# US 8,464,814 B2 · Systems for manufacturing downhole tools and downhole tool parts

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- Number: US 8,464,814 B2
- Document ID: US8464814B2
- Status: Granted
- Kind: B2
- Application number: 13/158,361
- Filed: 2011-06-10
- Published: 2011-10-27
- Granted: 2013-06-18
- Earliest claimed: 2009-06-05
- Assignees: Baker Hughes Incorporated
- Applicants: John H. Stevens; Jimmy W. Eason
- Inventors: John H. Stevens; Jimmy W. Eason
- Web page: https://patentgrep.com/patent/US8464814B2

## CPC

- E21B 10/46: characterised by wear resisting parts, e.g. diamond inserts
- B22D 19/06: for manufacturing or repairing tools
- B22F 5/007: {of moulds}
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B22F 2998/00: Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F 2998/10: Processes characterised by the sequence of their steps
- B33Y 80/00: Products made by additive manufacturing
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- 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
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

## Abstract

Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.

## Claims

### Claim 1

A downhole tool part for drilling subterranean material, the downhole tool part comprising:
a composite matrix composition comprising a constituent material and a carbide material, the composite matrix composition further comprising:
a continuous phase of the constituent material; and
a eutectic particulate phase formed from a eutectic composition of the constituent material and the carbide material; and
a particulate material dispersed throughout the composite matrix composition of the downhole tool part, the particulate material comprising at least one material selected from the group consisting of polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), and polycrystalline cubic boron nitride (PCBN).

### Claim 2 (depends on 1)

The downhole tool part of claim 1, wherein the constituent material and the carbide material are selected from the group consisting of: monotungsten carbide (WC), ditungsten carbide (W2C), cobalt, tungsten, iron, nickel, titanium, and boron carbide.

### Claim 3 (depends on 1)

The downhole tool part of claim 1, wherein the carbide material comprises tungsten carbide and the constituent material comprises cobalt.

### Claim 4 (depends on 3)

The downhole tool part of claim 3, wherein the composite matrix composition comprises about 25 atomic percent tungsten carbide and about 75 atomic percent cobalt.

### Claim 5 (depends on 3)

The downhole tool part of claim 3, wherein the composite matrix composition comprises equal to or greater than about 70 atomic percent cobalt.

### Claim 6 (depends on 1)

The downhole tool part of claim 1, wherein the downhole tool part is a bit body.

### Claim 7 (depends on 1)

The downhole tool part of claim 1, wherein the downhole tool part is a roller cone.

### Claim 8 (depends on 1)

The downhole tool part of claim 1, further comprising a bit body element comprising at least one material selected from the group consisting of: monotungsten carbide (WC), ditungsten carbide (W2C), macro-crystalline tungsten carbide, cobalt, titanium carbide, tantalum carbide, metal borides, metal oxides, metal nitrides, polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), tungsten, iron, nickel, titanium, and boron carbide.