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 rotary drill bit includes cutters arranged in a series of concentric rings, the cutters of one of the rings having a different wear resistance to the cutters of another of the rings with the result that the stability of the drill bit improves with wear. Although the wear resistance is different, the cutters have substantially the same impact toughness.

Abstract: A rotary cone bit, having a functionally-engineered surface of this invention, comprises a bit body having at least one leg extending therefrom, and a cone that is rotatably disposed on the leg. The cone typically comprises a plurality of cutting elements that project outwardly therefrom. The cutting elements comprises a cermet material selected from the group consisting of refractory metal carbides, nitrides, borides, carbonitrides and mixtures thereof. A functionally-engineered material is disposed over a surface portion of at least one of the cutting elements to form a wear resistant surface thereon. The wear resistant surface has a hardness that is different than that of the underlying cutting element. The wear resistant surface is provided by forming a conformable material mixture by combining one or more powders selected from the group consisting of cermets, carbides, borides, nitrides, carbonitrides, refractory metals, Co, Fe, Ni, and combinations thereof, with an applying agent.

Abstract: There is now provided a twist drill having an elongate body at a first end, a shank at a second and opposite end, the elongate body and the shank sharing a common axis, at least one face on the elongate body at an end opposite the shank, wherein the at least one face defines a corresponding flute extending along the elongate body toward the shank, at least one flank on an end of the elongate body at an end opposite the shank, and a cutting edge at a juncture of the at least one face and the at least one flank, and the like tools, having a sintered cemented carbide body, and the use thereof in material removing and dislodging tools.

Abstract: Composite constructions of this invention comprise a first structural phase formed from a hard material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof, and a second structural phase formed from a material that is relatively softer than that used to form the first structural phase. The material selected to form the second structural phase can be the same or different from that used to form the first structural phase. The second structural phase is positioned into contact with at least a portion of the first structural phase. The composite construction includes repeated structural units that each comprise an ordered microstructure of first and second structural phases.

Abstract: Using inserts which are welded in place allows the use of hardfacing in the immediate vicinity of the inserts. Areas of high wear, such as cutting structures and gage areas, can use a combination of ultra-hard inserts with hardfacing for protection against wear. The inserts slows wear, while the hardfacing prevents erosion around the inserts.

Abstract: A drill bit is provided for drilling holes in hard, reinforced material, including reinforced concrete. According to one aspect of the invention, wear-resistant inserts are provided in a cross-shaped pattern. The inserts ensure that the entire bottom surface of the drilled hole is engaged during each drill bit revolution. The inserts may be secured in pockets or slots. Fluid entry ports may be located between the inserts for efficient handling of drilling fluid and removal of drilled material, without impairing the structural integrity of the drill bit. According to another aspect of the invention, the drilling surface is separated into two or more stages to increase drilling efficiency, especially through composite material such as reinforced concrete.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.

Abstract: A rotary cone drill bit includes at least one leg carrying a journal provided with bearing surfaces cooperating via bearing elements with bearing races in a rotatable cone cutter. The cone cutter is provided with rows of crushing elements. Each crushing element has a greatest width (D) and a greatest height (H), wherein HID<1.2. The crushing elements are welded to the body of the cone cutter to form a metallurgical bond therewith.

Abstract: This invention relates to a roller bit applying for the oil, natural gas, mine and geological drilling, and more particularly relates to a kind of roller bit with the parallel inlayed compacts, it includes head and cone, the compact land and the teeth-groove are arranged on the cone, the difference is that there are 2 to 3 compacts having the cylindrical body being arranged on the top of the base teeth along the teeth direction. The cutting performance of the present invention is similar to that of the oblate compacts, and, by utilizing the conventional cylindrical compacts, it is not only easy to process and with low manufacturing cost, but the bit can effectively drill through the stringered earth formation with both hard and soft formation and thus better economic benefit from drilling the stringered formation can be obtained.

Abstract: An earth-boring bit comprises a bit body bit body in which are mounted a plurality of cutting structures inserts, wherein at least a portion of the cutting structures comprise diamond-impregnated inserts having a total thermal exposure of less than 25 minutes above 1500° F. The diamonds can be natural or synthetic diamond. The bit body itself may be diamond-impregnated, in which case it is preferred that the diamonds in the inserts make up at least 40% of the total diamond in the bit.

Abstract: A cutting element having a cutting table made from sheet segments of commingled ultra hard material and binder. Each segment may be made from a finer or a coarser grade of ultra hard material or from different types of ultra hard material. The segments are aligned side by side over a cutting face of the cutting element to form the cutting table. The material grade and/or the material type of each segment may alternate across the cutting face.

Abstract: A rotatable cutting bit for penetrating an earth formation wherein the rotatable cutting bit includes an elongate bit body having a forward end and a rearward end. The bit body further defines a peripheral surface. The bit body has a first cutting insert affixed thereto at the axially forward end thereof. The first cutting insert has a first leading cutting edge and a first side clearance cutting edge. The first cutting insert is attached to the bit body so that the first side clearance cutting edge radially extends past the peripheral surface of the bit body so as to engage the earth formation.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.

Abstract: A rotary drag bit and method for drilling subterranean formations including a bit body being provided with at least one cutter thereon exhibiting reduced, or limited, exposure to the formation so as to control the depth-of-cut of the at least one cutter, so as to control the volume of formation material cut per bit rotation, as well as to control the amount of torque experienced by the bit and an optionally associated bottomhole assembly regardless of the effective weight-on-bit. The exterior of the bit preferably includes a plurality of blade structures carrying at least one such cutter thereon and including a sufficient amount of bearing surface area to contact the formation so as to generally distribute the weight of the bit against the bottom of the borehole without exceeding the compressive strength of the formation rock.

Abstract: A cutter element for a drill bit has a non-rectilinear crest. The cutter element has a base portion and an extending portion and the extending portion has either a zero draft or a negative draft with respect to the base portion. The non-positive draft allows more of the borehole bottom to be scraped using fewer cutter elements. The cutter elements having non-positive draft can be either tungsten carbide inserts or steel teeth.

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: The invention provides a rotary drag-type drill bit in which the relationship of torque to rotary bit speed is such that torque generally increases with bit speed. Such a bit has a reduced tendency to exhibit the phenomenon known as “stick-slip” while drilling, when compared with bits having a different torque /speed characteristic, as a result of the positive damping effect of the torque/speed relationship. One method of designing such a drill bit comprises ascertaining the torque/rotary bit speed relationship, or other correlated relationships, for a number of different drill bit designs and then selecting from those designs a design having the desired type of relationship. Examples of drill bit structures specifically designed to achieve the desired torque/speed relationship are also disclosed.

Abstract: A roller cone for a rock bit is disclosed. The cone includes a cone substrate and hardfacing applied by a welding process in grooves on the exterior surface of the cone substrate. The cone also includes hardfacing applied by a thermal spraying process to insert lands on the exterior surface of the cone substrate.

Abstract: An insert for a rolling cone earth-boring bit has a cylindrical base that interferingly presses into a mating hole formed in a cone of the bit. The insert has a convex end that extends from the base. A polycrystalline diamond cap is bonded to the convex end. The body is formed of at least two layers of carbide material having different mechanical properties, particularly a different modulus of elasticity. The first layer may have a metallic binder with a lesser percentage than the binder of the second layer to reduces the stress at the interface between the first layer and the diamond cap. The layers may have different average carbide average grain sizes, with finer average grain sizes adjoining the diamond cap. Further, the layers may have different binders, with cobalt being the binder in the layer adjoining the diamond cap and either nickel or a nickel-cobalt alloy in another layer.

Abstract: A rotary cone drill bit is provided with at least one cutter cone assembly having a machined cutting structure which will maintain an effective cutting profile despite abrasion, erosion and/or wear of the associated cutting elements. The machined cutting structure may be formed on a generally cone shaped blank by a series of lathe turns and/or plunge cuts. The cutting elements may be formed with an aggressive cutting profile. For one application, the crest of each cutting element has the general configuration of an ogee curve. A layer of hardfacing material may be applied over all or selected portions of the machined cutting structure.

Abstract: An earth-boring device such as a drill bit is disclosed. The earth boring device includes a rotary main cutting structure, an insert on the main cutting structure. The insert is formed of a composition having tungsten carbide and cobalt. The cobalt makes up less than approximately 9% by weight of the composition. The composition has a Rockwell A hardness greater than approximately an Hmin as determined by the following formula: Hmin=91.1−0.63X, where X represents a cobalt content by weight of the composition.

Abstract: A cutting element for use on a rotary-type earth boring drill bit for drilling subterranean formations including a segment and a support member. The support member is preferably fabricated from a tough and ductile material, such as iron, an iron-based alloy, nickel, a nickel-based alloy, copper, a copper-based alloy, titanium, a titanium-based alloy, zirconium, a zirconium-based alloy, silver, or a silver-based alloy. A bit attachment portion of the support member is securable to a bit body. A segment-receiving portion of the support member is disposable within a recess formed in the segment to secure the segment to the bit body and support the segment during use of the drill bit. Preferably, the segment is fabricated from a hard continuous phase material that is impregnated with a particulate abrasive material, such as natural diamond, synthetic diamond, or cubic boron nitride.

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: An excavating tool has a tungsten carbide insert which is more wear resistant and not subject to breakage because of bring too brittle. The insert has a semispherical tip, a divergent midsection and a base with a conical rear surface. The insert is made with tungsten carbide particles sized between 1 and 8 microns and averaging between 2 and 5 microns, blended with particles of a binder of which the binder comprises 5.5 to 6.5 percent of the blend by weight, and the insert is sintered to a hardness of 89.5 Ra or more.

Abstract: A superabrasive cutting element, the substrate of which is structured with a reduced dimension circumferential portion about which is formed an annular portion of superabrasive material, such as sintered diamond in the form of a polycrystalline diamond compact, to provide a ring- or skirt-like portion of superabrasive material at the perimeter of the cutting element to reduce residual tensile stresses existing at the perimeter of the cutting element after formation.

Abstract: Thermal fatigue and shock resistant materials have been disclosed. Such materials have a thermal conductivity exceeding a minimal value as determined by Kmim=0.00102X2−0.03076X+0.5464, where Kmin is minimal thermal conductivity in the units of cal/cm·s·°K, and X is cobalt weight percentage. Cemented tungsten carbide with coarse tungsten carbide grains and a low cobalt content meet this criterion. The thermal conductivity of this type of cemented tungsten carbide may be further enhanced by using tungsten carbide of coarser grains and higher purity. By adjusting the tungsten carbide grain size and the cobalt content, a desired toughness and hardness may be achieved while still maintaining a relatively high thermal conductivity. Such materials have applications in forming inserts and other cutting elements.

Abstract: A drill for forming bores in constructional components, and including a sleeve-shaped stem (2; 12; 22; 32; 42; 52) having an axially-extending through-bore (3; 13; 23; 33; 43; 53) which opens into mouth openings (7; 10; 14; 24; 34; 44; 54) formed in opposite end sections of the stem (2; 12; 2; 32; 42; 52); a shank (5) provided at a rear end of the stem, and a drilling head (8; 15; 25; 35; 45; 55) formed of a hard material and secured in at least one slot (19; 29; 49; 59) formed in a free front end of the stem (2; 12; 22; 32; 42; 52), with a section of the drilling head (8; 15; 25; 32; 45; 55), which is embedded in the stem (2; 12; 22; 32; 42; 52), flatly engaging a material of the stem (2; 12; 22; 32; 42; 52) and being fixedly connected with the stem material.

Abstract: A design for a gage tooth of the milled tooth variety is provided. The gage facing surface of each tooth is shaped so that only a narrow surface of each tooth contacts the borehole wall. Adjacent areas on each tooth slope away from the wall. The narrow gage facing surfaces, the sloping areas, and other areas are all covered with a suitable hard metal facing material.

Abstract: A hard member for use as a wear part or a hard insert for a point attack style of tool or a rotary style of tool. The hard member having a composition of between about 5 volume percent and about 40 volume percent binder alloy, and between about 60 volume percent and about 95 volume percent tungsten carbide. The tungsten carbide has an average grain size between about 1 micrometer and about 30 micrometers. The binder alloy comprises an alloy of nickel and chromium wherein the nickel ranges between about 70 weight percent and less than 93 weight percent and the chromium ranges between greater than 7 weight percent and about 30 weight percent.

Abstract: An insert is provided for a rock bit for drilling bore holes in the ground and other downhole tools. The cutting portion of the inserts consist of encrusted cubic boron nitride pellets, tungsten carbide particles and a binder material which are fused together to form a unitary body. The cubic boron nitride particles of the fused insert are cubic in structure and substantially free of heat degradation and resultant hexagonal crystalline structure in response to fusing the elements together in a single step of simultaneously heating and compacting the elements.

Abstract: A wellbore mill has been invented that, in certain aspects, has a body having a top and a bottom and, optionally, a fluid flow channel extending therethrough from top to bottom with, optionally, one or more fluid jetting ports in fluid communication with the fluid flow channel, milling apparatus on the body including a plurality of milling inserts, each insert mechanically secured in a corresponding recess in the body, said mechanical securement sufficient for effective milling in a wellbore. A wellbore milling method for milling an opening in a selected tubular of a tubular string in a wellbore has been invented that includes installing and using such a mill.

Abstract: A method for applying cutting elements to a tool for cutting or milling a metal item in a well, along with the cutting element used in the method. The tool can include one or more blades extending outwardly or downwardly from the tool for cutting a metal item such as the wall of a casing string, or for removing a predetermined length of a casing string in a cutting action. The blade or blades have cutting elements positioned on the leading faces of the blades to engage the casing string or other metal item in the bore hole. Each cutting element is composed of a plurality of effective cutting faces. Each cutting face can have a substantially triangular shape, or a substantially square shape, or some other geometric shape. The cutting elements can be arranged in a random pattern. Each cutting element can be oriented in a random orientation relative to the blade.

Abstract: A wear resistant cutter insert structure and method include a stud having at least one face. A primary tapered ridge and at least one secondary tapered ridge extending from the primary tapered ridge are formed in the face. A layer of abrasive material is disposed over the face covering the primary and secondary tapered ridges.

Abstract: A preform cutting element, for a rotary drag-type drill bit, includes a facing table of polycrystalline diamond having a front face, a peripheral surface, and a rear surface bonded to the front surface of a tungsten carbide substrate. The facing table has at least one peripheral locking portion projecting rearwardly from the rear surface of the facing table into the substrate, the inner surface of the locking portion and the adjacent part of the substrate having interengaging formations whereby part of the substrate overlies at least one part of the locking portion. With this arrangement, forces acting on the facing table tending to lift it from the front surface of the substrate are resisted by the portion of the substrate which overlies the part of the locking portion.

Abstract: Formation engaging elements are moveably mounted onto a drill bit. Such elements may be used to protect other rigidly mounted formation engaging elements from impacts that occur during use of the drill bit, or they may be used to alter the aggressiveness of the drill bit when used in directional drilling operations.

Abstract: A preform element comprises a substrate having an outer peripheral surface and at least one end surface. At least a portion of the peripheral surface of the substrate has bonded thereto an inner surface of a peripherally extending facing layer of superhard material, such as polycrystalline diamond. The portion of the peripheral surface of the substrate and the inner surface of the peripheral facing layer are provided with inter-engaging formations, such as ribs and grooves, whereby the peripheral facing layer is keyed to the substrate.

Abstract: An earth-boring bit has a bit body with at least one bearing shaft depending inwardly and downwardly therefrom. A cutter is mounted for rotation on each bearing shaft and has a cutter shell surface and a plurality of cutting elements arranged on the shell surface in generally circumferential rows. A pair of surfaces extends from the cutter shell surface on opposing sides of one of the circumferential rows of cutting elements. The pair of surfaces converge together to define a kerf crest that is oriented transversely to the axis of rotation of the cutter. The kerf crest projects from the cutter shell surface by an amount less than the cutting elements in the kerf row having the kerf crest.

Abstract: The improved insert for a ground engaging tool, with a plurality of sockets for receiving a respective insert comprises a body having first and second portions and first and second zones. The first zone may consist of tungsten carbide and metallic cobalt, with preselected dimensions adapted for press fitting within a respective socket of the ground engaging tool. The second body portion may define an earth engaging portion. The second zone may consist of encrusted diamond pellets, tungsten carbide and metallic cobalt, fused together. The first and second zones may be fused together with the first zone being substantially free of encrusted diamond pellets.

Abstract: A drilling tool including a drilling head equipped with cutting edges and fitted with several shock-absorption elements, of which at least one part is made of an elastomer material. Each shock-absorption element having a block incorporating one portion inserted inside a receptor housing formed on the tool surface, and a portion which projects outward beyond the receptor housing.

Abstract: A polycrystalline diamond layer attached to a cemented metal carbide structure used as a cutter in a drill bit wherein the cutter has improved toughness or fracture resistance during use through the inclusion of boron, beryllium or the like therein.

Abstract: In one embodiment, composite constructions of the invention are in the form of a plurality of coated fibers bundled together to produce a fibrous composite construction in the form of a rod. Each fiber has a core formed from a hard phase material, that is surrounded by a shell formed from a binder phase material. In another embodiment of the invention, monolithic sheets of the hard phase material and the binder phase material are stacked and arranged to produce a swirled composite in the form of a rod. In still another embodiment of the invention, sheets formed from coated fibers are arranged to produce a swirled composite. Inserts for use in such drilling applications as roller cone rock bits and percussion hammer bits, and shear cutters for use in such drilling applications as drag bits, that are manufactured using conventional methods from these composite constructions exhibit increased fracture toughness due to the continuous binder phase around the hard phase of the composites.

Abstract: An earth-boring bit has a bit body which connects to a drill string. Three cutters are rotatably secured to a bearing shaft of the bit and a large number of chisel-like cutting elements are secured to each cutter. Each cutting element has a cylindrical base and a cutting end. An elongate crest is located at the tip of the cutting end. A conical chamfer connects the crest and the cutting end. The junction created by the chamfer is non-tangential and reduces the amount of unsupported material at the crest. The conical contour of the chamfer is defined by by a straight line moving in an oval path about the longitudinal axis. The contour of the cutting end avoids abrupt changes and associated stress concentrations. This is achieved by avoiding surfaces of rotation in non-axisymmetric configurations.

Abstract: This invention is directed to cutting elements having an ultra hard cutting layer such as polycrystalline diamond or polycrystalline cubic boron nitride bonded on a cemented carbide substrate. The interface between the substrate and the cutting layer of each such cutting element is non-planar. The non-planar interface is designed to enhance the operating life of the cutting element by reducing chipping, spalling, partial fracturing, cracking and/or exfoliation of the ultra hard cutting layer, and by reducing the risk of delamination of the cutting layer from the substrate.

Abstract: A rotary drill arrangement comprising a combination spade drill body having a rotational axis, a shank portion, and a generally planar spade cutter portion with a pair of oppositely directed cutting edges extending radially of the axis, and a rotatable frusto conical cutter mounted on the spade cutter portion adjacent the maximum radial extent of each cutting edge.

Abstract: A rotary drill bit comprises a bit body having a leading surface formed at least in part from solid infiltrated matrix material, a major part of the leading surface being impregnated with abrasive particles of diamond or other superhard material. There are also mounted at the leading surface a plurality of larger cutting elements having cutting edges formed of superhard material which project above the surface, the larger cutting elements being so spaced as to define a substantially continuous cutting profile, so that the cutting elements in combination sweep over the whole of a bottom of a hole being drilled by the bit, during each revolution. The abrasive particles normally carry out the majority of the drilling action in hard formations, but the larger cutting elements serve to cut more rapidly through temporary obstructions which may be encountered in the borehole, such as a shoetrack.

Abstract: A method of manufacturing preform elements comprises the initial step of forming a preliminary component including a facing table of superhard material having a front face, a peripheral surface, and a rear surface bonded to a less hard substrate. The rear surface of the facing table and the front surface of the substrate are formed with inter-engaging projections and recesses to provide a non-planar interface between the substrate and facing table. There are then cut from the preliminary component a plurality of separate preform elements each having a facing table and substrate with a non-planar interface between them. The configuration of the non-planar interface of the preliminary component may vary with distance from its center, so that the non-planar interface of each preform element also varies in configuration across the width of the element.

Abstract: Drill bit cutters and drill bits equipped with the cutters. The cutter is mounted on a bit to present the formation with a radiused, curving, side wall cutting face that is concave in one dimension and convex in another dimension. In a preferred form, the cutting face is in the form of a portion of a surface of revolution generated by an arc segment that is concave relative to the axis of revolution. The cutting face is formed on a layer of polycrystalline diamond disposed on a substrate of tungsten carbide. In another side wall cutter arrangement, a standard cylindrical cutter with a diamond cap is mounted to present the curved cylindrical side of the cap to the formation. Curved side wall cutting faces cut more efficiently than the usual flat end face of conventionally mounted cutters. A major portion of the diamond volume in a side mounted cutter trails the point of cutting face engagement with the formation to provide impact resistance and an increased diamond wear area.