Classifications

• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
  • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
  • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
  • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
  • C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C45/00—Amorphous alloys
  • C22C45/02—Amorphous alloys with iron as the major constituent
• • 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
  • E21B10/50—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of roller type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware

Definitions

• the present invention relates in general to hardfacing and, in particular, to an improved highly abrasive wear metal matrix composite hardfacing materials, such as for downhole tools.
• earth-boring bits 15 It is a long-standing practice in the design and manufacture of earth-boring bits 15 to apply wear-resistant hardfacing materials to the surfaces of such bits that are subjected to abrasive wear during drilling operations, hi earth-boring bits of the rolling cutter variety, these surfaces include the teeth of bits of the milled or steel tooth variety, the gage surfaces of the rolling cutters and the shirttails of the bit legs comprising the bit body.
• these hardfacing compositions generally comprise carbides of the elements of Groups IVB, VB and VIB in a matrix metal of iron, cobalt or nickel and alloys and mixtures thereof.
• the hardfacing is applied by melting the matrix and a portion of the surface to which the hardfacing is applied with an oxyacetylene or atomic hydrogen torch.
• the carbide particles give the hardfacing material hardness and wear 25 resistance, while the matrix metal lends the hardfacing fracture toughness.
• a hardfacing composition must strike an adequate balance between wear resistance (hardness) and fracture toughness.
• a hardfacing composition that is extremely hard and wear-resistant may lack fracture toughness, causing the hardfacing to crack and flake prematurely. Conversely, a hardfacing with adequate fracture toughness, but inadequate hardness 30 and wear resistance, is eroded prematurely and fails to serve its purpose.
• U.S. Pat. No. 4,836,307 to Keshavan, discloses a hardfacing composition employing particles of cemented or sintered tungsten carbide and relatively small particles of single crystal monotungsten carbide, sometimes referred to as "macrocrystalline" tungsten carbide, in a mild steel matrix.
• This composition purports to possess the advantages of sintered tungsten carbide, as disclosed in U.S. Pat. No. 3,800,891, with the advantages of single crystal monotungsten carbide, which is harder than the cemented or sintered tungsten carbide, yet is less brittle than the alternative cast carbide.
• U.S. Pat. No. 5,089,182 discloses a method of manufacturing cast carbide pellets that are generally spherical in shape and have improved mechanical and metallurgical properties over prior-art carbide pellets. These cast pellets are not truly spherical, but are sufficiently symmetrical that residual stresses in the pellets are minimized. Also, the generally spherical shape of these pellets eliminates corners, sharp edges and angular projections, which are present in conventional crushed particles, that increase residual stresses in the particles and tend to melt as the hardfacing composition is applied to the surface.
• U.S. Pat. No. 5,663,512 discloses a hardfacing composition which includes a quantity of spherical sintered tungsten carbide granules and a quantity of cast spherical cast tungsten carbide granules in a eutectic form of WC/W2C. During application, some melting of the sintered spherical carbide granules occurs, which precipitates into the metal matrix and coats the spherical WC/W2C granules.
• Embodiments of a system, method, and apparatus for a highly abrasive wear metal matrix composite hardfacing material for downhole tools are disclosed.
• the hardfacing material may comprise a matrix of relatively softer material with high hardness, such as amorphous nanocomposite steel alloys, and one or more hard component materials.
• the hard component materials may comprise sintered tungsten carbide (e.g., WC/Co), monocrystalline WC, multicrystalline or polycrystalline WC, and the additional component of spherical cast tungsten carbide (e.g., a eutectic of
• WC/W2C WC/W2C
• a matrix of softer material, hard component materials and crushed cast tungsten carbide may be used.
• FIG. 1 is an isometric view of one embodiment of a bit constructed in accordance with the present invention
• FIG. 2 is a micrograph illustration of one embodiment of hardfacing material constructed in accordance with the invention
• FIG. 3 is a micrograph illustration of another embodiment of hardfacing material constructed in accordance with the invention.
• Hardfacing materials formed from amorphous nanocomposite steel alloys such as NANOSTEEL®, such as those now commercially available for plasma transferred arc (PTA) welding applications. Some recent materials are reported to have high hardness while retaining their toughness, which is desirable for impact loading.
• sintered tungsten carbide or cast tungsten carbide e.g., spherical or crushed, monocrystalline or polycrystalline WC, or other carbide formers may be used as the hard component materials in the softer amorphous nanocomposite steel alloys to achieve even better wear resistance without losing toughness or compromising the end deposit.
• these hard component materials especially spherical sintered tungsten carbide pellets and/or spherical cast tungsten carbide, superior wear resistant compositions are achieved.
• FIG. 1 one embodiment of a highly abrasive wear metal matrix composite hardfacing material 21 is shown.
• the hardfacing material may comprise a matrix 11 of a softer material with high hardness (e.g., a minimum of 60 Rc, and in some embodiments, 65+ Rc, e.g., 72 Rc) such as amorphous nanocomposite steel alloys (e.g., NANOSTEEL®) and one or more hard component materials.
• a softer material with high hardness e.g., a minimum of 60 Rc, and in some embodiments, 65+ Rc, e.g., 72 Rc
• amorphous nanocomposite steel alloys e.g., NANOSTEEL®
• the hard component materials may be selected from, for example, sintered tungsten carbide (e.g., WC/Co) (spherical 13 or crushed 15), monocrystalline WC, macrocrystalline WC, multicrystal or polycrystalline WC and, in some embodiments, the additional component of spherical cast tungsten carbide (e.g., a eutectic of WC/W2C) 17, each of which may be crushed in form.
• a matrix 31 of relatively softer material e.g., amorphous nanocomposite steel alloy
• hard component materials such as monocrystalline WC 33 and crushed cast tungsten carbide 35.
• the invention may comprise numerous different size ratios between the various components.
• the particle size for each component may range from, for example, mesh -16 to +325.
• the distribution between the components also may be formulated in weight percentages as, for example, 30wt% soft component and 70wt% hard component.
• the range for other embodiments comprises a soft component low end of about 20wt% to a soft component high end of 90%, with complementary hard component low and high ends at 10wt% and 80wt%.
• the hard component may comprise up to 100% sintered tungsten carbide (e.g., crushed or spherical), or less than 100% spherical cast tungsten carbide (e.g., crushed), or mono- , macro- or polycrystalline WC, or any combination thereof.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Organic Chemistry (AREA)
• Metallurgy (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Geology (AREA)
• Mining & Mineral Resources (AREA)
• Fluid Mechanics (AREA)
• Geochemistry & Mineralogy (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Life Sciences & Earth Sciences (AREA)
• Environmental & Geological Engineering (AREA)
• Physics & Mathematics (AREA)
• Earth Drilling (AREA)
• Powder Metallurgy (AREA)
• Drilling Tools (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)
• Cutting Tools, Boring Holders, And Turrets (AREA)

Applications Claiming Priority (3)

Publications (1)

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• 2007
  • 2007-12-12 US US11/954,909 patent/US20080149397A1/en not_active Abandoned
  • 2007-12-20 MX MX2009006658A patent/MX2009006658A/es unknown
  • 2007-12-20 EP EP07853447A patent/EP2118329A1/de not_active Withdrawn
  • 2007-12-20 RU RU2009127643/02A patent/RU2009127643A/ru not_active Application Discontinuation
  • 2007-12-20 WO PCT/US2007/026050 patent/WO2008079285A1/en not_active Ceased

Non-Patent Citations (1)

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