Boronized wear-resistant materials and methods thereof

An insert obtained by the method comprising:

• providing an insert formed of cemented tungsten carbide in a cobalt matrix;
• contacting the insert with a boron-yielding material, an activator, and a filler;
• and
• heating the insert and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the insert and form an integral boride layer on the insert, wherein the integral boride layer comprises tungsten carbide and a compound having the formula W3CoB3.

An earth-boring bit, comprising:

• a bit body having a leg;
• a roller cone rotatably mounted on the leg;
• and
• an insert protruding from the roller cone, the insert having an inner core formed of a carbide and an outer layer integral with the inner core, the outer layer including a compound represented by the formula W3CoB3.

A method of making a boron-containing composition comprising:

• providing cemented tungsten carbide in a cobalt matrix;
• contacting the cemented tungsten carbide with a boron-yielding material, an activator, and a filler;
• and
• heating the cemented tungsten carbide and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the cemented tungsten carbide and form a boride layer integral with the cemented tungsten carbide, wherein the boride layer comprises a compound having the formula W3CoB3.

A method of making a wear-resistant body, comprising:

• providing a substrate formed of cemented tungsten carbide in a cobalt matrix;
• contacting the substrate with a boron yielding material, an activator and a filler;
• and
• heating the substrate and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the substrate and form a boride layer integral with the substrate, wherein the boride layer includes tungsten carbide and a compound having the formula W3CoB3.

A method of making a rock bit, comprising:

• providing an insert formed of cemented tungsten carbide in a cobalt matrix;
• contacting the insert with a boron-yielding material, an activator, and a filler;
• heating the insert and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the insert and form a boronized insert having an integral boride layer as an outer surface, the boride layer including tungsten carbide and a compound having the formula W3CoB3;
• securing a portion of the boronized insert in a roller cone;
• and
• rotatably mounting the roller cone to a leg attached to a bit body.

A boron-containing composition, obtained by the method comprising:

• providing a substrate formed of cemented tungsten carbide in a cobalt matrix;
• contacting the substrate with a boron-yielding material, an activator, and a filler;
• and
• heating the substrate and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the substrate and form a boride layer integral with the substrate, wherein the boride layer comprises a compound having the formula W3MB3, where M is selected from the group consisting of Co, Fe, and Ni.

A wear-resistant body, obtained by the method comprising:

• providing a substrate formed of cemented tungsten carbide in a cobalt matrix;
• contacting the substrate with a boron-yielding material, an activator, and a filler;
• and
• heating the substrate and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the substrate and form a boride layer integral with the substrate, wherein the boride layer includes tungsten carbide and a compound having the formula W3MB3, where M is selected from the group consisting of Co, Fe, and Ni.

A method of making a boron-containing composition, comprising:

• providing cemented tungsten carbide in a cobalt matrix;
• contacting the cemented tungsten carbide with a boron-yielding material, an activator, and a filler;
• and
• heating the cemented tungsten carbide and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the cemented tungsten carbide and form a boride layer integral with the cemented tungsten carbide, wherein the boride layer comprises a compound having the formula W3MB3, where M is selected from the group consisting of Co, Fe, and Ni.

A method of making a rock bit, comprising:

• providing an insert formed of cemented tungsten carbide in a cobalt matrix;
• contacting the insert with a boron-yielding material, an activator, and a filler;
• heating the insert and the boron-yielding material to at least 800° C. for at least 8 hours so as to allow boron to molecularly diffuse into the insert and form an integral boride layer as an outer surface, the boride layer including tungsten carbide and a compound having the formula W3MB3, where M is selected from the group consisting of Co, Fe, and Ni;
• securing a portion of the boronized insert in a roller cone;
• and
• rotatably mounting the roller cone to a leg attached to a bit body.