Methods for forming earth-boring tools having cutting elements mounted in cutting element pockets and tools formed by such methods
AssigneeBaker Hughes Incorporated
InventorsXiaomin C. Cheng, Eric C. Sullivan
Life of this patent
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Abstract
Methods of forming earth-boring tools include using a plasma spray device to gouge at least one recess through a hardfacing material and into a body. At least a portion of the recess may define a cutting element pocket in which a cutting element may be received and bonded. The recess formed using the plasma spray device optionally may be further machined to form the cutting element pocket. Earth-boring tools are fabricated using such methods.
Claims20
A method of forming an earth-boring tool, the method comprising:
- forming a hardfacing layer over at least one surface of a body;
- using a plasma spray device to gouge at least one recess through the hardfacing layer and into the body using a plasma emitted by the plasma spray device, at least a portion of the at least one recess defining a cutting element pocket;
- machining an interior surface of the at least one recess after using the plasma spray device to gouge the at least one recess;
- and
- securing at least one cutting element to the body at least partially within the cutting element pocket.
A method of forming an earth-boring rotary drill bit, the method comprising:
- depositing an abrasive and wear-resistant particle-matrix composite material over an outer surface of a blade of a bit body;
- gouging at least one recess extending through the composite material and into the bit body using a plasma;
- machining an interior surface of the at least one recess after using the plasma to gouge the at least one recess;
- and
- securing at least one cutting element to the bit body, the at least one cutting element disposed at least partially within the at least one recess extending through the composite material and into the bit body.
A method of forming an earth-boring tool, the method comprising:
- spraying plasma toward a body of an earth-boring tool having hardfacing thereon to partially form a cutting element pocket in the earth-boring tool;
- using a machining process to complete formation of the cutting element pocket in the earth-boring tool, the completely formed cutting element pocket extending through at least a portion of the hardfacing and into the body of the earth-boring tool;
- machining an interior surface of the cutting element pocket after spraying the plasma toward the body of the earth-boring tool;
- positioning at least one cutting element at least partially within the cutting element pocket;
- and
- securing the at least one cutting element to the body of the earth-boring tool.
An earth-boring tool, comprising:
- a hardfacing material on at least one surface of a body of the earth-boring tool;
- at least one cutting element pocket at least partially formed by gouging a recess through the hardfacing material and into the body of the earth-boring tool using plasma;
- an interior surface of the at least one cutting element pocket formed by machining the at least one cutting element pocket after using the plasma to gouge the recess;
- and
- at least one cutting element at least partially disposed within the at least one cutting element pocket and secured to the body of the earth-boring tool.
Dependencies are inferred from the claim text.