Back to results
US 5,957,006 AGranted
Fabrication method for rotary bits and bit components
AssigneeBaker Hughes Incorporated
InventorRedd H. Smith
Life of this patent
Estimating the term…
Abstract
A method of fabricating rotary bits for subterranean drilling by layering techniques such as are employed in rapid prototyping technology. Thin layers of powder may be sequentially deposited and fused or otherwise bonded to define the bit body, or thin sheets of material may be stacked, bonded and cut. Bit body components may also be formed by the method and subsequently assembled with other components made in like manner or by other methods to produce a bit body. Bits fabricated according to the method are also disclosed.
Claims52
A method of fabricating an article of manufacture from a three-dimensional, solid model of said article, comprising:
- depositing a first, substantially planar layer of matrix material;
- defining a periphery in said first layer at a first level corresponding to a periphery of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing said second layer to said first layer and defining a periphery in said second layer at a second level corresponding to a periphery of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing each of said third and successive layers to a next lower matrix material layer prior to depositing a next higher matrix material layer and defining a periphery in each of said third and successive layers corresponding to a periphery of said article solid model of a corresponding level until an article of matrix material corresponding in configuration and size to said three-dimensional article solid model is formed;
- and
- subsequently infiltrating said article of matrix material with a hardenable liquid binder material.
4 more elements
A method of fabricating an article of manufacture from a three-dimensional, solid model of said article, comprising:
- depositing a first, substantially planar layer of matrix material;
- defining a periphery in said first layer at a first level corresponding to a periphery of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing a portion of said second layer to said first layer to define a periphery in said second layer at a level corresponding to a periphery of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing a portion of each of said third and successive layers to a next lower matrix material layer prior to depositing a next higher matrix material layer to define a periphery in each of said third and subsequent layers corresponding to a periphery of said article solid model of a corresponding level until a matrix material exterior shell of an article corresponding in general exterior configuration and size to said three-dimensional article solid model is formed;
- and
- further comprising filling said shell with a hardenable material.
4 more elements
A method of fabricating an article of manufacture using a three-dimensional, solid model of at least one component of said article, comprising:
- depositing a first, substantially planar layer of matrix material;
- depositing a first, substantially planar layer of matrix material;
- defining a periphery in said first layer at a first level corresponding to a periphery of a first three-dimensional component of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing said second layer to said first layer and defining a periphery in said second layer at a second level corresponding to a periphery of said first three-dimensional component of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing each of said third and successive layers to a next lower matrix material layer prior to applying a next higher matrix material layer and defining a periphery in each of said third and successive layers corresponding to a periphery of said first three-dimensional component of said article solid model of a corresponding level until an article component corresponding in shape and size to said first three-dimensional component is formed;
- forming at least a second three-dimensional component of said article in substantially the same manner as said first three-dimensional component;
- and
- assembling said first three-dimensional component and said at least a second three-dimensional component of said article to define a larger component of said article.
6 more elements
A method of fabricating an article of manufacture from a three-dimensional, solid model of said article, comprising:
- providing a preformed element;
- depositing a first, substantially planar layer of matrix material over an area wherein said preformed element is located;
- defining a periphery in said first layer at a first level corresponding to a periphery of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing said second layer to said first layer and defining a periphery in said second layer at a second level corresponding to a periphery of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing each of said third and successive layers to a next lower matrix material layer prior to applying a next higher matrix material layer and defining a periphery in each of said third and successive layers corresponding to a periphery of said article solid model of a corresponding level until an article of matrix material corresponding in configuration and size to said three-dimensional article solid model is formed and said preformed element is at least partially enveloped by said deposited layers of matrix material.
3 more elements
A method of fabricating an article of manufacture from a three-dimensional, solid model of said article, comprising:
- depositing a first, substantially planar layer of matrix material;
- defining a periphery in said first layer at a first level corresponding to a periphery of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing said second layer to said first layer and defining a periphery in said second layer at a second level corresponding to a periphery of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing each of said third and successive layers to a next lower matrix material layer prior to applying a next higher matrix material layer and defining a periphery in each of said third and successive layers corresponding to a periphery of said article solid model of a corresponding level until an article of matrix material corresponding in configuration and size to said three-dimensional article solid model is formed;
- and
- machining said article of matrix material.
4 more elements
A method of fabricating an article of manufacture using a three-dimensional, solid model of at least one component of said article, comprising:
- depositing a first, substantially planar layer of matrix material;
- defining a periphery in said first layer at a first level corresponding to a periphery of a first three-dimensional component of said article solid model at said first level;
- depositing a second, substantially planar layer of matrix material on said first layer;
- securing said second layer to said first layer and defining a periphery in said second layer at a second level corresponding to a periphery of said first three-dimensional component of said article solid model at said second level;
- depositing third and successive layers of matrix material on said second layer, securing each of said third and successive layers to a next lower matrix material layer prior to applying a next higher matrix material layer and defining a periphery in each of said third and successive layers corresponding to a, periphery of said first three-dimensional component of said article solid model of a corresponding level until an article component corresponding in shape and size to said first three-dimensional component is formed;
- forming at least a second three-dimensional component of said article;
- and
- assembling said first three-dimensional component and said at least a second three-dimensional component of said article to define a larger component of said article and securing said first three-dimensional component and said at least a second three-dimensional component of said article together by infiltration of at least part of said assembly with a hardenable liquid binder.
5 more elements
Dependencies are inferred from the claim text.