Back to results
US 10,702,975 B2Granted
Drilling tools having matrices with carbide-forming alloys, and methods of making and using same
AssigneeLongyear TM, Inc.
InventorsCody A. Pearce, Michael D. Rupp, Christian M. Lambert
Life of this patent
Estimating the term…
Abstract
Drilling tools, such as drill bits, having a shank, a crown, and a plurality of abrasive cutting elements. In the case of impregnated drilling tools, the abrasive cutting elements are dispersed throughout at least a portion of the crown. In the case of surface-set drilling tools, the abrasive cutting media is secured to and projects from a cutting face of the crown. The matrix of the crown of the drilling tools includes a carbide-forming alloy that forms a direct carbide bond with at least one cutting element of the plurality of abrasive cutting elements.
Claims34
A diamond-impregnated drilling tool, comprising:
- a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;
- a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank;
- and
- a plurality of uncoated diamonds dispersed within at least a portion of the matrix of the crown body,
- wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond of the plurality of uncoated diamonds, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond and the carbide-forming alloy of the matrix, and
- wherein the carbide-forming alloy of the matrix is configured to convert portions of said at least one uncoated diamond of the plurality of uncoated diamonds to a carbide to form the direct carbide bond between the carbide-forming alloy of the matrix and said at least one uncoated diamond.
3 more elements
A drilling system, comprising:
- a drill string configured for rotation;
- and
- a diamond-impregnated drilling tool, wherein the drilling tool comprises:
- a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;
- a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank;
- and
- a plurality of uncoated diamonds dispersed within at least a portion of the matrix of the crown body,
- wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond of the plurality of uncoated diamonds, and wherein the drilling tool does not include oxide layers between said at least one uncoated diamond and the carbide-forming alloy of the matrix, and
- wherein the carbide-forming alloy is configured to convert portions of the said at least one uncoated diamond of the plurality of uncoated diamonds to a carbide to form the direct carbide bond between the carbide-forming alloy of the matrix and said at least one uncoated diamond.
6 more elements
A method of drilling, comprising:
- securing a diamond-impregnated drilling tool to a drill string, wherein the drilling tool comprises:
- a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;
- a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank;
- and
- a plurality of uncoated diamonds dispersed within at least a portion of the matrix of the crown body,
- wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond of the plurality of uncoated diamonds, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond and the carbide-forming alloy of the matrix, and
- wherein the carbide-forming alloy of the matrix is configured to convert portions of said at least one uncoated diamond of the plurality of uncoated diamonds to a carbide to form the direct carbide bond between the carbide-forming alloy of the matrix and said at least one uncoated diamond;
- and
- rotating the drill string to cause the drilling tool to penetrate an earthen formation.
6 more elements
A method of forming a diamond-impregnated drilling tool, comprising:
- preparing a matrix of the drilling tool, the matrix comprising hard particulate material and a carbide-forming alloy;
- dispersing a plurality of uncoated diamonds within at least a portion of the matrix;
- infiltrating the matrix with a binder;
- securing a shank to the matrix;
- and
- heating the shank and the matrix to consolidate the drilling tool,
- wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, and wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond of the plurality of uncoated diamonds, and
- wherein the carbide-forming alloy converts portions of said at least one uncoated diamond of the plurality of uncoated diamonds to a carbide to form the direct carbide bond between the carbide-forming alloy of the matrix and said at least one uncoated diamond,
- wherein the method does not comprise multiple heating operations.
6 more elements
Dependencies are inferred from the claim text.