# US 8,770,324 B2 · Earth-boring tools including sinterbonded components and partially formed tools configured to be sinterbonded

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- Number: US 8,770,324 B2
- Document ID: US8770324B2
- Status: Granted
- Kind: B2
- Application number: 12/136,703
- Filed: 2008-06-10
- Published: 2009-12-10
- Granted: 2014-07-08
- Earliest claimed: 2008-06-10
- Assignees: Baker Hughes Incorporated
- Applicants: Redd H. Smith; Nicholas J. Lyons
- Inventors: Redd H. Smith; Nicholas J. Lyons
- Web page: https://patentgrep.com/patent/US8770324B2

## CPC

- B24D 3/007: {the constituent being used as bonding agent between different parts of an abrasive tool}
- B22F 3/10: Sintering only
- B22F 3/1017: {Multiple heating or additional steps (B22F3/101 takes precedence)}
- B22F 3/16: in successive or repeated steps
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B22F 7/062: {involving the connection or repairing of preformed parts}
- B24D 3/06: metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements}
- B24D 3/20: and being essentially organic
- B24D 18/0009: {using moulds or presses}
- E21B 10/00: Drill bits (specially adapted for deflecting the direction of boring {E21B7/064}; with means for collecting substances E21B27/00)
- E21B 10/42: Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits (characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62)
- E21B 10/54: the bit being of the rotary drag type, e.g. fork-type bits
- E21B 10/55: with preformed cutting elements
- E21B 10/602: {the bit being a rotary drag type bit with blades}
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B22F 2005/002: {Tools other than cutting tools}
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)
- 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
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS

## Abstract

Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component. Earth-boring rotary drill bits comprise such components sinterbonded together.

## Claims

### Claim 1

A partially formed earth-boring rotary drill bit, comprising:
a first less than fully sintered particle-matrix component configured to form at least a portion of a bit body of an earth-boring rotary drill bit, the first less than fully sintered particle-matrix component having at least one recess therein;
wherein the first less than fully sintered particle-matrix component comprises a first amount of organic material; and
at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess in the first less than fully sintered particle-matrix component and at least partially surrounded by the first less than fully sintered particle-matrix component;
wherein the at least a second less than fully sintered particle-matrix component comprises a second amount of organic material, the second amount of organic material constituting a smaller volume percentage of the at least a second less than fully sintered particle-matrix component relative to a volume percentage of the first less than fully sintered particle-matrix component constituted by the first amount of organic material;
wherein each of the first and at least a second less than fully sintered particle-matrix components comprises a green structure including compacted hard particles and particles comprising a metal alloy matrix material, and the at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of the organic material from within the first less than fully sintered particle-matrix component and from within the at least a second less than fully sintered particle-matrix component in a sintering process to be used to sinterbond the at least a second less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component.

### Claim 2 (depends on 1)

The partially formed earth-boring rotary drill bit of claim 1, wherein the first less than fully sintered particle-matrix component has a composition selected to exhibit a first wear resistance upon sintering and the at least a second less than fully sintered particle-matrix component has a composition selected to exhibit a second wear resistance greater than the first wear resistance upon sintering.

### Claim 3 (depends on 1)

The partially formed earth-boring rotary drill bit of claim 1, wherein the at least a second less than fully sintered particle-matrix component is configured to form at least a portion of a blade of the earth-boring rotary drill bit.

### Claim 4 (depends on 1)

The partially formed earth-boring rotary drill bit of claim 1, wherein the at least a second less than fully sintered particle-matrix component comprises an extension.