Earth-boring rotary drill bits and methods of manufacturing earth-boring rotary drill bits having particle-matrix composite bit bodies

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a plurality of green powder components, at least one green powder component of the plurality being configured to form a region of a bit body, providing the plurality of green powder components comprising isostatically pressing a powder mixture to form at least one green powder component of the plurality of green powder components;
• assembling the plurality of green powder components to form a green unitary structure;
• sintering the green unitary structure to a desired final density to form the bit body for the earth-boring rotary drill bit;
• attaching an extension to the bit body after sintering the green unitary structure to a desired final density;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming for an earth-boring rotary drill bit, the method comprising:

• providing a plurality of green powder components, at least one green powder component of the plurality configured to form a crown region of a bit body;
• at least partially sintering the plurality of green powder components to form a plurality of brown components;
• assembling the plurality of brown components to form a brown unitary structure;
• sintering the brown unitary structure to a final density to form the bit body;
• attaching an extension to the bit body after sintering the brown unitary structure to a final density;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a plurality of green powder components, at least one green powder component of the plurality configured to form a crown region of a bit body;
• sintering the plurality of green powder components to a desired final density to provide a plurality of fully sintered components;
• assembling the plurality of fully sintered components to form a unitary structure;
• sintering the unitary structure to bond the fully sintered components together and form the bit body;
• attaching an extension to the bit body after sintering the unitary structure;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• and
• at least partially sintering the green bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• machining at least one of a fluid passageway, a junk slot, and a cutter pocket in the green bit body;
• and
• at least partially sintering the green bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• partially sintering the green bit body to form a brown bit body;
• and
• machining at least one of a fluid passageway, a junk slot, and a cutter pocket in the brown bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• partially sintering the green bit body to form a brown bit body;
• machining at least one feature in the brown bit body;
• and
• subliquidus phase sintering the brown bit body to a final density;
• attaching an extension to the bit body after sintering the brown bit body to the final density;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• partially sintering the green bit body to form a brown bit body;
• machining at least one feature in the brown bit body;
• and
• sintering the brown bit body to a final density, comprising:
• subjecting the brown bit body to elevated temperatures in a vacuum furnace;
• and
• subjecting the brown bit body to substantially isostatic pressure after subjecting the brown bit body to the elevated temperatures in the vacuum furnace;
• attaching an extension to the bit body after sintering the brown bit body to the final density;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• a plurality of hard particles selected from the group consisting of diamond, boron carbide, boron nitride, aluminum nitride, and carbides or borides of the group consisting of W, Ti, Mo, Nb, V, Hf, Zr, and Cr;
• and
• a plurality of particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture with substantially isostatic pressure to form a green bit body;
• and
• at least partially sintering the green bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body comprising a particle-matrix composite material, providing a bit body comprising:
• providing a powder mixture comprising:
• providing a plurality of −400 ASTM mesh tungsten carbide particles, the plurality of tungsten carbide particles comprising between about 60% and about 95% by weight of the powder mixture;
• and
• mixing the plurality of a plurality of tungsten carbide particles with particles comprising a matrix material, the matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• pressing the powder mixture to form a green bit body;
• and
• at least partially sintering the green bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising:

• providing a bit body substantially formed of a particle-matrix composite material, the particle-matrix composite material comprising a plurality of hard particles dispersed throughout a matrix material, providing a bit body comprising:
• providing a first powder mixture;
• pressing the first powder mixture to form a first green component;
• partially sintering the first green component to form a first brown component;
• providing at least one additional powder mixture that is different from the first powder mixture;
• pressing the at least one additional powder mixture to form at least one additional green component;
• partially sintering the at least one additional green component to form at least one additional brown component;
• assembling the first brown component with the at least one additional brown component to form a brown bit body;
• and
• sintering the brown bit body to a final density;
• attaching an extension to the bit body after sintering the brown bit body to the final density;
• and attaching a shank that is configured for attachment to a drill string to the extension.

A method of forming a bit body for an earth-boring rotary drill bit, the method comprising:

• providing a plurality of components each comprising one of a green powder component, a brown component, and a fully sintered component, at least one component of the plurality of components including a plurality of hard particles and a matrix material, at least one component of the plurality of components being configured to form a region of a bit body, at least one component of the plurality of components comprising a fully sintered component;
• assembling the plurality of components to form a unitary structure;
• at least partially sintering the unitary structure to bond the plurality of components together and form the bit body;
• attaching an extension to the bit body after at least partially sintering the unitary structure;
• and attaching a shank configured for attachment to a drill string to the extension.

A method of forming a bit body for an earth-boring rotary drill bit, the method comprising:

• providing a plurality of components each comprising one of a green powder component, a brown component, and a fully sintered component, at least one component of the plurality of components including a plurality of hard particles and a matrix material, at least one component of the plurality of components being configured to form a region of a bit body, at least one component of the plurality of components comprising a fully sintered component;
• forming at least one component of the plurality of components, comprising:
• forming the at least one component of the plurality of components to comprise a plurality of −400 ASTM mesh tungsten carbide particles, the plurality of tungsten carbide particles comprising between about 60% and about 95% by weight of the at least one component, and a matrix material selected from the group consisting of cobalt-based alloys, iron-based alloys, nickel-based alloys, cobalt and nickel-based alloys, iron and nickel-based alloys, iron and cobalt-based alloys, aluminum-based alloys, copper-based alloys, magnesium-based alloys, and titanium-based alloys;
• assembling the plurality of components to form a unitary structure;
• and
• at least partially sintering the unitary structure to bond the plurality of components together and form the bit body;
• attaching an extension to the bit body after at least partially sintering the unitary structure;
• and attaching a shank configured for attachment to a drill string to the extension.

A method of forming an earth-boring rotary drill bit, the method comprising forming a bit body comprising a particle-matrix composite material, forming a bit body comprising:

• providing a powder mixture comprising a plurality of hard particles and a plurality of particles comprising a matrix material in a deformable member;
• providing at least one displacement at a location within the deformable member selected to form at least one feature of the bit body;
• pressing the powder mixture in the deformable member to form a green bit body;
• removing the green bit body from the deformable member;
• at least partially sintering the green bit body;
• attaching an extension to the bit body after at least partially sintering the green bit body;
• and
• attaching a shank that is configured for attachment to a drill string to the extension.