Methods of forming earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B21K-005/04
E21B-010/04
출원번호
US-0022308
(2011-02-07)
등록번호
US-8230762
(2012-07-31)
발명자
/ 주소
Choe, Heeman
Stevens, John H.
Westhoff, James C.
Eason, Jimmy W.
Overstreet, James L.
출원인 / 주소
Baker Hughes Incorporated
대리인 / 주소
TraskBritt
인용정보
피인용 횟수 :
7인용 특허 :
139
초록▼
Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating the plurality of boron carbide particles with a molt
Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating the plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.
대표청구항▼
1. A method of forming an earth-boring rotary drill bit, the method comprising: forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit for drilling subterranean formations, forming a plurality of boron carbide
1. A method of forming an earth-boring rotary drill bit, the method comprising: forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit for drilling subterranean formations, forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit for drilling subterranean formations comprising placing the plurality of boron carbide particles within a cavity of a mold, the cavity having a shape corresponding to the shape of the at least a portion of the bit body;infiltrating the plurality of boron carbide particles with molten aluminum or a molten aluminum-based material; andcooling the molten aluminum or molten aluminum-based material to form a solid matrix material surrounding the plurality of boron carbide particles. 2. The method of claim 1, further comprising heat treating the solid matrix material to increase the hardness of the solid matrix material. 3. The method of claim 1, further comprising embedding a blank comprising a metal or metal alloy at least partially within the plurality of boron carbide particles inside the cavity of the mold. 4. The method of claim 1, wherein infiltrating the plurality of boron carbide particles comprises infiltrating the plurality of boron carbide particles with a molten material comprising at least 75% by weight aluminum and at least trace amounts of at least one of copper, iron, lithium, magnesium, manganese, nickel, scandium, silicon, tin, zirconium, and zinc. 5. The method of claim 1, wherein forming a plurality of boron carbide particles into a body comprises forming a plurality of -70 ASTM Mesh boron carbide particles into a body. 6. The method of claim 1, wherein forming a plurality of boron carbide particles into a body comprises forming a plurality of -70 ASTM Mesh boron carbide particles having a multi-modal particle size distribution into a body. 7. The method of claim 1, further comprising securing a plurality of polycrystalline diamond compact cutters to a face of the bit body. 8. A method of forming an earth-boring rotary drill bit, the method comprising: forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit for drilling subterranean formations;infiltrating the plurality of boron carbide particles with a molten material comprising at least 90% by weight aluminum and at least about 3% by weight of at least one of copper, iron, lithium, magnesium, manganese, nickel, scandium, silicon, tin, zirconium, and zinc; andcooling the molten aluminum or molten aluminum-based material to form a solid matrix material surrounding the plurality of boron carbide particles. 9. The method of claim 8, further comprising: cooling the molten material to form a solid solution; andforming at least one discontinuous precipitate phase within the solid solution, the at least one discontinuous phase causing the solid matrix material to exhibit a bulk hardness that is harder than a bulk hardness of the solid solution at the same temperature. 10. The method of claim 9, wherein forming at least one discontinuous precipitate phase comprises forming at least one metastable precipitate phase. 11. The method of claim 9, wherein forming at least one discontinuous precipitate phase comprises forming an intermetallic compound. 12. The method of claim 11, wherein forming an intermetallic compound comprises forming CuAl2. 13. A method of forming an earth-boring rotary drill bit, the method comprising: providing a bit body comprising: providing a green powder component comprising: a plurality of particles each comprising boron carbide; anda plurality of particles each comprising aluminum or an aluminum-based alloy material; andat least partially sintering the green powder component;providing a shank that is configured for attachment to a drill string; andattaching the shank to the bit body. 14. The method of claim 13, wherein providing a green powder component comprises: providing a first region having a first composition substantially comprised by the plurality of particles each comprising boron carbide and the plurality of particles each comprising aluminum or an aluminum-based alloy material; andproviding a second region having a second composition that differs from the first composition. 15. The method of claim 13, wherein providing a green powder component comprises: providing a powder mixture comprising: the plurality of particles each comprising boron carbide;the plurality of particles each comprising aluminum or an aluminum-based alloy material; anda binder material; andpressing the powder mixture. 16. The method of claim 15, wherein pressing the powder mixture comprises: providing a die or container; andpressing the powder mixture in the die or container. 17. The method of claim 16, wherein pressing the powder mixture in the die or container comprises isostatically pressing the powder mixture.
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