Rock Drill Patents (Class 76/108.2)
  • Patent number: 10443313
    Abstract: A method for forming localized binder in a drilling tool is disclosed. A method includes placing a reinforcement material in a matrix bit body mold, placing a localized binder material within the reinforcement material at a selected location in the matrix bit body mold, wherein the localized binder material confers a selected physical property at the selected location, placing a universal binder material in the matrix bit body mold on top of the reinforcement material, heating the matrix bit body mold, the reinforcement material, the localized binder material, and the universal binder material to a temperature above the melting point of the universal binder material, infiltrating the reinforcement material and the localized binder material with the universal binder material, and cooling the matrix bit body mold, the reinforcement material, the localized binder material, and the universal binder material to form a matrix drill bit body.
    Type: Grant
    Filed: March 5, 2015
    Date of Patent: October 15, 2019
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Grant O. Cook, III, Daniel B. Voglewede
  • Patent number: 10415319
    Abstract: A low surface friction body for a drill bit includes a matrix drill bit body. The body includes a particulate phase having a friction-reducing additive, and a binding material that bonds the particulate phase using a suitable manufacturing process such as selective laser sintering. The particulate phase may include tungsten carbide, the friction-reducing additive may be polytetrafluoroethylene, and the binder material may be copper or cobalt. The friction-reducing additive is distributed throughout at least a portion of the drill bit body that includes the surface that will come into contact with drill cuttings and drilling fluid during operation. The molecular properties of the friction-reducing additive result in a drill bit body having a surface that is resistant to sticking even after enduring chipping and other types of wear.
    Type: Grant
    Filed: March 12, 2014
    Date of Patent: September 17, 2019
    Assignee: Halliburton Energy Services, Inc.
    Inventor: Garrett T. Olsen
  • Patent number: 10144113
    Abstract: Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the at least a second less than fully sintered particle-matrix component.
    Type: Grant
    Filed: June 23, 2017
    Date of Patent: December 4, 2018
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, Nicholas J. Lyons
  • Patent number: 9987675
    Abstract: A method of manufacturing a well tool can include loading a matrix material into a mold, then sintering the matrix material in the mold; and then loading another matrix material into the mold. A well tool can include a longitudinal axis, an erosion resistant layer exposed to one or more erosive factors when the well tool is installed in a well, and a support layer which supports the erosion resistant layer. The erosion resistant and support layers can include respective matrix materials, and the erosion resistant layer can extend greater than approximately 1.27 cm in a direction parallel to the longitudinal axis. Another method of manufacturing a well tool can include forming a rigid layer from a powdered matrix material; and then infiltrating both that matrix material and another matrix material with a hot liquid binder material.
    Type: Grant
    Filed: May 30, 2012
    Date of Patent: June 5, 2018
    Assignee: HALLIBURTON ENERGY SERVICES, INC.
    Inventor: Jeffrey G. Thomas
  • Patent number: 9192987
    Abstract: A method of casting an article includes positioning a first portion of the article, formed from a first material, in a rotatable mold. Additionally, the method includes, while rotating the mold, pouring a molten second material into the mold over the first portion to form a second portion of the article that is metallurgically bonded to the first portion of the article.
    Type: Grant
    Filed: April 2, 2014
    Date of Patent: November 24, 2015
    Assignee: Caterpillar Inc.
    Inventors: Thomas John Yaniak, Thomas Majewski
  • Patent number: 9056799
    Abstract: The present invention includes a matrix powder system comprising one or more polycrystalline carbides, binderless carbides, or a combination thereof, a composite comprising the matrix powder system and a metal bond phase, a matrix bit body for a drill bit for oil and gas drilling made of this composite material, and a drill bit for oil and gas drilling comprising the matrix bit body and at least one cutter. The polycrystalline and/or binderless carbides may comprise carbides of W, Ti, V, Cr, Nb, Mo, Ta, Hf, Zr, or a combination thereof. The binderless carbides have less than 3 wt. % binder and the binderless and/or polycrystalline carbides may have a grain size of ?15 ?m and a hardness of ?1900 HV (0.5 kgf). Additional ceramic components and/or metals may also be present in the matrix powder system. Alternatively, the composite material may be present on only a portion of the matrix bit body surface.
    Type: Grant
    Filed: November 24, 2010
    Date of Patent: June 16, 2015
    Assignee: Kennametal Inc.
    Inventors: Xin Deng, Debangshu Banerjee, Michael Wilfert
  • Patent number: 9027674
    Abstract: A blank may include a tang section, a base section, and an angled section with a recess. The tang section may have an outer surface with an outer diameter. The base section may have an outer surface with a diameter greater than the outer diameter of the tang section. The angled section may lie between the tang section and the base section and may have an outer surface that transitions in diameter from the outer diameter of the tang section to the outer diameter of the base section. The recess in the angled section may be shaped to engage a tip of a former.
    Type: Grant
    Filed: June 22, 2011
    Date of Patent: May 12, 2015
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Jeffrey G. Thomas, Ronald E. Joy
  • Publication number: 20150122551
    Abstract: A multi-layer downhole drilling tool designed for directional and horizontal drilling is disclosed. The drilling tool includes a bit body including a rotational axis extending therethrough. A plurality of primary blades are disposed on exterior portions of the bit body and a plurality of secondary blades are disposed on exterior portions of the bit body between the primary blades. The drilling tool further includes a plurality of first-layer cutting elements disposed on exterior portions of the primary blades and a plurality of second-layer cutting elements disposed on exterior portions of the secondary blades. The second-layer cutting elements are track set with the first-layer cutting elements in an opposite track set configuration.
    Type: Application
    Filed: May 30, 2012
    Publication date: May 7, 2015
    Applicant: Halliburton Energy Services, Inc.
    Inventor: Shilin Chen
  • Publication number: 20150117940
    Abstract: A release assembly and a method of forming a drilling tool for rock or overburden drilling is provided. The release assembly is arranged axially between two drilling tool components. The release assembly includes a release mechanism allowing an initial axial length to shorten when a joint of the drilling tool components provided with connecting threads is turned in an opening direction. The release assembly has a decreased second axial length and friction forces in the joint decrease.
    Type: Application
    Filed: October 29, 2014
    Publication date: April 30, 2015
    Inventors: Mauri ESKO, Markku KESKINIVA
  • Publication number: 20150101868
    Abstract: A method including of manufacturing a drill bit includes inputting bit characteristics into a simulator. The bit characteristics may include a drill bit mass, coordinates of the bit center of gravity, and an inertia tensor of the bit. The bit center of gravity and a vector of the inertia tensor may be aligned with a bit axis in the simulator. Based on the alignment of the center of gravity and the inertia tensor with the bit axis, new bit characteristics may be determined. A drill bit with the new bit characteristics may be produced.
    Type: Application
    Filed: October 14, 2014
    Publication date: April 16, 2015
    Inventors: Luca Tedeschi, Gary Portwood, Zhehua Zhang
  • Publication number: 20150090501
    Abstract: A roller cutter drill bit with mixed bearing types includes a bit body with at least one journal facet and a cavity facet. A cavity extends into the bit body from the cavity facet. The bit body is configured to rotate about a bit axis during drilling. A journal extends outward from the at least one journal facet. A first rotatable cutter that supports a first plurality of cutting structures has a journal portion received by the cavity. A second rotatable cutter that supports a second plurality of cutting structures has a cavity portion that is receives the journal.
    Type: Application
    Filed: September 25, 2014
    Publication date: April 2, 2015
    Applicant: VAREL INTERNATIONAL IND., L.P.
    Inventor: William W. King
  • Patent number: 8973683
    Abstract: An apparatus and method for manufacturing a downhole tool that reduces failures occurring along a bondline between a cemented matrix coupled around a blank. The cemented matrix material is formed from a powder and a binder material. The blank includes an internal blank component and a coating coupled around at least a portion of the surface of the internal blank component. The internal blank component includes a top portion and a bottom portion. The internal blank component is substantially cylindrically shaped and defines a channel extending through the top portion and the bottom portion. The coating is a metal in some exemplary embodiments. The coating reduces the migration of the binder material into the blank thereby allowing the control of intermetallic compounds thickness within the bondline.
    Type: Grant
    Filed: May 21, 2012
    Date of Patent: March 10, 2015
    Assignee: Varel Europe S.A.S.
    Inventors: Bruno Cuillier De Maindreville, Williams Gomez
  • Patent number: 8973466
    Abstract: Earth-boring drill bits include a bit body, an element having an attachment feature bonded to the bit body, and a shank assembly. Methods for assembling an earth-boring rotary drill bit include bonding a threaded element to the bit body of a drill bit and engaging the shank assembly to the threaded element. A nozzle assembly for an earth-boring rotary drill bit may include a cylindrical sleeve having a threaded surface and a threaded nozzle disposed at least partially in the cylindrical sleeve and engaged therewith. Methods of forming an earth-boring drill bit include providing a nozzle assembly including a tubular sleeve and nozzle at least partially within a nozzle port of a bit body.
    Type: Grant
    Filed: February 25, 2013
    Date of Patent: March 10, 2015
    Assignee: Baker Hughes Incorporated
    Inventors: Oliver Matthews, III, David A. Stockey, Redd H. Smith
  • 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: 8955209
    Abstract: A method for bonding together components, such as a tip and a shaft which include mutually facing carbide end surfaces. The tip includes circumferentially spaced flutes formed in its cylindrical outer periphery. The shaft has a cylindrical outer periphery and a plurality of coolant holes extending through the shaft. Bonding of the tip to the shaft is performed by inserting gauge wires into the coolant holes and associated flutes, and positioning brazing material between the first and second end surfaces. A water-soluble bond-blocking material is applied to the gauge wires for preventing brazing of the gauge wires to the brazing material. The brazing material is heated to braze the first and second end surfaces together while the flutes and their associated coolant holes are maintained in alignment by the gauge wires. Then, the gauge wires are removed, and residual bond-blocking material is dissolved in water.
    Type: Grant
    Filed: October 24, 2012
    Date of Patent: February 17, 2015
    Assignee: Diamond Innovations, Inc.
    Inventors: Dwight E. Dyer, Ray Phillip Conley
  • Patent number: 8936115
    Abstract: A cutting table includes a cutting surface, an opposing surface, a cutting table outer wall, and one or more fins. The cutting table outer wall extends from the circumference of the opposing surface to the circumference of the cutting surface. The fins extend from a portion of the cutting surface to a portion of the cutting table outer wall. The cutting table is optionally leached prior to forming the fins. One or more fins are positioned in parallel with at least another fin in some embodiments. In some embodiments, the fins are positioned circumferentially around the cutting surface. In some embodiments, the cutting table is coupled to a substrate to form a cutter. The fins are formed either after or during the formation of the cutting table.
    Type: Grant
    Filed: August 24, 2010
    Date of Patent: January 20, 2015
    Assignee: Varel Europe S.A.S.
    Inventor: Federico Bellin
  • Patent number: 8925422
    Abstract: A method of manufacturing a drill bit having a bit body and a plurality of blades extending radially from the bit body is disclosed, wherein the method includes adhering a first matrix material to at least a portion of a mold cavity corresponding to an outer surface of the bit body, loading a second matrix material into the other portions of the mold cavity, and heating the mold contents to form a matrix body drill bit.
    Type: Grant
    Filed: December 10, 2010
    Date of Patent: January 6, 2015
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Youhe Zhang, Yuelin Shen
  • Patent number: 8915166
    Abstract: A bit mold is milled using a turning stage which forms a base mold component and a base gagering component. Next, a blade milling stage is performed in which the base mold component and base gagering component are milled to define integral junkslot formers separated by blade regions. Lastly, a pocket milling stage is performed in which the blade regions and integral junkslot formers of the base mold component are milled to define a plurality of cutter pockets in primary and perhaps secondary rows. Each cutter pocket includes a seat portion and a face portion. The milling of the pocket milling stage provides, at one or more of the cutter pockets, a facet. This facet is provided in an area about the junkslot former associated with the face portion of the cutter pocket, the face portion having, due to the presence of the facet, a surface for matching a cutter core displacement end surface without voids of a size which would require the use of fill material.
    Type: Grant
    Filed: July 25, 2008
    Date of Patent: December 23, 2014
    Assignee: Varel International Ind., L.P.
    Inventors: Scott Buteaud, Cary Maurstad
  • 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
  • Publication number: 20140328641
    Abstract: A drill bit has a shank (4) between a drilling head (3) and an insertable end (5) along an axis (2). The shank (4) is provided with at least two first flutes (34) that run along the axis (2) and at least a second helical flute (31). The first flutes (34) and the second flute (31) cross each other at several crossings (41).The width (35) of the first flute 34 steadily decreases over the area between two adjacent crossings (41) from one of the crossings (41) all the way to the narrowest place (42) and subsequently steadily increases all the way to the other crossing (41).
    Type: Application
    Filed: July 18, 2012
    Publication date: November 6, 2014
    Applicant: Hilti Aktiengesellschaft
    Inventors: Carsten Peters, Guenther Domani, Marcel Roessner, Josef Starkmann
  • Publication number: 20140246249
    Abstract: Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 4, 2014
    Inventors: Xiaomin C. Cheng, Eric C. Sullivan
  • Publication number: 20140216827
    Abstract: Cutter assemblies include an outer support and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also disclosed is downhole tools incorporating such cutter assemblies and methods of making such downhole tools.
    Type: Application
    Filed: April 11, 2014
    Publication date: August 7, 2014
    Applicant: Smith International, Inc.
    Inventors: Youhe Zhang, Yuelin Shen, Yuri Burhan, Gregory T. Lockwood
  • Publication number: 20140190752
    Abstract: A rotary drag bit for drilling subterranean formations includes a bit body having a face extending from a centerline to a gage. A plurality of blades may be disposed on the face, and may generally extend radially outwardly toward the gage. The bit may further include a plurality of discrete impregnated cutting posts, each of which may extend outwardly from an associated blade. Each discrete impregnated cutting post angles generally toward a front edge of the associated blade and generally toward the intended direction of rotation of the bit. The rotary drag bit may further include a plurality of matrix pockets disposed on the blades. The discrete impregnated cutting posts may be housed within corresponding matrix pockets.
    Type: Application
    Filed: March 10, 2014
    Publication date: July 10, 2014
    Applicant: Baker Hughes Incorporated
    Inventor: Michael L. Doster
  • Patent number: 8770324
    Abstract: Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component.
    Type: Grant
    Filed: June 10, 2008
    Date of Patent: July 8, 2014
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, Nicholas J. Lyons
  • Patent number: 8739904
    Abstract: Cutters for a drill bit wherein the cutters have at least one groove in a face of a superabrasive table of the cutters. The cutters may also include ribs adjacent to the at least one groove.
    Type: Grant
    Filed: August 7, 2009
    Date of Patent: June 3, 2014
    Assignee: Baker Hughes Incorporated
    Inventor: Suresh G. Patel
  • Publication number: 20140144711
    Abstract: A blank may include a tang section, a base section, and an angled section with a recess. The tang section may have an outer surface with an outer diameter. The base section may have an outer surface with a diameter greater than the outer diameter of the tang section. The angled section may lie between the tang section and the base section and may have an outer surface that transitions in diameter from the outer diameter of the tang section to the outer diameter of the base section. The recess in the angled section may be shaped to engage a tip of a former.
    Type: Application
    Filed: June 22, 2011
    Publication date: May 29, 2014
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Jeffrey G. Thomas, Ronald E. Joy
  • Publication number: 20140138162
    Abstract: A core drill bit includes an elongate hollow cylindrical body having opposite first and second end sections, a plurality of cutting segments with a connecting portion joined to the second end section, a plurality of reinforcing members joined to the second end section between the cutting segments and contacting adjacent cutting segments to offer rotational support thereto, and a plurality of current concentrators disposed on one or both of the second end section and the connecting portion. The cutting segments being capacitive discharge welded to the second end section whereby the surface of the second end section melts during the welding to affix the cutting segments with the tool body. The cutting segments include diamonds dispersed therein with portions having varying diamond concentrations.
    Type: Application
    Filed: October 3, 2013
    Publication date: May 22, 2014
    Applicant: Diamond Products, Limited
    Inventors: Karl H. Moller, Thomas G. Ruffner
  • Patent number: 8731717
    Abstract: Methods include one or more of robotically positioning a cutting element on an earth-boring tool, using a power-driven device to move a cutting element on an earth-boring tool, and robotically applying a bonding material for attaching a cutting element to an earth-boring tool. Robotic systems are used to robotically position a cutting element on an earth-boring tool. Systems for orienting a cutting element relative to a tool body include a power-driven device for moving a cutting element on or adjacent the tool body. Systems for positioning and orienting a cutting element on an earth-boring tool include such a power-driven device and a robot for carrying a cutting element. Systems for attaching a cutting element to an earth-boring tool include a robot carrying a torch for heating at least one of a cutting element, a tool body, and a bonding material.
    Type: Grant
    Filed: January 15, 2013
    Date of Patent: May 20, 2014
    Assignee: Baker Hughes Incorporated
    Inventors: David Keith Luce, Sean W. Wirth, Alan J. Massey, Crystal A. Parrot
  • Publication number: 20140054027
    Abstract: Internal coarse particle injection plasma transferred arc torch nozzles comprising: a heat-resistant nozzle body; at least one coarse hard-metal particle internal injection port; at least one fine hard-metal particle and matrix internal injection port; at least one gas port; and a cathode. Related systems, apparatus, compositions, and methods involving such arc torch nozzles are also disclosed.
    Type: Application
    Filed: June 15, 2011
    Publication date: February 27, 2014
    Applicant: Halliburton Energy Services, Inc.
    Inventor: Jay Stuart Bird
  • Patent number: 8601908
    Abstract: A method includes the steps of assembling cone-leg assemblies, rotating the cones on their respective cone-leg assemblies to predetermined orientations such that cutting structures of one of the cone-leg assemblies are clear from the cutting structures of neighboring cone-leg assemblies, and installing the cone-leg assemblies in a predetermined sequence such that the plurality of cone-leg assemblies to intermesh with each other. Another method includes the steps of thermally fitting a plurality of one piece extended mud nozzles into the bit body to form a plurality of substantially straight direct unobstructed mud laminar flow paths, inserting a plurality of guide pins in preformed locator recesses in the body, and orienting a pre-assembled cone-leg assembly to align a groove on an inner surface of the leg with one of the plurality of guide pins, while thermally fitting the cone-leg assembly into a preformed bore in the body.
    Type: Grant
    Filed: April 2, 2012
    Date of Patent: December 10, 2013
    Inventor: Edward Vezirian
  • Publication number: 20130277121
    Abstract: Methods, systems, and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.
    Type: Application
    Filed: June 17, 2013
    Publication date: October 24, 2013
    Inventors: John H. Stevens, Jimmy W. Eason
  • Patent number: 8534384
    Abstract: A drill bit in one aspect includes a cutting device on a selected section of the drill bit, which cutting device is configured to cut formation on the high side of a wellbore during drilling of the wellbore. In one aspect, the cutting device comprises a cutting element disposed on a substantially non-rotating member placed around the selected section. In another aspect, the selected section may be a gage section of the drill bit.
    Type: Grant
    Filed: December 23, 2009
    Date of Patent: September 17, 2013
    Assignee: Baker Hughes Incorporated
    Inventors: Chad J. Beuershausen, Thorsten Schwefe, Britney E. Meckfessel, Trung Q. Huynh
  • 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
  • Publication number: 20130160611
    Abstract: Earth-boring drill bits include a bit body, an element having an attachment feature bonded to the bit body, and a shank assembly. Methods for assembling an earth-boring rotary drill bit include bonding a threaded element to the bit body of a drill bit and engaging the shank assembly to the threaded element. A nozzle assembly for an earth-boring rotary drill bit may include a cylindrical sleeve having a threaded surface and a threaded nozzle disposed at least partially in the cylindrical sleeve and engaged therewith. Methods of forming an earth-boring drill bit include providing a nozzle assembly including a tubular sleeve and nozzle at least partially within a nozzle port of a bit body.
    Type: Application
    Filed: February 25, 2013
    Publication date: June 27, 2013
    Applicant: BAKER HUGHES INCORPORATED
    Inventor: Baker Hughes Incorporated
  • 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: 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: 8355815
    Abstract: Methods include one or more of robotically positioning a cutting element on an earth-boring tool, using a power-driven device to move a cutting element on an earth-boring tool, and robotically applying a bonding material for attaching a cutting element to an earth-boring tool. Robotic systems are used to robotically position a cutting element on an earth-boring tool. Systems for orienting a cutting element relative to a tool body include a power-driven device for moving a cutting element on or adjacent the tool body. Systems for positioning and orienting a cutting element on an earth-boring tool include such a power-driven device and a robot for carrying a cutting element. Systems for attaching a cutting element to an earth-boring tool include a robot carrying a torch for heating at least one of a cutting element, a tool body, and a bonding material.
    Type: Grant
    Filed: February 12, 2009
    Date of Patent: January 15, 2013
    Assignee: Baker Hughes Incorporated
    Inventors: David Keith Luce, Sean W. Wirth, Alan J. Massey, Crystal A. Parrott
  • Patent number: 8347990
    Abstract: A drill bit may include a bit body having a plurality of blades extending radially therefrom, the bit body comprising a first matrix region and a second matrix region, wherein the first matrix region is formed from a moldable matrix material having carbide particles with a unimodal particle size distribution; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.
    Type: Grant
    Filed: November 18, 2009
    Date of Patent: January 8, 2013
    Assignee: Smith International, Inc.
    Inventors: Gregory T. Lockwood, Youhe Zhang, Yuelin Shen
  • Publication number: 20120318584
    Abstract: Rotary rock bit comprising a tool body having an axial core (1) and radial blades (2) made of steel, grooves (6) hollowed out in the edge (5) of the blades, transversely thereto, and cylindrical abrasive elements (8) comprising impregnated diamonds, which are disposed in the grooves, transversely to the blades.
    Type: Application
    Filed: December 31, 2010
    Publication date: December 20, 2012
    Applicant: Diamant Drilling Services S.A.
    Inventors: Abdelhakim Hahati, Sebastian Desmette
  • Patent number: 8333814
    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.
    Type: Grant
    Filed: March 3, 2009
    Date of Patent: December 18, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Van J. Brackin, Jeffrey B. Lund, Danny E. Scott, Marcus R. Skeem, Matthew R. Isbell
  • Patent number: 8309018
    Abstract: Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material.
    Type: Grant
    Filed: June 30, 2010
    Date of Patent: November 13, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, John H. Stevens, James L. Duggan, Nicholas J. Lyons, Jimmy W. Eason, Jared D. Gladney, James A. Oxford, Benjamin J. Chrest
  • Patent number: 8307739
    Abstract: Methods of forming cutting element pockets in earth-boring tools may include forming a first recess and a second recess. A filler material is disposed in the second recess to the form at least a portion of a back surface of the pocket. Methods of forming cutting element pockets in earth-boring tools may include orienting a rotating cutter generally parallel to a longitudinal axis of a cutting element pocket to be formed in a body of an earth-boring tool and machining the cutting element pocket in the earth-boring tool. Methods of forming earth-boring tools include forming a body comprising at least one blade and forming at least one cutting element pocket in the at least one blade.
    Type: Grant
    Filed: October 20, 2010
    Date of Patent: November 13, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: John H. Stevens, Nicholas J. Lyons
  • Publication number: 20120273281
    Abstract: A cutting element is disclosed that has a sleeve with a first inner diameter and a second inner diameter, wherein the second inner diameter is larger than the first inner diameter and located at a lower axial position than the first inner diameter, a rotatable cutting element having an axis of rotation extending therethrough, the rotatable cutting element at least partially disposed within the sleeve, wherein the rotatable cutting element has a cutting face and a body extending axially downward from the cutting face, at least one hole extending from an outer surface of the body toward the axis of rotation, and a locking device disposed in each hole, wherein the locking device protrudes from the hole to contact the second inner diameter of the sleeve, thereby retaining the rotatable cutting element within the sleeve.
    Type: Application
    Filed: April 26, 2012
    Publication date: November 1, 2012
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: Yuri Burhan, Jiaqing Yu, Jonan M. Fulenchek, Youhe Zhang, Yuelin Shen
  • Patent number: 8272295
    Abstract: Displacement members for use in forming a bit body of an earth-boring rotary drill bit include a body having an exterior surface, at least a portion of which is configured to define at least one surface of the bit body as the bit body is formed around the displacement member. In some embodiments, the body may be hollow and/or porous. Methods for forming earth-boring rotary drill bits include positioning such a displacement member in a mold and forming a bit body around the displacement member in the mold. Additional methods include pressing a plurality of particles to form a body, forming at least one recess in the body, positioning such a displacement member in the recess, and sintering the body to form a bit body.
    Type: Grant
    Filed: December 7, 2006
    Date of Patent: September 25, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: 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
  • Publication number: 20120192680
    Abstract: A mill body is machined integrally with blades that have pockets to receive PDC inserts. The insert pockets can have an orientation feature to ensure that inserts that require specific rotational orientation are put into the pockets at the right orientation for efficient milling. The orientation of some of the pockets closest to the bottom and center of the bit have their axis reoriented to a near parallel orientation to the bit center axis to allow the bit body and blade fabrication equipment access to drill the insert pocket.
    Type: Application
    Filed: January 27, 2011
    Publication date: August 2, 2012
    Applicant: BAKER HUGHES INCORPORATED
    Inventor: James S. Trahan
  • Patent number: 8230952
    Abstract: Earth-boring tools comprise a bit body comprising a face and a plurality of blades extending radially outward over the face and forming gage regions. A shank is coupled to the bit body and includes a threaded portion for connecting to a drill string. A sleeve structure is positioned adjacent to the bit body and surrounds a portion of the shank, the sleeve structure extending from adjacent the bit body to proximate the threaded portion of the shank. An outer surface of the sleeve structure comprises a plurality of circumferentially spaced gage pads extending thereover and may comprise a plurality of breaker flats.
    Type: Grant
    Filed: July 30, 2008
    Date of Patent: July 31, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Thorsten Schwefe, Henning Finke, Thomas Ganz
  • Patent number: 8230762
    Abstract: Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating the plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.
    Type: Grant
    Filed: February 7, 2011
    Date of Patent: July 31, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Heeman Choe, John H. Stevens, James C. Westhoff, Jimmy W. Eason, James L. Overstreet
  • 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: 8191658
    Abstract: Methods of forming cutting elements for earth-boring tools include providing a barrier material between a first powder and a second powder each comprising diamond grains, and subjecting the powders and barrier material to high temperature and high pressure conditions to form polycrystalline diamond material. The formation of the polycrystalline diamond material is catalyzed, and catalytic material may be hindered from migrating across the layer of barrier material. Cutting elements for use in earth-boring tools include a barrier material disposed between a first layer of polycrystalline diamond material and a second layer of polycrystalline diamond material. Earth-boring tools include one or more such cutting elements for cutting an earth formation.
    Type: Grant
    Filed: August 20, 2009
    Date of Patent: June 5, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: Kurtis Schmitz, Danny E. Scott