit body, a bearing journal depending from the bit body, and a single roller cone rotatably attached to the journal. The roller cone has a plurality of inserts disposed thereon. In another aspect, the inserts are arranged such that at most about 20 percent of the inserts are crossed substantially at centerlines thereof by any single plane which contains the axis of the cone axis 10 and which crosses at least two of the inserts.

Abstract: A roller cone drill bit is disclosed which includes a bit body adapted to be coupled to a drill string. A bearing journal depends from the bit body. A single roller cone is rotatably attached to the bearing journal. The roller cone has a plurality of inserts disposed at selected positions about the cone. The journal defines a rotation angle with respect to an axis of rotation of the bit such that the roller cone includes a wall contact zone and a bottom contact zone. At least one of the inserts disposed in the wall contact zone has an extension portion terminating in a substantially planar upper surface.

Abstract: An insert for a drill bit is disclosed which includes an exposed surface having a contact portion adapted to periodically contact earthen formation. The contact portion includes a polycrystalline diamond material having a hardness in the range of about 2000 HV to about 3000 HV. In some embodiments, the polycrystalline diamond material includes a composite having a first phase material including polycrystalline diamond and a second phase material selected from the group of oxide particulates metal carbides, and metallic particulates, nitrides, and mixtures of thereof.

Abstract: A drill bit having one or more nozzle retention bodies attached by a single orientation mounting is disclosed, as is the associated method for its manufacture. The upper end of the nozzle retention body has a fluid inlet in communication with the internal fluid plenum of the drill bit, and the lower end of the nozzle retention body includes a fluid outlet that defines an exit flow angle. The exit flow angle is angularly disposed from the longitudinal axis of the drill bit. The nozzle retention body may advantageously be chamfered or the like to provide a reduced cross-sectional area at the lower end of the nozzle retention body. The outer surface of the nozzle retention body (and attached hardened elements) may extend substantially to gage, or may fall short of that diameter.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a cutting layer. The substrate comprises a grip portion and an extension portion, where the grip portion has an insert axis and an extension portion including an interface surface having a first apex. The cutting layer is affixed to the interface surface and has a cutting surface having a second apex. The cutting layer is shaped such that when a plane passing through the first apex and lying parallel to the insert axis and normal to a radius from the insert axis, the plane divides the cutting layer into major and minor portions and the major portion has a major volume that is at least 60 percent of the total volume of said cutting layer. Alternative embodiments of the present invention include variations wherein the first and second apices do not coincide and wherein the interface surface of the substrate is not axisymmetric. Using these variations, cutter elements having sizeable variations in thickness are constructed.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: An insert for a drill bit is disclosed which includes an exposed surface having a contact portion adapted to periodically contact earthen formation. The contact portion includes a polycrystalline diamond material having a hardness in the range of about 2000 HV to about 3000 HV. In some embodiments, the polycrystalline diamond material includes a composite having a first phase material including polycrystalline diamond and a second phase material selected from the group of oxide particulates metal carbides, and metallic particulates, nitrides, and mixtures of thereof.

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.

Abstract: A drill bit having a canted or non-canted leg backface, a canted or non-canted seal in the interface between the cone backface and the shirttail, and a canted seal that can be semi-encapsulated so that there is no straight-line path across the seal.

Abstract: A nozzle and retainer assembly is provided for use in a rotary cone earth boring bit that allows for a larger internal passage in the nozzle. In one aspect, the assembly has a nozzle seated on a shoulder in a receptacle with a stepped portion extending radially outward with a first nozzle shoulder spaced from and facing toward the shoulder in the receptacle to partially define a seal gland. The stepped portion has a second nozzle shoulder facing toward the open end of the receptacle and the retainer engages the inside surface of the receptacle and the second nozzle shoulder to retain the nozzle in the receptacle.

Abstract: A polycrystalline diamond enhanced insert is disclosed. The insert includes a body portion adapted for attachment to an earth-boring bit and a top portion for contacting an earthen formation. The top portion of the insert is provided with two different compositions of polycrystalline diamond. In the primary surface of the top portion, a tougher or less wear-resistant polycrystalline diamond layer is provided, whereas a more wear-resistant polycrystalline diamond layer is provided in the remaining region of the top portion. In addition to polycrystalline diamond, polycrystalline boron nitride and other superhard materials also may be used.

Abstract: Superhard material enhanced inserts include a body portion adapted for attachment to the earth-boring bit and a top portion for contacting an earthen formation to be drilled. The top portion includes a substrate and a layer of superhard material over a portion of the substrate other than in the outer lateral face. For example, superhard material is provided on the leading edge, the leading face, the crest, the trailing edge, and the trailing face, but not on a portion of the outer lateral face of the top portion. Suitable superhard materials include boron nitride and diamond.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: Dual functioning seals for use in forming a lubricant seal in a rotary rock bit comprise an annular elastomeric seal body having a dynamic seal surface for sealing against a dynamic surface and a static seal surface for sealing against a static surface. The seal body has an asymmetric axial cross-sectional geometry the dynamic seal surface having a greater radius of curvature than that of the static seal surface. The dynamic and static seal surfaces are formed from different elastomeric materials, and the dynamic seal surface is formed from an elastomeric material that is harder and more wear resistant than the elastomeric material used to form the static seal surface. A rotary rock bit seal constructed in this manner is well adapted to accommodate the different operating conditions and sealing requirements that exist both at the dynamic and static surfaces of the seal to ensure optimal seal performance and, thereby enhance the service life of the rock bit.