EP1944461A2 - Verstärkende Deckschicht für Matrixbitkörper - Google Patents

Verstärkende Deckschicht für Matrixbitkörper Download PDF

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Publication number
EP1944461A2
EP1944461A2 EP07120761A EP07120761A EP1944461A2 EP 1944461 A2 EP1944461 A2 EP 1944461A2 EP 07120761 A EP07120761 A EP 07120761A EP 07120761 A EP07120761 A EP 07120761A EP 1944461 A2 EP1944461 A2 EP 1944461A2
Authority
EP
European Patent Office
Prior art keywords
matrix
drill bit
cutter
reinforcing overlay
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP07120761A
Other languages
English (en)
French (fr)
Other versions
EP1944461A3 (de
Inventor
Madapusi K. Keshavan
Kumar T. Kembaiyan
Alysia C. White
Anthony Griffo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Smith International Inc
Original Assignee
Smith International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Smith International Inc filed Critical Smith International Inc
Publication of EP1944461A2 publication Critical patent/EP1944461A2/de
Publication of EP1944461A3 publication Critical patent/EP1944461A3/de
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • E21B10/55—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits with preformed cutting elements

Definitions

  • Embodiments disclosed herein relate generally to PDC bit bodies.
  • embodiments disclosed herein relate generally to PDC matrix bit bodies having a reinforcing overlay disposed thereon.
  • PDC cutters are known in the art for use in earth-boring drill bits.
  • bits using PDC cutters include an integral bit body which may be made of steel or fabricated from a hard matrix material such as tungsten carbide (WC).
  • WC tungsten carbide
  • a plurality of PDC cutters is mounted along the exterior face of the bit body in extensions of the bit body called “blades.”
  • Each PDC cutter has a portion which typically is brazed in a recess or pocket formed in the blade on the exterior face of the bit body.
  • the PDC cutters are positioned along the leading edges of the bit body blades so that as the bit body is rotated, the PDC cutters engage and drill the earth formation.
  • high forces may be exerted on the PDC cutters, particularly in the forward-to-rear direction.
  • the bit and the PDC cutters may be subjected to substantial abrasive forces. In some instances, impact, vibration, and erosive forces have caused drill bit failure due to loss of one or more cutters, or due to breakage of the blades.
  • the bit body may be selected from a steel bit body and a matrix bit body. While steel body bits may have toughness and ductility properties which make them resistant to cracking and failure due to impact forces generated during drilling, steel is more susceptible to erosive wear caused by high-velocity drilling fluids and formation fluids which carry abrasive particles, such as sand, rock cuttings, and the like. Thus, steel body PDC bits are generally coated with a more erosion-resistant material, such as tungsten carbide, to improve their erosion resistance.
  • a hardfacing material is applied, such as by arc or gas welding, to the exterior surface of the drill bit to protect the bit against erosion and abrasion, such as by techniques described U.S. Patent No. 6,601,475 , which is herein incorporated by reference in its entirety.
  • Hardfacing is typically applied to the bit prior to brazing of the cutters to the to the bit body.
  • the hardfacing material typically includes one or more metal carbides, which are bonded to the steel body by a metal alloy (“binder alloy”), which is typically a steel alloy.
  • bin alloy metal alloy
  • the carbide particles are suspended in a matrix of steel forming a layer on the surface of the steel substrate.
  • the carbide particles give the hardfacing material hardness and wear resistance, while the matrix metal provides fracture toughness to the hardfacing.
  • hardfacing materials used on steel bit bodies generally exhibit better erosion and abrasion resistance than the matrix material used in matrix bit bodies.
  • Hardfacing materials have also been applied in localized regions of a bit body, such as, for example, in the area surrounding the cutter pocket described in U.S. Patent No. 6,772,849 , which is herein incorporated by reference in its entirety.
  • hardfacing materials used are relatively hard and brittle. During use of hardfaced bits, a thin coating of the erosion-resistant material may crack, peel off or wear, exposing the softer steel body which is then rapidly eroded. This can lead to loss of PDC cutters as the area around the cutter is eroded away, causing the bit to fail. Due to the high failure rates caused by the undercutting of the steel body and poor coverage of hardfacing near and between the cutter pockets, a typical steel body bit generally achieve only 1-2 runs per bit.
  • the matrix bit body generally is formed by packing a graphite mold with tungsten carbide powder and then infiltrating the powder with a molten copper-based alloy binder.
  • macrocrystalline tungsten carbide and cast tungsten carbide have been used to fabricate bit bodies.
  • Macrocrystalline tungsten carbide is essentially stoichiometric WC which is, for the most part, in the form of single crystals. Some large crystals of macro-crystalline WC are bi-crystals.
  • Carburized tungsten carbide has a multi-crystalline structure, i.e., they are composed of WC agglomerates.
  • Cast tungsten carbide is formed by melting tungsten metal (W) and tungsten monocarbide (WC) together such that a eutectic composition of WC and W 2 C, or a continuous range of compositions therebetween, is formed.
  • Cast tungsten carbide typically is frozen from the molten state and comminuted to a desired particle size.
  • Sintered tungsten carbide comprises small particles of tungsten carbide (e.g., 1 to 15 microns) bonded together with cobalt.
  • Sintered tungsten carbide is made by mixing organic wax, tungsten carbide and cobalt powders, pressing the mixed powders to form a green compact, and "sintering" the composite at temperatures near the melting point of cobalt. The resulting dense sintered carbide can then be crushed and comminuted to form particles of sintered tungsten carbide for use in hardfacing.
  • hardfacing materials which have been conventionally applied to steel bit bodies to improve wear/erosion resistance have never been extended to matrix bit bodies because the difference in the substrate material, i.e., matrix material, has always been thought to prevent adhesion/bonding of the hardfacing materials to the matrix body substrate.
  • embodiments disclosed herein relate to a drill bit that includes a matrix bit body having a reinforcing overlay thereon and 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; and a braze material disposed between the at least one cutter and the at least one cutter pocket, wherein the reinforcing overlay comprises carbide particles and at least one binder and has a melting point greater than a melting point of the braze material.
  • embodiments disclosed herein relate to a drill bit that includes a matrix bit body having a reinforcing overlay thereon and 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; and a braze material disposed between the at least one cutter and the at least one cutter pocket, wherein the reinforcing overlay comprises carbide particles and at least one binder and has a hardness greater than about 50 HRc.
  • embodiments disclosed herein relate to a method of forming a drill bit that includes forming a matrix bit body having at least one blade thereon, wherein the at least one blade has at least one cutter pocket disposed thereon; applying a reinforcing overlay to the formed matrix bit body; and brazing at least one cutter in the at least one cutter pocket with a braze material.
  • FIG. 1 is an illustration of a PDC drill bit.
  • a fixed cutter drill bit 10 has a matrix bit body 12 on which a reinforcing overlay may be disposed (not shown).
  • the lower face of the bit body 12 is formed with a plurality of blades 14, which extend generally outwardly away from a central longitudinal axis of rotation 16 of the drill bit.
  • a plurality of PDC cutters 18 are disposed side by side along the length of each blade. The number of PDC cutters 18 carried by each blade may vary.
  • the PDC cutters 18 are individually brazed to a stud-like carrier (or substrate), which may be formed from tungsten carbide, and are received and secured (brazed) within sockets in the respective blade.
  • a matrix bit body may include tungsten carbide particles may be surrounded by a metallic binder.
  • the matrix bit body may be formed, for example, by packing a graphite mold with tungsten carbide powder and then infiltrating the powder with a molten binder.
  • tungsten carbide particles used in the fabrication of the bit body, those generally used include, for example, macrocrystalline tungsten carbide, cast tungsten carbide, carburized tungsten carbide, and cemented or sintered tungsten carbide.
  • the metallic binder surrounding the tungsten carbide particles may be formed from a metallic binder powder and an infiltration binder.
  • the metallic binder powder may be pre-blended with the matrix powder hard carbide particles, which is then is infiltrated by an infiltration binder.
  • infiltration binder refers to a metal or an alloy used in an infiltration process to bond the various particles of tungsten carbide forms together. Suitable metals include all transition metals, main group metals and alloys thereof. For example, copper, nickel, iron, and cobalt may be used as the major constituents in the infiltration binder.
  • the infiltration binder is selected from at least one of nickel, copper, and alloys thereof.
  • the infiltration binder includes a Cu-Mn-Ni-Zn alloy.
  • Such matrix bit bodies may have, for example, a hardness ranging from 38-45 HRc, a fracture toughness of at least 20 ksi(in 0.5 ), and a transverse rupture strength of at least 120 ksi in one embodiment and ranging from about 130 to 180 in another embodiment.
  • the matrix powder comprises a mixture of tungsten carbides and a metallic binder powder.
  • nickel and/or iron powder may be present as the balance of the matrix powder, typically from about 2% to 12% by weight.
  • other Group VIIIB metals such as cobalt and various alloys may also be used.
  • Co and/or Ni is present as the balance of the mixture in a range of about 2% to 15 % by weight.
  • Metal addition in the range of about 1 % to about 15 % may yield higher matrix strength and toughness, as well as higher braze strength.
  • the matrix powder mixture may include at least 80% by weight carbide of the total matrix powder. While reference is made to tungsten carbide, other carbides of Group 4a, 5a, or 6a metals may be used. Although the total carbide may be used in an amount less than 80% by weight of the matrix powder, such matrix bodies may not possess the desired physical properties to yield optimal performance.
  • the amount of the metallic binder and carbide hard particles in forming the matrix body may range, in one embodiment, in a ratio of from 30:70 to 40:60 by volume (binder: carbide). In other embodiments, the total carbide may be used in an amount less than 60% by volume or greater than 70% by volume of the matrix body, such matrix bodies may also not possess the desired physical properties to yield optimal performance.
  • the reinforcing overlay that may be disposed on the matrix bit body may include particles of tungsten carbide or other wear resistant particles (e.g., borides, nitrides, carbides or mixtures thereof) bonded to the matrix bit body by a metal alloy, which is also generally referred to as a binder alloy.
  • a metal alloy which is also generally referred to as a binder alloy.
  • the carbide particles are suspended in a matrix of metal forming a layer on the surface.
  • the wear resistant particles give the reinforcing overlay hardness and wear resistance, while the matrix metal (or alloy) provides fracture toughness to the reinforcing overlay and contributes to the bonding between the reinforcing overlay and the matrix bit body.
  • tungsten carbide may be used in the reinforcing overlay, including cast tungsten carbide, macro-crystalline tungsten carbide, cemented tungsten carbide, and carburized tungsten carbide.
  • cast tungsten carbide macro-crystalline tungsten carbide
  • cemented tungsten carbide cemented tungsten carbide
  • carburized tungsten carbide tungsten carbide
  • carbide combinations suitable for use in the reinforcing overlay disclosed herein may include those combinations described in U.S. Patent Nos. 4,836,307 , 5,791,422 , 5,921,330 , and 6,659,206 , which are herein incorporated by reference in their entirety.
  • the carbide content in the reinforcing overlay may vary from about 40 to 80 weight percent, with a binder alloy constituting the balance of the reinforcing overlay.
  • Binder alloys that may be used in various embodiments disclosed herein may include Ni and Co.
  • the binder alloy may include Group VIII metals such as Co, Ni, Fe, alloys thereof, or mixtures thereof.
  • the reinforcing overlay may have a hardness greater than that of the matrix bit body on which it is disposed. In other embodiments, the reinforcing overlay has a hardness of greater than about 50 HRc; from about 50 to 75 HRc in another embodiment; and greater than about 60, 65, and 70 HRc in various other embodiments. In another embodiment, the reinforcing overlay may have a strength greater than the strength of the matrix bit body on which the reinforcing overlay is disposed.
  • the melting point of the reinforcing overlay may be selected in accordance with a particular process of manufacturing the matrix bit body having a reinforcing overlay thereon. That is, the melting point of the reinforcing overlay may be selected to be greater than that of the braze material used to secure the PDC cutting element to the matrix bit body if the reinforcing overlay is applied prior to brazing the cutting elements to the bit body, and conversely, less than the melting point of braze material if the reinforcing overlay is applied subsequent to the brazing of the cutting elements to the bit body.
  • the reinforcing overlay has a melting point greater than that of the braze material used to secure the PDC cutters to the matrix bit body.
  • the reinforcing overlay has a melting point greater than about 1000°C.
  • the reinforcing overlay has a melting point ranging from about 1050 to 1400°C.
  • the reinforcing overlay may be disposed on substantially all surfaces of the matrix bit body.
  • the thickness of the reinforcing overlay may range from about 0.01 to 0.125 inches in one embodiment.
  • One of skill in the art would recognize the thickness need not be uniform across all surfaces of the matrix bit body; rather, it is within the scope of the present invention that the thickness may be varied to optimize performance.
  • the reinforcing overlay disclosed herein may be applied to the matrix bit body by using one of several various spraying techniques.
  • the reinforcing overlay may be applied by one of a d-gun, spray-and-fuse, or high velocity cold spray technique.
  • D-gun (detonation gun) coatings such as, for example, those described in U.S. Patent No. 5,535,838 , which is herein incorporated by reference in its entirety, include those coatings applied by the use of a d-gun.
  • the d-gun process includes gases, usually consisting of oxygen and a fuel gas mixture, that are fed into a barrel of the gun along with a charge of fine tungsten carbide-based powder.
  • the gases and the resulting detonation wave heat and accelerate the powder as it moves down the barrel.
  • the powder is entrained for a sufficient distance for it to be accelerated to a high velocity and for virtually all of the powder to become molten.
  • a pulse of inert nitrogen gas is used to purge the barrel after each detonation.
  • a reinforcing overlay applied by a d-gun process may be applied either prior to or subsequent to brazing of the cutting elements to the bit body.
  • the high velocity cold spray such as that described in U.S. Patent No. 6,780,458 , which is herein incorporated by reference in its entirety, involves a kinetic spray process that uses supersonic jets of compressed gas to accelerate near-room temperature powder particles at ultra high velocities.
  • the unmelted particles traveling at speeds between 500 to 1,500 m/sec plastically deform and consolidate on impact with their substrate to create a coating.
  • the basis of the cold spray process is the gas-dynamic acceleration of particulates to supersonic velocities (500-1500 m/sec), and hence high kinetic energies, so that solid-state plastic deformation and fusion occur on impact to produce dense coatings without the feedstock material being significantly heated.
  • the spray-and-fuse process is a two-step process in which a powdered coating material is deposited by using either a combustion gun or plasma spray gun, and subsequently fused to the matrix body substrate using either a heating torch or a furnace, for example, to temperatures ranging from 700-1200°C depending on the melting point of the overlay material.
  • the coatings are usually made of nickel or cobalt self-fluxing alloys to which hard particles, such as tungsten carbide, may be added for increased wear resistance.
  • a reinforcing overlay having the desired thickness may be formed by building up several layers at a rate of 0.005 to 0.030 inches per pass. Deposit thickness is controlled by the traverse speed of rotation (when done between centers on cylindrical parts), powder flow, and the number of layers applied.
  • thermal spray process examples include high velocity oxy-fuel spraying (HVOF), high velocity air fuel spraying (HVAF), flame spray, plasma spray or other applicable process as known by one of ordinary skill in the art.
  • HVOF high velocity oxy-fuel spraying
  • HVAC high velocity air fuel spraying
  • flame spray plasma spray or other applicable process as known by one of ordinary skill in the art.
  • OXY oxyacetylene welding process
  • PTA plasma transferred arc
  • AW atomic hydrogen welding
  • TOG welding via tungsten inert gas
  • GTAW gas tungsten arc welding
  • embodiments disclosed herein provides for a fixed cutter drill bit that may simultaneously achieve the inversely related properties of toughness and wear/erosion resistance.
  • a matrix bit body that includes a reinforcing overlay disclosed herein may possess the benefits of a tough core, providing resistance to cracking, and a superior wear resistant surface.
  • conventional matrix body bits are designed by balancing toughness and wear/erosion resistance; however, the bits disclosed herein may allow for a matrix bit body having improved transverse strength and toughness with aggressive blade design, without the concern of blade failure by erosion or wear.
  • the combination of the tough core and superior wear/erosion resistant exterior may allow faster rate of penetration, superior cutting element retention strength and durability due to the protected cutter surface by preventing erosion of the braze alloy and other areas surrounding the cutters, improved bit life due to minimal erosion of the bit body, and rebuildability of the bit.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
EP07120761A 2007-01-08 2007-11-15 Verstärkende Deckschicht für Matrixbitkörper Withdrawn EP1944461A3 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/650,860 US20080164070A1 (en) 2007-01-08 2007-01-08 Reinforcing overlay for matrix bit bodies

Publications (2)

Publication Number Publication Date
EP1944461A2 true EP1944461A2 (de) 2008-07-16
EP1944461A3 EP1944461A3 (de) 2009-11-25

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EP (1) EP1944461A3 (de)

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US11808089B2 (en) 2020-08-21 2023-11-07 Saudi Arabian Oil Company Coatings to prevent cutter loss in steel body PDC downhole tools

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US9987726B2 (en) 2013-10-17 2018-06-05 Halliburton Energy Services, Inc. Particulate reinforced braze alloys for drill bits
US11808089B2 (en) 2020-08-21 2023-11-07 Saudi Arabian Oil Company Coatings to prevent cutter loss in steel body PDC downhole tools

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Publication number Publication date
US20080164070A1 (en) 2008-07-10
EP1944461A3 (de) 2009-11-25

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