Fusible metal clay, structures formed therefrom, and associated methods

A method of overlaying a downhole tool for engagement downhole, the method comprising:

• molding a clay in a wet state into a structure, the clay in the wet state being a workable combination comprising a first grain, a second grain, and a binder, the first grain comprising a metal alloy having a first hardness and a first melting point, the second grain comprising a second material, the second material having a second hardness greater than the first hardness of the metal alloy and having a second melting point higher than of the first melting point of the metal alloy, the binder binding the first and second grains into the workable combination and having a combustion temperature at least not greater than the first melting point;
• fusing the structure by applying a heat treatment to the molded clay at least up to the first melting point;
• cooling the fused structure;
• and
• attaching the fused structure to the downhole tool.

A downhole tool dressed by a method of overlaying the downhole tool for engagement downhole, the method comprising:

• molding a clay in a wet state into a structure, the clay in the wet state being a workable combination comprising a first grain, a second grain, and a binder, the first grain comprising a metal alloy having a first hardness and a first melting point, the second grain comprising a second material, the second material having a second hardness greater than the first hardness of the metal alloy and having a second melting point higher than of the first melting point of the metal alloy, the binder binding the first and second grains into the workable combination and having a combustion temperature at least not greater than the first melting point;
• and
• affixing the structure to the downhole tool by:
• positioning the structure in a fusible state adjacent the downhole tool;
• applying a heat treatment to the structure at least up to the first melting point;
• fusing the structure together with the applied heat treatment;
• and
• forming a metallurgical bond between the structure with the downhole tool with the applied heat treatment.