Abstract: A drill bit including at least one stress-relieved cutting element, wherein the at least one cutting element is mounted on the drill bit, wherein the stress-relieved cutting element includes a substrate, at least one transition layer disposed upon the substrate and a polycrystalline diamond layer having a thickness of at least 0.008 inches disposed upon the at least one transition layer.

Abstract: Roller cone bits of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each project outwardly a distance therefrom. At least one of the cutting elements comprises a steel base portion that is integral with the cone and that projects a distance therefrom. A cutting element end portion is attached to the base portion and extends therefrom to form a tip of the cutting element. The base and end portions are permanently attached together when the cone and base are in a preexisting rigid state. The cutting element end portion is formed from a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: A drill bit having a bit body, at least one roller cone attached to the bit body and able to rotate with respect to the bit body, and a plurality of cutting elements disposed on the at least one roller cone is disclosed. At least one of the plurality of cutting elements includes a first area defining a trailing edge, a second area proximate the first area defining a main wear surface, and a third area proximate the second area and defining a leading edge relief zone. Further, an insert for a drill bit having a contact portion adapted to contact an earth formation, the contact portion including a first area defining a relieved trailing edge, a second area defining a main wear surface, and a third area proximate the second area and defining a leading edge relief zone.

Abstract: A drill bit assembly has a bit body intermediate a shank and a working face. At least one wear resistant insert is press-fitted within a pocket formed in an outer surface of the bit. An urging element is disposed between the outer surface and a bore of the bit and the urging element is adapted to push the insert away from the bore.

Abstract: Casing bits include a crown having a substantially hollow interior. The bit crown has blades over a face portion thereof, the blades including a plurality of cutting elements attached thereto. The bit crown further includes a composite inlay positioned at least within the substantially hollow interior. Casing bits also include case hardened outer surfaces radially outside the drill-out region. Casing bits further include short-substrate cutting elements. Methods of forming a casing bit are also disclosed.

Abstract: Hardened metal inserts are inserted in a tine plate of a tamping tine for tamping ballast of a railroad track. The cylindrical inserts have a boundary surface bordering on a side surface of the tine plate, thus forming a part thereof. Owing to that configuration, the abrasion resistance of the side surfaces can be improved.

Abstract: In one aspect of the invention, a wear resistant assembly has at least one hard insert disposed within a recess formed within a surface. A hard material substantially surrounds the hard insert and is also disposed within the surface. The hard material is separated from the insert by an intermediate material softer than both the insert and the hard material.

Abstract: A rotary drag bit for drilling a subterranean formation includes a plurality of support elements affixed to the bit body, each forming at least a portion of a cutting element pocket. Each of a plurality of cutting elements has a substantially cylindrical body and is at least partially disposed within a cutter pocket. At least a portion of the substantially cylindrical body of each cutting element is directly secured to at least a portion of a substantially arcuate surface of the bit body. At least a portion of a substantially planar surface of each cutting element matingly engages at least a portion of a substantially planar surface of a support element.

Abstract: PCD composite constructions comprise a diamond body bonded to a substrate. The diamond body comprises a thermally stable diamond bonded region that is made up of a single phase of diamond crystals bonded together. The diamond body includes a PCD region bonded to the thermally stable region and that comprises bonded together diamond crystals and interstitial regions interposed between the diamond crystals. The PCD composite is prepared by combining a first volume of PCD) with a second volume of diamond crystal-containing material consisting essentially of a single phase of bonded together diamond crystals. A substrate is positioned adjacent to or joined to the first volume. The first and second volumes are subjected to high pressure/high temperature process conditions, during process the first and second volumes form a diamond bonded body that is attached to the substrate, and the second volume forms the thermally stable diamond bonded region.

Abstract: This invention relates to cutting inserts for earth boring bits comprising a cutting zone, wherein the cutting zone comprises first cemented hard particles and a body zone, wherein the body zone comprises second cemented hard particles. The first cemented hard particles may differ in at least one property from the second cemented hard particles. As used herein, the cemented hard particles means a material comprising hard particles in a binder. The hard particles may be at least one of a carbide, a nitride, a boride, a silicide, an oxide, and solid solutions thereof and the binder may be at least one metal selected from cobalt, nickel, iron and alloys of cobalt, nickel or iron.

Abstract: A hard composite cutting insert useful for cutting strata such as earth or rock that includes a body that is tough. The body contains a member that is harder than the body (i.e., has a harder region). The combination of the tough body with the harder member (or region) embedded therein provides a hard composite cutting insert with advantageous properties when used in conjunction with a bit body for impinging upon, and thereby disintegrating, the earth strata.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

Abstract: An abrasive-impregnated cutting structure for use in drilling a subterranean formation is disclosed. The abrasive-impregnated cutting structure may comprise a plurality of abrasive particles dispersed within a substantially continuous matrix, wherein the abrasive-impregnated cutting structure exhibits an anisotropic wear resistance. One or more of the amount, average size, composition, properties, shape, quality, strength, and concentration of the abrasive particles may vary within the abrasive-impregnated cutting structure. Anisotropic wear resistance may relate to a selected direction, such as, for example, one or more of an expected direction of engagement of the abrasive-impregnated cutting structure with the subterranean formation and an anticipated wear direction. Anisotropic wear resistance of an abrasive-impregnated cutting structure may be configured for forming or retaining a formation-engaging leading edge thereof.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: A cutting element and a method for forming a cutting element is described and shown. The cutting element includes a substrate, a TSP diamond layer, a metal interlayer between the substrate and the diamond layer, and a braze joint securing the diamond layer to the substrate. The thickness of the metal interlayer is determined according to a formula. The formula takes into account the thickness and modulus of elasticity of the metal interlayer and the thickness of the TSP diamond. This prevents the use of a too thin or too thick metal interlayer. A metal interlayer that is too thin is not capable of absorbing enough energy to prevent the TSP diamond from fracturing. A metal interlayer that is too thick may allow the TSP diamond to fracture by reason of bending stress. A coating may be provided between the TSP diamond layer and the metal interlayer. This coating serves as a thermal barrier and to control residual thermal stress.

Abstract: A cutting element for use with a drill bit includes a substrate having a longitudinal axis, a lateral surface substantially symmetric about the longitudinal axis and one or more key elements coupled to the lateral surface. The lateral surface lies between an insertion end and a cutting end of the substrate. The one or more key elements are substantially axially aligned with the longitudinal axis and configured to selectively rotationally locate the substrate in a pocket. A drill bit configured for retaining a cutting element having one or more key elements is also disclosed.

Abstract: Superabrasive inserts are disclosed. More particularly, a superabrasive insert may comprise a superabrasive layer bonded to a substrate at an interface. Further, the superabrasive layer may include a central substantially planar surface, a peripheral side surface, and an arcuate peripheral surface extending between the central substantially planar surface and the peripheral side surface. In one embodiment, the arcuate peripheral surface may comprise a lateral extent and an extension depth, wherein a ratio of the lateral extent to the extension depth is at least about 1.5. In another embodiment, an arcuate peripheral surface may comprise a substantially circular arc, wherein the substantially planar surface is tangent to the substantially circular arc and a tangent reference line to the substantially circular arc forms an angle of at least about 10° with the peripheral side surface. Subterranean drilling tools (e.g., drill bits) including at least one superabrasive insert are disclosed.

Abstract: A hardfacing composition for a drill bit that includes an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy is disclosed. Drill bits having hardfacing compositions that include an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy are also disclosed.

Abstract: A drill bit for cutting a borehole through an earthen formation comprises a bit body having a bit axis. In addition, the drill bit comprises a rolling cone cutter mounted on the bit body and adapted for rotation about a cone axis. Further, the drill bit comprises an insert having a base portion secured in the rolling cone cutter and having a cutting portion extending therefrom, the insert having an initial impact direction. The cutting portion of the insert has a cutting surface comprising a planar surface defining an extension height. Moreover, the cutting portion of the insert comprises an indentation extending at least partially through the upper planar surface, the indentation including a forward facing formation engaging surface and a lower surface defining a depth of the indentation.

Abstract: A tool for chip removing machining, including a basic body having a connecting surface included in an insert seat, and an indexable cutting insert mounted in the basic body and having a connecting surface in mechanical engagement with the connecting surface of the basic body, and fixed by a tightening element. The connecting surface of the basic body includes a solitary, polygonal elevation that protrudes from a bottom surrounding the elevation from all sides. The elevation includes two external side support surfaces orientated at an angle to each other. The connecting surface of the cutting insert includes a solitary depression that is wider and deeper than the elevation.

Abstract: High energy sheer cutting elements and bits incorporating the same are provided. The cutting elements have at least a portion of their cutting layers which will be exposed to high temperatures during drilling formed from a PCBN material capable of operating at temperatures of at least 1000° C.

Abstract: A fixed cutter drill bit and a method for designing a fixed cutter drill bit includes simulating the fixed cutter drill bit drilling in an earth formation. A performance characteristic of the simulated fixed cutter drill bit is determined. A side rake angle distribution of the cutters is adjusted at least along a cone region of a blade of the fixed cutter drill bit to change the performance characteristic of the fixed cutter drill bit.

Abstract: Cutting elements offering increased toughness and thermal fatigue resistance can be formed of a wear resistant material having coarse grains disposed in a binder matrix with a binder content of at least about 18% by weight. The coarse grains include grains of at least one selected from the group of a transition metal carbide, a transition metal boride, and transition metal nitride. The binder content and coarse grain size may be selected to provide a Rockwell A hardness of at least about 75 Ra or a wear number of at least about 1.5.

Abstract: This invention provides an improved cutting element for downhole cutting tools comprising a support element and a shearing element disposed on said support; a drill bit insert comprising a body and said cutting element disposed on said body; and a cutting tool, such as a hole opener or a reamer, comprising said cutting element and/or said drill bit insert. Also provided are methods for forming the said cutting element, drill bit insert and downhole cutting tools and a method for drilling mixed earth formation using the improved downhole cutting tools of the present invention.

Abstract: A composite body for cutting tools that includes a ductile phase; a plurality of carbide particles dispersed the ductile phase; and a plurality of nanotubes integrated into the composite body is disclosed. Methods of making such composite bodies and drill bits formed of such material are also disclosed.

Abstract: The present invention includes consolidated hard materials, methods for producing them, and industrial drilling and cutting applications for them. A consolidated hard material may be produced using hard particles such as B4C or carbides or borides of W, Ti, Mo, Nb, V, Hf, Ta, Zr, and Cr in combination with an iron-based, nickel-based, nickel and iron-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, or titanium-based alloy for the binder material. Commercially pure elements such as aluminum, copper, magnesium, titanium, iron, or nickel may also be used for the binder material. The mixture of the hard particles and the binder material may be consolidated at a temperature below the liquidus temperature of the binder material using a technique such as rapid omnidirectional compaction (ROC), the Ceracon™ process, or hot isostatic pressing (HIP). After sintering, the consolidated hard material may be treated to alter its material properties.

Abstract: A shaped insert that includes a top portion, and a grip length, wherein the grip length is modified to have a non-uniform cross sectional area is disclosed. In another case, a shaped insert includes a top portion, and a grip length, wherein the grip length is modified such that the insert is non-cylindrical. In another case, a shaped insert includes a top portion, and a grip length, wherein the grip length is coated in a non-uniform manner.

Abstract: A drill bit for cutting a borehole comprises a bit body including a bit axis. In addition, the drill bit comprises a rolling cone cutter mounted on the bit body. Further, the drill bit comprises a cutter element having a base portion with a diameter and a cutting portion extending therefrom. The cutting portion comprising a first pair of flanking surfaces that taper towards one another to form a first elongate chisel crest, and a second pair of flanking surfaces that taper towards one another to form a second elongate chisel crest that intersects the first elongate chisel crest in top view. The first crest tangent angle at 10% of the diameter measured radially from the central axis on the first elongate chisel crest in profile view is greater than 75° and less than or equal to 90°.

Abstract: In one aspect of the invention a drill bit comprises an axis of rotation a body and a working face. The body comprises a fluid passageway with a first seat and houses a jack element substantially coaxial with the axis. A stop element is disposed within the passageway and has a first near-sealing surface. The jack element has a shaft intermediate an indenting end and a valve portion. The valve portion has a second near-sealing surface disposed adjacent the first near-sealing surface and a second seat disposed adjacent the first seat. As a formation strongly resists the jack element, the distance between the sealing surfaces narrows. This causes an increase in fluid pressure within the passageway and forces the indenting end down into the formation. This movement of the jack element relieves the pressure build up such that the formation pushes the jack element back, thereby oscillating the jack element.

Abstract: Composite constructions comprise a plurality of granules that are arranged together in a randomly-oriented manner. The granules each comprise an ordered arrangement of a first material phase and a second material phase, wherein the first and second material phases are each continuous, and each occupy different and distinct regions of the granule. At least a portion of the first and second material phases of each granule are in contact with one another. The first material phase comprises a material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof. The second material phase comprises a material that is relatively softer, e.g., more ductile, than the first material phase.

Abstract: In one aspect of the invention, a wear resistant assembly has at least one hard insert disposed within a recess formed within a surface. A hard material substantially surrounds the hard insert and is also disposed within the surface. The hard material is separated from the insert by an intermediate material softer than both the insert and the hard material.

Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC—SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC—SiC material, and the ABC—SiC material may be toughened to increase a fracture toughness exhibited by the ABC—SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.

Abstract: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

Abstract: Drill bits comprise a plurality of steel cutting teeth each having a crest positioned at a tip portion of each tooth, a first flank surface extending from the crest to the cone, a second flank surface opposite the first flank surface and extending from the crest to the cone, and edge surfaces extending from the crest to the cone and interposed between the first and second flank surfaces. Each cutting tooth includes corners that extend from the crest to the cone that are defined by the interface between the first and second flank surfaces and the edge surfaces. A wear resistant surface is positioned on selective tooth surfaces comprising at least the crest and a portion of one or more of the corners. The wear surface is not disposed on at least a surface portion of one of the first and second flank surfaces and the edge surfaces.

Abstract: An apparatus for cutting a window in a casing pipe in a well, having only a single mill with full gage primary cutting inserts of a very hard, highly wear resistant, material. The primary inserts can be protected from damage by forming each blade on the mill with an outside edge profile having a shallower angle than the angle of the whipstock which is used to guide the mill through the casing, preventing the primary inserts from riding directly on the whipstock. The primary inserts on each blade can be further protected from damage by a row of secondary inserts of a relatively more durable material, arranged behind each row of primary inserts, or by a full diameter buffer section of mill body or blade.

Abstract: A rolling cone drill bit is provided that has gage inserts on the first row from the bit axis to cut to full gage diameter that have a cutting portion enhanced with a layer of super abrasive material. The gage cutting surface has a center axis that is canted to be more normal to the gage curve such that its point of contact at gage is away from the thinner portion of the layer of super abrasive material.

Abstract: In one aspect of the invention, a superhard insert has a carbide substrate bonded to ceramic layer at an interface. The substrate has a generally frusto-conical end at the interface with a tapered portion leading to a flat portion. The central section of the ceramic layer may have a first thickness immediately over the flat portion of the substrate. The peripheral section of the ceramic layer has a second thickness being less than the first thickness covering the tapered portion of the substrate. The ceramic layer may be formed using HPHT technology.

Abstract: Improved cutter design as well as an improved design for downhole cutters, such as mandrel cutters and rotary cutter mills. A cutter is described with a rectangular, rounded “lozenge” shape. The cutter presents a cross-sectional cutting area having a pair of curvilinear end sections and an elongated central section. Preferably, the overall length of the cutter is 1.5 times the width. The cutter may also include a raised cutter edge for chip breaking during cutting.

Abstract: An insert for a drill bit that includes diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less is disclosed. A method of forming a diamond-impregnated cutting structure, that includes loading a plurality of substantially uniformly coated diamond particles into a mold cavity, pre-compacting the substantially uniformly coated diamond particles using a cold-press cycle, and heating the compacted, substantially uniformly coated diamond particles with a matrix material to form the diamond impregnated cutting structure is also disclosed.

Abstract: A drill bit includes a plurality of cutting elements are positioned on the at least two roller cones, wherein cutting elements contributing to an operative gage row of the drill bit comprise less than 31 percent of a total cutting elements of the drill bit that contact the bottom of the borehole. A method to design a roller cone drill bit includes designing an initial bit, testing the initial bit; and adjusting the bit design to optimize at least one of rate of penetration and wear resistance, wherein cutting elements contributing to an operative gage row of the adjusted bit design comprise less than 31 percent of a total of cutting elements on the adjusted bit design that contact a bottom of a borehole.

Abstract: A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed.

Abstract: A drill bit includes a cutter element having a tapered and faceted side surface extending to a peak, and a polygonal wear face that slopes from the peak toward the cutter element base. The cutter element is mounted in a cone cutter of a rolling cone drill bit and, in certain embodiments, is positioned such that, when the cutter element is in a position farthest from the bit axis, the wear face generally faces and is parallel to the borehole sidewall and the peak engages the borehole bottom.

Abstract: In one aspect of the invention, a drill bit assembly has a body portion intermediate a shank portion and a working portion, the working portion having at least one cutting element. The working portion also has an opening to an axial chamber disposed in the body portion of the assembly. The drill bit assembly also has an axial shaft rotationally isolated from the body portion, the shaft being at least partially disposed within the chamber, and partially protruding form the working portion. The shaft is also in communication with an energy adapter disposed within the drill but assembly and is adapted to use relative motion between the body portion and the shaft to provide power to at least one downhole device.

Abstract: Roller cone drill bits are provided with cutting elements and cutting structures optimized for efficient drilling of soft and medium formations interspersed with hard stringers. The cutting elements and cutting structures may be satisfactorily used to drill downhole formations with varying amounts of hardness. The cutting elements and cutting structures may also be optimized to reduce tracking and increase wear resistance.

Abstract: Disclosed are a variety of arcuate-shaped inserts for drill bits, and in particular, for placement in rolling cone cutters of drill bits. The arcuate inserts include 360° or ring-shaped inserts, as well as inserts of smaller arcuate length. The arcuate inserts are suitable for use in all surfaces of the rolling cone cutter, and in other locations in drill bits, and may have specialized cutting surfaces and material enhancements to enhance their cutting duty performance. Certain arcuate inserts may include stress relieving discontinuities such that, upon assembly into the cone or during drilling, the arcuate inserts may fragment in a controlled and predicted manner into shorter arcuate lengths.

Abstract: An earth-boring bit has a steel body and bearing pin for rotatably supporting a cone. The cone has an exterior surface containing rows of cutting elements. The cone and cutting elements are formed of cemented tungsten carbide. The cone may be manufactured by applying pressure to a mixture of hard particles and metal alloy powder to form a billet, then machining the billet to a desired over-sized conical shaped product. Then the conical-shaped product is liquid-phase sintered to a desired density, which causes shrinking to the desired final shape.

Abstract: A cutting element for a drill bit that includes an outer support element having at least a bottom portion and a side portion; and an inner rotatable cutting element, a portion of which is disposed in the outer support element, wherin the inner rotatable cutting element includes a substrate and a diamond cutting face having a thickness of at least 0.050 inches disposed on an upper surface of the substrate; and wherein a distance from an upper surface of the diamond cutting face to a bearing surface between the inner rotatable cutting element and the outer support element ranges from 0 to about 0.300 inches is disclosed.

Abstract: A hardfacing composition for a drill bit includes a carbide phase made from carbide particles having a barrier coating disposed thereon, and binder alloy. Also, a drill bit includes a steel bit body having hardfacing thereon and having at least one blade thereon, at least one cutter pocket disposed on the blade, at least one cutter disposed in the cutter pocket; and hardfacing applied to at least composition that includes a carbide phase formed from carbide particles having a barrier coating disposed thereon; and a binder alloy.

Abstract: In one aspect of the invention a drill bit assembly has a body portion intermediate a shank portion and a working portion. The working portion has a recess with a side wall which is substantially coaxial with the shank portion. At least one cutting element is attached to the side wall and an indenting member is disposed within the closed end. In another aspect of the invention a method includes providing a drill bit assembly with a recess formed in a working portion of the assembly. The working portion has a plurality of cutting elements and the recess has at least one cutting element. The method further has steps of cutting a formation with the plurality of cutting elements and also of penetrating a conical profile of the formation which is formed by the recess.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.