# US 2009/0260893 A1 · Matrix powder for matrix body fixed cutter bits

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- Number: US 2009/0260893 A1
- Document ID: US20090260893A1
- Status: Published application
- Kind: A1
- Application number: 12/189,992
- Filed: 2008-08-12
- Published: 2009-10-22
- Earliest claimed: 2008-04-18
- Assignees: Smith International, Inc.
- Inventors: Xiayang Sheng; Alan W. Lockstedt; Gregory T. Lockwood
- Web page: https://patentgrep.com/patent/US20090260893A1

## CPC

- C22C 29/08: based on tungsten carbide
- C22C 19/07: based on cobalt
- B22F 2998/00: Supplementary information concerning processes or compositions relating to powder metallurgy
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER

## Abstract

A matrix powder for forming a matrix bit body, the matrix powder essentially consisting of a plurality of carbide particles having a particle size distribution of ±20% of a median particle size; and a plurality of metal binder particles is disclosed.

## Claims

### Claim 1

A matrix powder for forming a matrix bit body, the matrix powder essentially consisting of:
a plurality of carbide particles having a particle size distribution of ±20% or less of a median particle size; and
a plurality of metal binder particles.

### Claim 2 (depends on 1)

The matrix powder of claim 1, wherein the plurality of metal binder particles comprise 8 to 12 wt % of the matrix powder.

### Claim 3 (depends on 1)

The matrix powder of claim 1, wherein the plurality of carbide particles comprise at least one of cast tungsten carbide, cemented tungsten carbide, and macrocrystalline tungsten carbide.

### Claim 4 (depends on 3)

The matrix powder of claim 3, wherein the plurality of carbide particles comprise at least one of spherical cast tungsten carbide and crushed cast tungsten carbide.

### Claim 5 (depends on 1)

The matrix powder of claim 1, wherein a mean particle size of the plurality of carbide particles ranges from 50 to 840 microns.

### Claim 6

A matrix powder for forming a matrix bit body, the matrix powder essentially consisting of:
a plurality of carbide particles, wherein 90% of the plurality of carbide particles have a particle size within 20% or less of a median particle size of the plurality of carbide particles; and
a plurality of metal binder particles.

### Claim 7 (depends on 6)

The matrix powder of claim 6, wherein the plurality of metal binder particles comprise 8 to 12 wt % of the matrix powder.

### Claim 8 (depends on 6)

The matrix powder of claim 6, wherein the plurality of carbide particles comprise at least one of cast tungsten carbide, cemented tungsten carbide, and macrocrystalline tungsten carbide.

### Claim 9 (depends on 8)

The matrix powder of claim 8, wherein the plurality of carbide particles comprise at least one of spherical cast tungsten carbide and crushed cast tungsten carbide.

### Claim 10 (depends on 6)

The matrix powder of claim 6, wherein a mean particle size of the plurality of carbide particles ranges from 50 to 840 microns.

### Claim 11

A drill bit, comprising:
a bit body having a plurality of blades extending radially therefrom, at least a portion of the plurality of blades comprises a first matrix region comprising a plurality of first carbide particles separated by a first binder phase, wherein the plurality of first carbide particles have a mean free path of at least 40 microns; and
at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.

### Claim 12 (depends on 11)

The drill bit of claim 11, wherein the plurality of first carbide particles have a mean free path of at least 50 microns.

### Claim 13 (depends on 12)

The drill bit of claim 12, wherein the plurality of first carbide particles have a mean free path of at least 60 microns.

### Claim 14 (depends on 11)

The drill bit of claim 11, wherein the first binder phase comprises from about 35 to 55 percent by volume of the first matrix region.

### Claim 15 (depends on 14)

The drill bit of claim 14, wherein the first binder phase comprises from about 40 to 50 percent by volume of the first matrix region.

### Claim 16 (depends on 12)

The drill bit of claim 12, wherein the first matrix region is formed from a first matrix powder and an infiltrant binder, the matrix powder consisting essentially of:
a plurality of first carbide particles having a particle size distribution of ±20% of a median particle size; and
a plurality of first binder particles.

### Claim 17 (depends on 11)

The drill bit of claim 11, wherein at least a portion of the plurality of blades comprises a second matrix region a plurality of second carbide particles separated by a second binder phase, wherein the plurality of second carbide particles have a particle size distribution of greater than ±20% of a median particle size.

### Claim 18 (depends on 17)

The drill bit of claim 17, wherein the plurality of second carbide particles comprise at least one of cemented tungsten carbide, cast tungsten carbide, macrocrystalline tungsten carbide, carburized tungsten carbide, and combinations thereof.

### Claim 19 (depends on 17)

The drill bit of claim 17, wherein the plurality of second carbide particles comprise at least two types of carbide particles each having a particle size distribution of greater than ±20% of a median particle size for each type of carbide particle.

### Claim 20 (depends on 17)

The drill bit of claim 17, wherein the first matrix region forms a cutting portion of the plurality of blades, and the second matrix region forms a base portion of the plurality of blades.