Abstract: The disclosed drill tools have metal matrix composite (MMC) or steel alloy bodies that are formed around one or more pre-fabricated components using either a casting or infiltration process. The pre-fabricated components are made of sintered, infiltrated, and/or cemented particles of an ultrahard material, and may form any suitable portion of the bit blades. The pre-fabricated components may be loaded into a machined mold, and the mold cavity is subsequently filled with powder, such as tungsten carbide powder, filler metal powder, binder metal powder, or combinations thereof. During a casting or infiltration process, the mold and pre-fabricated components are heated to a sufficient temperature to melt the binder metal and/or filler metal, wherein the molten metal superficially interacts with the inner surfaces of the pre-fabricated components to form a metallurgical bond to secure the pre-fabricated components to the bit body.

Abstract: A blade on a downhole drilling tool includes a blade body and a blade cover. The blade cover is pre-sintered and conforming to the blade outer shape. The blade cover is attached to the blade body. The blade cover includes a seamless connection between a cover leading face and a cover outer face to reduce wear on the outer face of the blade.

Abstract: The disclosed drill tools have metal matrix composite (MMC) or steel alloy bodies that are formed around one or more pre-fabricated components using either a casting or infiltration process. The pre-fabricated components are made of sintered, infiltrated, and/or cemented particles of an ultrahard material, and may form any suitable portion of the bit blades. The pre-fabricated components may be loaded into a machined mold, and the mold cavity is subsequently filled with powder, such as tungsten carbide powder, filler metal powder, binder metal powder, or combinations thereof. During a casting or infiltration process, the mold and pre-fabricated components are heated to a sufficient temperature to melt the binder metal and/or filler metal, wherein the molten metal superficially interacts with the inner surfaces of the pre-fabricated components to form a metallurgical bond to secure the pre-fabricated components to the bit body.

Abstract: A drill bit includes a bit insert. A bit body of the bit includes an insert cavity. The bit insert is inserted into the insert cavity. The bit insert is secured to the insert cavity, such as by braze or with a connection mechanism. The bit insert may be replaceable, thereby allowing a drilling operator to adjust the configuration of the bit based on which bit insert is used.

Abstract: A blade on a downhole drilling tool includes a blade body and a blade cover. The blade cover is pre-sintered and conforming to the blade outer shape. The blade cover is attached to the blade body. The blade cover includes a seamless connection between a cover leading face and a cover outer face to reduce wear on the outer face of the blade.

Abstract: The disclosed drill tools have metal matrix composite (MMC) or steel alloy bodies that are formed around one or more pre-fabricated components using either a casting or infiltration process. The pre-fabricated components are made of sintered, infiltrated, and/or cemented particles of an ultrahard material, and may form any suitable portion of the bit blades. The pre-fabricated components may be loaded into a machined mold, and the mold cavity is subsequently filled with powder, such as tungsten carbide powder, filler metal powder, binder metal powder, or combinations thereof. During a casting or infiltration process, the mold and pre-fabricated components are heated to a sufficient temperature to melt the binder metal and/or filler metal, wherein the molten metal superficially interacts with the inner surfaces of the pre-fabricated components to form a metallurgical bond to secure the pre-fabricated components to the bit body.

Abstract: Systems, tools, and methods include using a milling assembly with a mill having multiple, different types of cutting element inserts. A gage region of the mill includes a first type of cutting element insert, and a shoulder region of the mill includes a second type of cutting element insert. One cutting element insert may include chip-breaking features, and the other may be a shear or gouging cutting element.

Abstract: Systems, tools, and methods include using a milling assembly with a mill having multiple, different types of cutting element inserts. A gage region of the mill includes a first type of cutting element insert, and a shoulder region of the mill includes a second type of cutting element insert. One cutting element insert may include chip-breaking features, and the other may be a shear or gouging cutting element.

Abstract: A downhole tool includes a body having a bore extending at least partially therethrough. A component is disposed within the bore and arranged and designed to move axially from a first position to a second position within the bore. An axial end portion of the component has a first contact surface that is oriented at an angle from about 1° to about 45° with respect to a longitudinal axis extending through the component.

Abstract: A downhole tool is disclosed for measuring wellbore geometry. The downhole tool may include a body with a bore extending at least partially therethrough. The body may include a radial recess. An arm may be movably coupled to the body at a first end portion of the arm. The arm may be within the radial recess in a retracted position and be pivotable in a radially-outward direction relative to the body to an expanded position. A measurement device coupled to the body may measure the pivoting motion of the arm. A piston coupled to the body may be movably coupled to a second end portion of the arm, and the piston may respond to changes in hydraulic pressure to pivot the arm between the retracted position and the expanded position.

Abstract: A downhole tool includes a body having a bore extending, at least partially therethrough. A component is disposed within the bore and arranged and designed to move axially from a first position to a second position within the bore. An axial end portion of the component has a first contact surface that is oriented at an angle from about 1° to about 45° with respect to a longitudinal axis extending through the component.

Abstract: A downhole tool includes a first portion having a first metal protrusion configured to seal against a first metal surface and a second portion having a second metal protrusion configured to seal against a second metal surface. A ratcheting device includes a first element having a plurality of grooves, and a second element having at least two sets of teeth, wherein one of the at least two sets of teeth engages the plurality of grooves. Additionally, a method of forming a downhole seal includes disposing in a wellbore a downhole tool including an inner tubular, a lock ring, a lower ring, an upper ring, an insert ring, and a deformable element. The method further includes moving a wedge sleeve axially downward with respect to the downhole tool such that the wedge sleeve engages the deformable ring and forces a first metal protrusion on the deformable element into contact with an outer tubular.

Abstract: A sealing element for a rotating control device is disclosed, wherein the sealing element has an inner surface which forms a drillstring bore extending axially through the sealing element, an attachment end having a receiving cavity extending into the attachment end substantially parallel with the drillstring bore, a nose end opposite from the attachment end, wherein the nose end has an inner diameter smaller than the inner diameter of the attachment end, a throat region between the attachment end and the nose end, at least one soft elastomer region comprising a soft elastomer material having a hardness of 70 duro or less, and at least one stiff elastomer region comprising a stiff elastomer material having a hardness greater than 70 duro.

Abstract: A sealing element for a rotating control device is disclosed, wherein the sealing element has an inner surface which forms a drillstring bore extending axially through the sealing element, an attachment end having a receiving cavity extending into the attachment end substantially parallel with the drillstring bore, a nose end opposite from the attachment end, wherein the nose end has an inner diameter smaller than the inner diameter of the attachment end, a throat region between the attachment end and the nose end, at least one soft elastomer region comprising a soft elastomer material having a hardness of 70 duro or less, and at least one stiff elastomer region comprising a stiff elastomer material having a hardness greater than 70 duro.

Abstract: A seal assembly for sealing between a journal shaft and a rotating cone cutter of a drill bit. In an embodiment, the seal assembly comprises a seal gland positioned between the journal shaft and the cone cutter. In addition, the seal assembly comprises an annular seal body disposed about the journal shaft within an annular recess. The seal body comprises a dynamic sealing surface at its outer diameter D1 that forms a dynamic seal with the sealing surface of the recess and a static sealing surface at its inner diameter D2 that forms a static seal with an outer bearing surface of the journal shaft.

Abstract: A downhole tool includes a first portion having a first metal protrusion configured to seal against a first metal surface and a second portion having a second metal protrusion configured to seal against a second metal surface. A ratcheting device includes a first element having a plurality of grooves, and a second element having at least two sets of teeth, wherein one of the at least two sets of teeth engages the plurality of grooves. Additionally, a method of forming a downhole seal includes disposing in a wellbore a downhole tool including an inner tubular, a lock ring, a lower ring, an upper ring, an insert ring, and a deformable element. The method further includes moving a wedge sleeve axially downward with respect to the downhole tool such that the wedge sleeve engages the deformable ring and forces a first metal protrusion on the deformable element into contact with an outer tubular.

Abstract: A drill bit and seal assembly therefor include a seal gland, an elastomeric sealing seal disposed in the seal gland and having a dynamic sealing surface and a static sealing surface, and at least one auxiliary elastomeric annular seal member disposed between the static sealing surface of the sealing seal and the seal gland. The auxiliary annular seal member serves to prevent relative movement of the sealing seal relative to the surfaces of the seal gland and to permit sealing seals of various cross-sections and shapes to adapt to and function with a conventionally sized and shaped gland. The auxiliary annular seal member is sized and configured and its material properties selected so as to impart the appropriate squeeze to the sealing seal to provide the desired contact pressure and footprint. Choice of the appropriate auxiliary seal member may permit the same sized seal to be employed in seal glands of differing sizes.

Abstract: A seal assembly for sealing between a journal shaft and a rotating cone cutter of a drill bit. In an embodiment, the seal assembly comprises a seal gland positioned between the journal shaft and the cone cutter. In addition, the seal assembly comprises an annular seal body disposed about the journal shaft within an annular recess. The seal body comprises a dynamic sealing surface at its outer diameter D1 that forms a dynamic seal with the sealing surface of the recess and a static sealing surface at its inner diameter D2 that forms a static seal with an outer bearing surface of the journal shaft.

Abstract: Sealing arrangements for a rotary cone rock-bit comprising a leg extending from a bit body and a cone rotatably mounted to the leg. A seal is disposed radially between the cone and the leg. A footprint defines an area of contact between the seal and the leg. Compression of the seal generates a contact pressure between the seal and the leg. An axial centerline evenly bisects the footprint into a mud side and a grease side. A contact pressure profile defines the contact pressure over the footprint, wherein the contact pressure on the mud side of the footprint is greater than the contact pressure on the grease side of the footprint.

Abstract: A drill bit and seal assembly therefor include a seal gland, an elastomeric sealing seal disposed in the seal gland and having a dynamic sealing surface and a static sealing surface, and at least one auxiliary elastomeric annular seal member disposed between the static sealing surface of the sealing seal and the seal gland. The auxiliary annular seal member serves to prevent relative movement of the sealing seal relative to the surfaces of the seal gland and to permit sealing seals of various cross-sections and shapes to adapt to and function with a conventionally sized and shaped gland. The auxiliary annular seal member is sized and configured and its material properties selected so as to impart the appropriate squeeze to the sealing seal to provide the desired contact pressure and footprint. Choice of the appropriate auxiliary seal member may permit the same sized seal to be employed in seal glands of differing sizes.