Abstract: An additively manufactured metal matrix composite (MMC) includes hard particles and a binder. The hard particles are greater than 27 vol % of the MMC, and are spherically shaped. The binder includes at least nickel and silicon. The binder is less than 73 vol % of the MMC. The silicon is more than 6.0 wt % of the binder yet less than 12.5 wt % of the binder. A transverse rupture strength (TRS) of the MMC is greater than 200 ksi, and the erosion resistance factor is greater than 30.

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 bit may include a matrix portion, the matrix portion exposed at a cone region and a nose region of the bit. A bit may include a steel portion, the steel portion including a bit connection, the steel portion exposed at a gauge region of the bit. A bit may include a plurality of cutting elements secured to the matrix portion at the cone region and the nose region.

Abstract: A method for extracting germanium based on acid decomposition is provided, including acid decomposition and post-treatment steps, and specifically including: adding an acid to a coal ash for conditioning to obtain a material a; heating the material a to 350° C. to 800° C., and keeping the material a at this temperature for 10 min to 10 h to obtain an acid-decomposed material b; milling the acid-decomposed material b until more than 60% of a milled material has a particle size of less than 200 mesh to obtain a material c; subjecting the material c to distillation to obtain a residual slurry d and a distillation fraction e; and hydrolyzing the distillation fraction e with a dilute hydrochloric acid solution, and then oven-drying to obtain GeO2.

Abstract: A method for extracting germanium based on acid decomposition is provided, including acid decomposition and post-treatment steps, and specifically including: adding an acid to a coal ash for conditioning to obtain a material a; heating the material a to 350° C. to 800° C., and keeping the material a at this temperature for 10 min to 10 h to obtain an acid-decomposed material b; milling the acid-decomposed material b until more than 60% of a milled material has a particle size of less than 200 mesh to obtain a material c; subjecting the material c to distillation to obtain a residual slurry d and a distillation fraction e; and hydrolyzing the distillation fraction e with a dilute hydrochloric acid solution, and then oven-drying to obtain GeO2.

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 bit may include a matrix portion, the matrix portion exposed at a cone region and a nose region of the bit. A bit may include a steel portion, the steel portion including a bit connection, the steel portion exposed at a gauge region of the bit. A bit may include a plurality of cutting elements secured to the matrix portion at the cone region and the nose region.

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 method for reducing stress in a downhole tool. The method includes varying a temperature of the downhole tool by at least 5° C. Vibrational energy may be transferred to the downhole tool with a vibration device coupled to the downhole tool. The vibrational energy may cause the downhole tool to move with a frequency from about 10 Hz to about 5 kHz.