Welded, Brazed, Or Soldered Patents (Class 175/435)
  • Patent number: 10046402
    Abstract: A rotary cutting tool (10) comprises a shank (12) formed of a first material of a first hardness. The shank (12) has a first end (12a), and a plurality of elements (14) are provided at the first end (12a) of the shank (12). The elements (14) are formed of a second material of a second hardness greater than that of the first hardness. The elements (14) provide a platform to be able to create a plurality of cutting edges or teeth (18, 20a). A method of forming such a rotary cutting tool is also provided.
    Type: Grant
    Filed: April 26, 2013
    Date of Patent: August 14, 2018
    Assignee: EXACTAFORM CUTTING TOOLS LIMITED
    Inventor: Peter Raynor
  • Patent number: 9724765
    Abstract: The rotating tool, in particular a drill, includes a fluted cutting shank made of a resistant material, in particular carbide, extending in an axial direction along a rotational axis. Connecting to the cutting shank in the axial direction is an intermediate shank made of a material of greater elasticity in comparison the resistant material, in particular of tool steel. The intermediate shank includes an insertable cutting insert that may be exchanged. The cutting shank is preferably a cutting shank recycled from a used solid carbide drill.
    Type: Grant
    Filed: April 15, 2015
    Date of Patent: August 8, 2017
    Assignee: KENNAMETAL INC.
    Inventors: Eduard Ach, Horst Manfred Jäger, Fabian Rosenberger
  • Patent number: 9464486
    Abstract: A cutting element assembly includes a sleeve, a lining extending a distance axially from an end of the sleeve, and an inner cutter. The inner cutter has a cutting end, wherein the cutting end extends a depth from a cutting face, a side surface, and a body, wherein the body is at least partially disposed within the sleeve, and wherein the side surface of the cutting end interfaces with an interfacing surface of the lining.
    Type: Grant
    Filed: December 23, 2013
    Date of Patent: October 11, 2016
    Assignee: Smith International, Inc.
    Inventors: Youhe Zhang, Chen Chen, Yuri Burhan, Jibin Shi
  • Patent number: 8978790
    Abstract: A cutter retention method which uses brazed material placed in cutter pockets and cutter pocket grooves or recesses to allow braze material between the cutters and cutter pockets and in said grooves and overlapping onto the top of the cutters to better retain the cutters in the cutting bore hole tool apparatus for enhanced cutter retention and extended drilling or boring time of drill bits, underreamers, section mills hole openers, casing cutters or other down hole tools used in bore hole drilling and completion operations.
    Type: Grant
    Filed: June 23, 2011
    Date of Patent: March 17, 2015
    Inventor: Alan L. Nackerud
  • Patent number: 8960338
    Abstract: A superabrasive compact (e.g., a polycrystalline diamond compact) including a substrate pre-coated with at least one braze layer and an in-process drill bit assembly including at least one of such superabrasive compacts are disclosed. Pre-coating the substrate with at least one braze layer and dimensioning the pre-coated substrate to fit within the tolerances of a conventionally-sized cutter recess of a drill bit body enables a drill bit manufacture to easily and rapidly braze the disclosed superabrasive compacts into the conventionally-sized cutter recess without substantially decreasing the superabrasive volume of the superabrasive compact.
    Type: Grant
    Filed: April 17, 2013
    Date of Patent: February 24, 2015
    Assignee: US Synthetic Corporation
    Inventor: Robert K. Galloway
  • Patent number: 8899357
    Abstract: Various downhole drilling tools designed and manufactured at least in part on evaluating respective forces acting on respective groups and sets of cutting elements during simulated engagement with the downhole end of a wellbore and drilling from a first downhole formation into a second downhole formation. Simulating forces acting on each cutting element as the cutting element contacts a downhole formation may be used to force balance downhole drilling tools during transition drilling or non-uniform downhole drilling conditions. Multilevel force balanced downhole drilling tools may be designed using five respective simulations, cutter group level, neighbor cutter group level, cutter set level, group of N (N=3 or N=4) consecutive cutters level and all cutters level. Various cutter layout procedures and algorithms may also be used to design multilevel force balanced downhole drilling tools which may drill faster with higher lateral stability, especially during downhole transiting drilling conditions.
    Type: Grant
    Filed: December 9, 2009
    Date of Patent: December 2, 2014
    Assignee: Halliburton Energy Services, Inc.
    Inventor: Shilin Chen
  • Patent number: 8881361
    Abstract: Embodiments of the invention relate to superabrasive compacts including multiple superabrasive cutting portions and methods of repairing a rotary drill bit that employs at least one of such superabrasive compacts.
    Type: Grant
    Filed: March 6, 2012
    Date of Patent: November 11, 2014
    Assignee: US Synthetic Corporation
    Inventors: Jair J. Gonzalez, Jed Clarke, Neil Haddock
  • Patent number: 8776913
    Abstract: A method of brazing a top loading cutter into a cutter pocket is disclosed, wherein the method includes placing at least one braze disc between an inner wall of the cutter pocket and a portion of the top loading cutter and heating the at least one braze disc to a temperature above the melting temperature of the braze disc.
    Type: Grant
    Filed: October 13, 2011
    Date of Patent: July 15, 2014
    Assignee: Smith International, Inc.
    Inventors: Jimykumar Prajapati, Gregory T. Lockwood
  • Patent number: 8763730
    Abstract: Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: July 1, 2014
    Assignee: Smith International, Inc.
    Inventors: Peter Cariveau, Georgiy Voronin, J. Daniel Belnap
  • Patent number: 8757299
    Abstract: A cutting element for use in a drilling bit and/or milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further including a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.
    Type: Grant
    Filed: July 8, 2010
    Date of Patent: June 24, 2014
    Assignees: Baker Hughes Incorporated, Element Six (Production) (Pty) Ltd., Element Six Limited
    Inventors: Anthony A. DiGiovanni, Nicholas J. Lyons, Matthew S. Hale, Konstantin E. Morozov, John H. Liversage, Danny E. Scott, Allen Sinor
  • Patent number: 8740048
    Abstract: Thermally stable polycrystalline constructions comprise a body having a polycrystalline ultra-hard phase and a plurality of empty voids. A population of the voids can be filled with a reaction product. The body is substantially free of a catalyst material. The construction comprises a first support member attached to the body by a first braze material. A second support member is attached to the body and the first support member by a second braze material. The construction may include a third support member attached to the body that is integral or separate from one of the other support members. The braze materials used to attached the support members can be the same or different, as can be the materials used to form the different support members.
    Type: Grant
    Filed: June 29, 2010
    Date of Patent: June 3, 2014
    Assignee: Smith International, Inc.
    Inventors: Georgiy Voronin, J. Daniel Belnap
  • Patent number: 8701799
    Abstract: A pocket restitution assembly comprises a pocket formed in a surface that includes a central axis, an anchor seated in the pocket and aligned with the central axis, a tool attachment comprising an end for connection to the anchor, and a hollow bit slidably and rotatably sitting on the tool attachment. The hollow bit may fit within the pocket. Weld material may be deposited within the pocket to form an interior of the pocket. The weld material may be shaped by the hollow bit to accept a cutting element.
    Type: Grant
    Filed: April 29, 2009
    Date of Patent: April 22, 2014
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, Francis Leany
  • Patent number: 8689913
    Abstract: In various embodiments, a polycrystalline diamond compact (“PDC”) comprises a substrate including an interfacial surface having a raised region. The PDC comprises a polycrystalline diamond (“PCD”) table bonded to the interfacial surface of the substrate. The PCD table defines an upper surface and exhibits a thickness over the raised region. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. A first region of the PCD table adjacent to the substrate includes metal-solvent catalyst disposed interstitially between the bonded diamond grains thereof, and a leached second region of the PCD table extends inwardly from the upper surface. The interstitial regions of the leached second region are depleted of metal-solvent catalyst. The geometry of the PCD table and raised region may be selected so that residual compressive stresses therein are retained to a sufficient level after leaching to provide a damage tolerant/thermally-stable PCD table.
    Type: Grant
    Filed: December 13, 2012
    Date of Patent: April 8, 2014
    Assignee: US Synthetic Corporation
    Inventors: Craig H. Cooley, Jair J. Gonzalez
  • Patent number: 8689911
    Abstract: A cutter for a downhole cutting tool is disclosed. The cutter includes a cutter body having a cutting face, a peripheral sidewall flank, and a base. The base has a recessed channel that extends inwardly from the peripheral sidewall flank and provides an inlet opening therein. A downhole cutting tool employing the cutter is also disclosed. The cutting tool includes a tool body having a cutter face. The tool also includes a cutter body having a cutting face, a peripheral sidewall flank, and a base, the base having a recessed channel that extends inwardly from the peripheral sidewall flank and provides an inlet opening therein. The tool also includes a braze joint between the base and the bonding surface.
    Type: Grant
    Filed: August 7, 2009
    Date of Patent: April 8, 2014
    Assignee: Baker Hughes Incorporated
    Inventors: Calvin J. Stowe, II, Andrew Ponder
  • Patent number: 8672061
    Abstract: Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device to improve the compact attachment strength with respect to the end-use device.
    Type: Grant
    Filed: February 10, 2011
    Date of Patent: March 18, 2014
    Assignee: Smith International, Inc.
    Inventors: Georgiy Voronin, Nephi A Mourik, J. Daniel Belnap
  • Publication number: 20130341100
    Abstract: A modular cutting-teeth drill bit with controllable drilling specific pressure comprises a module (1), a modular unit (2), a bit body (3), conventional cutting teeth (4) and a nozzle (5). According to mechanical performance of the rocks in the strata drilled and requirements of drilling well, a combination of shapes, sizes and numbers of the module and the modular unit is optimized; effective abrasion edge length of the cutting element on a certain portion of the bit is controlled; and a constant specific pressure of the cutting element of the bit during the drilling process is maintained. The modular cutting-teeth bit substantially improves the effective abrasion volume of the cutting element, and improves the effective utilization rate of the cutting element.
    Type: Application
    Filed: June 21, 2013
    Publication date: December 26, 2013
    Inventors: Liang Zhang, Shu Li, Jialin Tian, Defa Zeng
  • Patent number: 8602133
    Abstract: A wear insert comprised of cemented metal carbide is welded to a workpiece made of steel or cemented metal carbide without causing fracturing of the carbide or creating residual stresses that reduce the impact resistance of the part. The part is fabricated using a microwave sintering process prior to welding.
    Type: Grant
    Filed: June 3, 2010
    Date of Patent: December 10, 2013
    Assignee: Dennis Tool Company
    Inventor: Mahlon D. Dennis
  • Patent number: 8522646
    Abstract: A method for forming a borehole enlargement tool that includes providing a steel body structure, forming at least one rib structure from a matrix material and abrasive particles, affixing the at least one rib structure to the body structure, and affixing the steel body structure to an elongated tubular body is disclosed.
    Type: Grant
    Filed: April 1, 2011
    Date of Patent: September 3, 2013
    Assignee: Smith International, Inc.
    Inventors: Tommy Laird, Navish Makkar
  • Patent number: 8517123
    Abstract: A PDC cutter includes a diamond table layer and an underlying substrate layer. A cap structure for the PDC cutter includes a first portion overlying, but not attached to, a front face of the diamond table layer and a second portion extending perpendicularly from the first portion which is overlying and attached to an outer peripheral surface of the underlying substrate layer.
    Type: Grant
    Filed: May 25, 2010
    Date of Patent: August 27, 2013
    Assignee: Varel International, Ind., L.P.
    Inventor: Michael R. Reese
  • Patent number: 8439137
    Abstract: A superabrasive compact (e.g., a polycrystalline diamond compact) is disclosed, which includes a substrate pre-coated with at least one braze layer and an in-process drill bit assembly including at least one of such superabrasive compacts. Pre-coating the substrate with at least one braze layer and dimensioning the pre-coated substrate to fit within the tolerances of a conventionally-sized cutter recess of a drill bit body enables a drill bit manufacture to easily and rapidly braze the disclosed superabrasive compacts into the conventionally-sized cutter recess without substantially decreasing the superabrasive volume of the superabrasive compact.
    Type: Grant
    Filed: January 15, 2010
    Date of Patent: May 14, 2013
    Assignee: US Synthetic Corporation
    Inventor: Robert K. Galloway
  • Patent number: 8365845
    Abstract: In one aspect of the present invention, a high impact resistant tool comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface, the body comprising a substantially pointed geometry with an apex, the apex comprising a curved surface that joins a leading side and a trailing side of the body at a first and second transitions respectively, an apex width between the first and second transitions is less than a third of a width of the substrate, and the body also comprises a body thickness from the apex to the interface greater than a third of the width of the substrate.
    Type: Grant
    Filed: October 5, 2011
    Date of Patent: February 5, 2013
    Inventors: David R. Hall, Ronald B. Crockett, Casey Webb, Michael Beazer
  • Patent number: 8360176
    Abstract: A method for a down hole cutting tool is disclosed, wherein the cutting tool includes a cutting element support structure having at least one cutter pocket to support a cutting element comprising a substrate and an ultrahard layer. The method includes inserting a base portion of the cutting element into the cutter pocket; locating a first braze alloy such that when heated the first braze alloy melts and fills a space in the cutter pocket between the cutting element and the cutting element support structure adjacent the ultrahard layer; locating a second braze alloy such that when heated the second braze alloy melts and fills a space in the cutter pocket between the cutting element and the cutting element support structure non-adjacent the ultrahard layer; and heating the first and second braze alloy such that they melt.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: January 29, 2013
    Assignee: Smith International, Inc.
    Inventors: Youhe Zhang, Yuelin Shen, Hong Deng
  • Patent number: 8353974
    Abstract: Methods of manufacturing a superabrasive element and/or compact are disclosed. In one embodiment, a superabrasive volume including a tungsten carbide layer may be formed. Polycrystalline diamond elements and/or compacts are disclosed. Rotary drill bits for drilling a subterranean formation and including at least one superabrasive element and/or compact are also disclosed.
    Type: Grant
    Filed: May 23, 2012
    Date of Patent: January 15, 2013
    Assignee: US Synthetic Corporation
    Inventors: Craig H. Cooley, Kenneth E. Bertagnolli, Michael A. Vail
  • Patent number: 8342268
    Abstract: A drill bit that includes a bit body having a plurality of blades extending radially therefrom, wherein at least a portion of the bit body comprises a first matrix region comprising a plurality of primary carbide particles having an average mean free path of at least about 10 microns; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades is disclosed.
    Type: Grant
    Filed: August 11, 2009
    Date of Patent: January 1, 2013
    Assignee: Smith International, Inc.
    Inventors: Alan W. Lockstedt, Gregory T. Lockwood
  • Patent number: 8268452
    Abstract: Methods for forming earth-boring tools include providing a metal or metal alloy bonding agent at an interface between a first element and a second element and sintering the first element, the second element, and the boding agent to form a bond between the first element and the second element at the interface. The methods may be used, for example, to bond together portions of a body of an earth-boring tool (which may facilitate, for example, the formation of cutting element pockets) or to bond cutting elements to a body of an earth-boring tool (e.g., a bit body of a fixed-cutter earth-boring drill bit or a cone of a roller cone earth-boring drill bit). At least partially formed earth-boring tools include a metal or metal alloy bonding agent at an interface between two or more elements, at least one of which may comprise a green or brown structure.
    Type: Grant
    Filed: July 31, 2007
    Date of Patent: September 18, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Nicholas J. Lyons, Jimmy W. Eason, Redd H. Smith, John H. Stevens
  • Patent number: 8240403
    Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase a yield strength of the pockets, which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than an outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the outer diameter of the cutting elements. After the rock bit has been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.
    Type: Grant
    Filed: October 8, 2010
    Date of Patent: August 14, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Tu Tien Trinh, Eric C. Sullivan
  • Patent number: 8210287
    Abstract: A core drill bit includes an elongate hollow cylindrical body having opposite first and second ends with an end section having an end face defining an annular non-planar surface. The cutting head includes a plurality of circumferentially spaced apart cutting segments, the cutting segments being electrical welded to the non-planar surface whereby raised portions of the surface melt during the welding to affix the cutting segments with the face of the tool body.
    Type: Grant
    Filed: January 4, 2010
    Date of Patent: July 3, 2012
    Assignee: Diamond Products, Limited
    Inventors: Karl H. Moller, Andrew L. Jedick, Thomas G. Ruffner
  • Patent number: 8202335
    Abstract: Methods of manufacturing a superabrasive element and/or compact are disclosed. In one embodiment, a superabrasive volume including a tungsten carbide layer may be formed. Polycrystalline diamond elements and/or compacts are disclosed. Rotary drill bits for drilling a subterranean formation and including at least one superabrasive element and/or compact are also disclosed.
    Type: Grant
    Filed: September 7, 2007
    Date of Patent: June 19, 2012
    Assignee: US Synthetic Corporation
    Inventors: Craig H. Cooley, Kenneth E. Bertagnolli, Michael A. Vail
  • Patent number: 8176825
    Abstract: A method for producing carbide and diamond cutting tool inserts adapted to compensate for braze-induced warp is provided. In this method, the anticipated warpage of the insert from brazing is considered prior to cutting the insert from a PCD and carbide disk and the cutting path for the insert is adjusted to compensate. The adjusted cutting path creates an insert shape that, after warping as a result of the brazing process, will conform substantially to the originally intended insert or cutting tool shape. Also, a method of providing relief on the bottom surface of a brazeable insert is provided. Further, tools produceable by these methods are disclosed, such as a diamond edged rotary cutting tool with a substantially sinusoidal rake face and cutting edge.
    Type: Grant
    Filed: May 22, 2007
    Date of Patent: May 15, 2012
    Inventors: Glenn Isaacson, Mark P. O'Brien
  • Patent number: 8162082
    Abstract: Embodiments of the invention relate to superabrasive compacts including multiple superabrasive cutting portions and methods of fabricating such superabrasive compacts. In an embodiment, a superabrasive compact comprises a cemented carbide substrate including a first interfacial surface and a second interfacial surface longitudinally spaced from the first interfacial surface. A first superabrasive cutting portion may be bonded to the first interfacial surface of the cemented carbide substrate. The first superabrasive cutting portion includes a first working surface. A second superabrasive cutting portion may be bonded to the second interfacial surface of the cemented carbide substrate and spaced from the first superabrasive cutting portion. The second superabrasive cutting portion includes a second working surface that generally opposes the first working surface of the first superabrasive cutting portion.
    Type: Grant
    Filed: April 16, 2009
    Date of Patent: April 24, 2012
    Assignee: US Synthetic Corporation
    Inventors: Jair J. Gonzalez, Jed Clarke, Neil Haddock
  • Patent number: 8104550
    Abstract: Earth-boring tools include wear-resistant materials disposed in at least one recess formed in an exterior surface of a body thereof. Exposed surfaces of the wear-resistant material are substantially level with exterior surfaces of the body adjacent the wear-resistant material. In some embodiments, recesses may be formed in formation-engaging surfaces of blades of earth-boring rotary tools, adjacent one or more inserts secured to bodies of earth-boring tools, or adjacent one or more cutting elements secured to bodies of earth-boring tools. Methods of forming earth-boring tools include filling one or more recesses formed in an exterior surface of a body with wear-resistant material and causing exposed surfaces of the wear-resistant material to be substantially level with the exterior surface of the body.
    Type: Grant
    Filed: September 28, 2007
    Date of Patent: January 31, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: James L. Overstreet, Michael L. Doster, Mark E. Morris, Kenneth E. Gilmore, Robert M. Welch, Danielle V. Roberts
  • Patent number: 8066087
    Abstract: Thermally stable ultra-hard compact constructions comprise a polycrystalline diamond body substantially free of a catalyst material, and a substrate that is joined thereto. The substrate can be ceramic, metallic, cermet and combinations thereof, and can be joined to the body by a braze material or other material that forms an attachment bond at high pressure/high temperature conditions. The body and substrate are specially formed having complementary interfacing surface features to facilitate providing an improved degree of attachment therebetween. The complementary surface features can in the form of openings and projections, e.g., one of the body or substrate can comprise one or more openings, and the other of the body or substrate can comprise one or more projections, disposed within or extending from respective interfacing surfaces. The complementary surface features operate to resist unwanted delamination between the body and substrate, thereby extending effective service life of the construction.
    Type: Grant
    Filed: May 8, 2007
    Date of Patent: November 29, 2011
    Assignee: Smith International, Inc.
    Inventors: Anthony Griffo, Madapusi K. Keshavan, Youhe Zhang, Yuelin Shen, Michael Janssen
  • Patent number: 8061454
    Abstract: An ultra-hard and metallic construction comprises an ultra-hard component that is attached to a metallic component via a braze joint. The braze joint is interposed between the ultra-hard component and the metallic component, and comprises a first braze material bonded to a surface of the ultra-hard component. The braze joint includes an intervening layer in direct contact with the first braze material, and that is formed from a rigid material. The braze joint further comprises a second braze material that is interposed between the intervening layer and the metallic component, and that is different from the first braze material.
    Type: Grant
    Filed: January 9, 2008
    Date of Patent: November 22, 2011
    Assignee: Smith International, Inc.
    Inventors: Georgiy Voronin, J. Daniel Belnap
  • Patent number: 8028774
    Abstract: A high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches from the apex to a central region of the cemented metal carbide substrate. The diamond material comprises a 1 to 5 percent concentration of binding agents by weight.
    Type: Grant
    Filed: November 25, 2009
    Date of Patent: October 4, 2011
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, Ronald B. Crockett, Jeff Jepson, Scott Dahlgren, John Bailey
  • Patent number: 8016057
    Abstract: Subterranean drill bits having good erosion resistance, strength, toughness, and thermal stability are disclosed. The drill bits comprise a bit body carrying at least one cutting element and having an infiltrated metal matrix. The infiltrated metal matrix comprises a matrix powder composition bound together by an infiltrant. The matrix powder mixture includes cast tungsten carbide powder having a particle size of ?30 (600 micron) +140 mesh (106 micron), a second component powder consisting of one or more other types of tungsten carbide particles, and a metal powder.
    Type: Grant
    Filed: June 19, 2009
    Date of Patent: September 13, 2011
    Assignee: Kennametal Inc.
    Inventors: Xin Deng, Jonathan W. Bitler
  • Patent number: 7997358
    Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.
    Type: Grant
    Filed: October 20, 2009
    Date of Patent: August 16, 2011
    Assignee: Smith International, Inc.
    Inventors: Saul N Izaguirre, Thomas W. Oldham, Kumar T Kembaiyan, Gary Chunn, Anthony Griffo, Robert Denton, Brian A White
  • Patent number: 7950746
    Abstract: An attack tool for degrading materials is disclosed which comprises a base segment comprising an attachment to a driving mechanism, a first wear-resistant segment bonded to the base segment, a second wear-resistant segment bonded to the first wear-resistant segment at a brazed joint opposite the base segment, and at least a portion of exterior surfaces of both the wear-resistant segments proximate the joint, the portion of exterior surfaces comprising a finish ground surface.
    Type: Grant
    Filed: June 16, 2006
    Date of Patent: May 31, 2011
    Assignee: Schlumberger Technology Corporation
    Inventors: David R. Hall, Ronald B. Crockett, Joe Fox, Jeff Jepson, Michael Barnhill
  • Patent number: 7926597
    Abstract: A blade, which is useful on a tool that impinges earth strata, that has a blade body with a leading surface. The blade body has a first portion defining at least a part of the leading surface and a second portion. The first portion is made of a first material composition and the second portion is made of a second material composition.
    Type: Grant
    Filed: May 21, 2007
    Date of Patent: April 19, 2011
    Assignee: Kennametal Inc.
    Inventors: Shivanand I. Majagi, Jonathan W. Bitler
  • Patent number: 7909121
    Abstract: Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device.
    Type: Grant
    Filed: January 9, 2008
    Date of Patent: March 22, 2011
    Assignee: Smith International, Inc.
    Inventors: Georgiy Voronin, Nephi M. Mourik, J. Daniel Belnap
  • Patent number: 7861806
    Abstract: A shank configuration for rotary drill bits is disclosed for positioning of the shank in relation to a bit body. A tapered surface or feature of the shank may be configured and sized to matingly engage a complementarily shaped surface or feature of the drill bit body and thereby become centered or positioned in relation thereto. A deformable element may be disposed between the shank and bit body. Also, the shank may comprise a material having a carbon equivalent of less than about 0.35%. A multi-pass weld procedure may be employed to affix the shank and bit body to one another wherein welds may be formed so that one weld originates at a circumferential position that differs from the origination circumferential position of its immediately preceding weld by at least about 90°. Further, a stress state may be developed within the multi-pass weld. A method of manufacture is also disclosed.
    Type: Grant
    Filed: September 25, 2009
    Date of Patent: January 4, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Anton F. Zahradnik, Eric C. Sullivan, R. Scot Smith, Daniel E. Ruff, Danielle V. Roberts, Alan J. Massey
  • Patent number: 7842111
    Abstract: Embodiments of the present invention relate to PDCs including a PCD table having an exterior cutting region that exhibits enhanced thermal stability. In one embodiment, a method comprises forming an assembly including a first region having non-diamond carbon material and a second region having a plurality of diamond particles. The method comprises subjecting the assembly to heat and pressure sufficient to form the PDC. In another embodiment, a PDC comprises a substrate and a PCD table bonded to the substrate. The PCD table comprises an exterior cutting region including a plurality of elongated diamond grains that are generally randomly oriented. The PCD table comprises a main region positioned between the substrate and exterior cutting region, and including a plurality of bonded diamond grains. In another embodiment, the first region may include coarse-sized diamond particles instead of non-diamond carbon material.
    Type: Grant
    Filed: April 29, 2008
    Date of Patent: November 30, 2010
    Assignee: US Synthetic Corporation
    Inventor: Mohammad N. Sani
  • Publication number: 20100270078
    Abstract: Disclosed herein is a drill bit. The drill bit includes, a body of the drill bit having at least two blades defining a junk slot therebetween, at least one cutter positioned on at least one of the at least two blades, and at least one diverter positioned downstream of the at least one cutter defined by a direction of travel of the cuttings, the at least one diverter configured to divert cuttings to travel along a trajectory more parallel to a profile of the junk slot.
    Type: Application
    Filed: April 28, 2009
    Publication date: October 28, 2010
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Michael R. Wells, Timothy K. Marvel, Chad J. Beuershausen
  • Patent number: 7779901
    Abstract: A debris catching device for downhole milling features modular debris receptacles that are held in the housing in a manner that facilitates stacking and a generally undulating flow path to facilitate dropping of the debris into the receptacles as the remaining fluid travels up the tool for ultimate screening before the fluid exits the tool to flow up to the surface or in a reverse circulation pattern back to the mill below the debris catcher. The modules can also be aligned with flapper valves at the top of each module to prevent debris in the tool from falling to the mill if circulation is turned off. The mill is configured to have an off-center return path preferably as large as the passage through the mill body to aid circulation and cutting performance.
    Type: Grant
    Filed: March 18, 2009
    Date of Patent: August 24, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: John P. Davis, James S. Trahan, Paul L. Connell
  • Patent number: 7775287
    Abstract: Earth-boring rotary drill bits including a bit body attached to a shank. In some embodiments, the bit body and the shank may have abutting surfaces concentric to an interface axis offset relative to a longitudinal axis of the drill bit. In additional embodiments, the bit body and the shank may have generally frustoconical abutting surfaces. Methods for attaching a shank and a bit body of an earth-boring rotary drill bit include abutting a surface of a shank against a surface of a bit body, and causing the abutting surfaces to be concentric to an axis that is offset or shifted relative to a longitudinal axis of the drill bit.
    Type: Grant
    Filed: December 12, 2006
    Date of Patent: August 17, 2010
    Assignee: Baker Hughes Incorporated
    Inventors: James L. Duggan, Redd H. Smith
  • Publication number: 20100193255
    Abstract: An earth-boring rotary drill bit includes a bit body, with a first region configured to carry a plurality of cutters for engaging a subterranean earth formation of a first particle-matrix composite material and a second region configured for attachment to a drill string of a second particle-matrix composite material having a second material composition, and an annular shank extending from the second region. Each of the first particle-matrix composite material and second particle-matrix composite material has a cast microstructure. A method of making an earth-boring rotary drill bit includes providing a plurality of hard particles in a mold to define a particle precursor; infiltrating the particle precursor sequentially with a plurality of molten matrix materials to form a corresponding plurality of layers, each comprising a particle-matrix mixture; and cooling the plurality of particle-matrix mixtures to solidify the matrix materials and form the bit body.
    Type: Application
    Filed: August 3, 2009
    Publication date: August 5, 2010
    Inventors: John H. Stevens, Jimmy W. Eason
  • Patent number: 7757793
    Abstract: Thermally stable polycrystalline constructions comprise a body having a polycrystalline ultra-hard phase and a plurality of empty voids. A population of the voids can be filled with a reaction product. The body is substantially free of a catalyst material. The construction comprises a first support member attached to the body by a first braze material. A second support member is attached to the body and the first support member by a second braze material. The construction may include a third support member attached to the body that is integral or separate from one of the other support members. The braze materials used to attached the support members can be the same or different, as can be the materials used to form the different support members.
    Type: Grant
    Filed: October 31, 2006
    Date of Patent: July 20, 2010
    Assignee: Smith International, Inc.
    Inventors: Georgiy Voronin, J. Daniel Belnap
  • Publication number: 20100108402
    Abstract: A downhole cutting tool includes, a body, a first contoured cutting element in operable communication with the body, and at least one contingency contoured cutting element in operable communication with the first contoured cutting element and the body. A contour of the at least one contingency contoured cutting element substantially matches a contour of the first contoured cutting element, and the at least one contingency contoured cutting element is maintainable in reserve and positioned to substitute for the first contoured cutting element if the first contoured cutting element becomes detached.
    Type: Application
    Filed: October 31, 2008
    Publication date: May 6, 2010
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Andrew D. Ponder, Calvin J. Stowe, II
  • Patent number: 7669674
    Abstract: In one aspect of the invention, a tool has a working portion with at least one impact tip brazed to a carbide extension. The carbide extension has a cavity formed in a base end and is adapted to interlock with a shank assembly of the cutting element assembly. The shank assembly has a locking mechanism adapted to interlock a first end of the shank assembly within the cavity. The locking mechanism has a radially extending catch formed in the first end of the shank assembly. The shank assembly has an outer surface at a second end of the shank assembly adapted to be press-fitted within a recess of a driving mechanism. The outer surface of the shank assembly has a coefficient of thermal expansion of 110 percent or more than a coefficient of thermal expansion of a material of the driving mechanism.
    Type: Grant
    Filed: March 19, 2008
    Date of Patent: March 2, 2010
    Inventors: David R. Hall, Ronald Crockett, Scott Dahlgren
  • Publication number: 20100012392
    Abstract: A shank configuration for rotary drill bits is disclosed for positioning of the shank in relation to the bit body. A tapered surface or feature of the shank may be configured and sized to matingly engage a complementarily shaped surface or feature of the drill bit body and thereby become centered or positioned in relation thereto. A deformable element may be disposed between the shank and bit body. Also, the shank may comprise a material having a carbon equivalent of less than about 0.35%. A multi-pass weld procedure may be employed to affix the shank and bit body to one another wherein welds may be formed so that one weld originates at a circumferential position that differs from the origination circumferential position of its immediately preceding weld by at least about 90°. Further, a stress state may be developed within the multi-pass weld. A method of manufacture is also disclosed.
    Type: Application
    Filed: September 25, 2009
    Publication date: January 21, 2010
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Anton F. Zahradnik, Eric C. Sullivan, R. Scot Smith, Daniel E. Ruff, Danielle V. Roberts, Alan J. Massey
  • Patent number: 7628233
    Abstract: A degradation assembly has a carbide bolster brazed within a hole formed in a surface. The bolster has a substantially straight cylindrical portion mostly disposed below the surface and a top end and a bottom end. The top end narrows from the cylindrical portion with a substantially annular concave curve to a planar interface adapted for bonding to a carbide substrate and the bottom end narrows from the cylindrical portion to a stem which bottoms out on a geometry of the hole.
    Type: Grant
    Filed: July 23, 2008
    Date of Patent: December 8, 2009
    Inventors: David R. Hall, Scott Dahlgren, Casey Webb