Erosion resistant hard composite materials

Patent metadata

Field	Value
Publication number	US-10022823-B2
Application number	US-201514826667-A
Country	US
Kind code	B2
Filing date	Aug 14, 2015
Priority date	Jun 25, 2010
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima.

First claim

The invention claimed is:

1. A drill bit comprising:
a bit body; and
at least one cutting element for engaging a formation;
wherein at least a portion of the bit body comprises a hard composite material comprising:
a binder;
a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder is characterized by a particle size distribution having at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm, wherein the local minima has a volume percent value that is less than the first local maxima;

wherein the polymodal blend of matrix powder comprises at least one particle having an aspect ratio of about 5 or greater selected from the group consisting of: a whisker, a rod, a nanorod, a wire, a nanowire, a nanostar, and a nanorice.

2. The drill bit of claim 1 wherein the drill bit is a fixed cutter drill bit.

3. The drill bit of claim 1 wherein the drill bit is a rotary cone drill bit.

4. The drill bit of claim 1 wherein the first local maxima is at a particle size of about 0.5 nm to about 1 μm.

5. The drill bit of claim 1 wherein the first local maxima is at a particle size of about 1 μm to about 10 μm.

6. The drill bit of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of: a carbide, a nitride, a natural diamond, a synthetic diamond, predominantly carbon structures, iron oxides, steels, stainless steels, austenitic steels, ferritic steels, martensitic steels, precipitation-hardening steels, duplex stainless steels, iron alloys, nickel alloys, chromium alloys, and any combination thereof.

7. The drill bit of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of: stoichiometric tungsten carbide, cemented tungsten carbide, cast tungsten carbide, and any combination thereof.

8. The drill bit of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of: molybdenum carbide, titanium carbide, tantalum carbide, niobium carbide, chromium carbide, vanadium carbide, silicon carbide, boron carbide, solid solutions thereof, and any combination thereof.

9. The drill bit of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of: silicon nitride, cubic boron nitride, and any combination thereof.

10. The drill bit of claim 1 wherein the binder comprises at least one material selected from the group consisting of: copper, cobalt, nickel, iron, zinc, manganese, any alloys of these elements, and any combinations thereof.

11. The drill bit of claim 1 wherein the hard composite material has an erosion rate of less than 0.06% volume per hour based on a Specific Slurry Erosion Test Procedure comprising eroding a test specimen of the hard composite material against an erosion material for a test run time; measuring a volume loss of the test specimen; and calculating an erosion rate by dividing the volume loss by the test run time.

Assignees

• Halliburton Energy Services Inc

Inventors

• Olsen Garrett T

Classifications

• B22F1/054

  Nanosized particles · CPC title

• B22F1/062

  Fibrous particles · CPC title

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• B22F1/065

  Spherical particles · CPC title

• B22F1/0547

  Nanofibres or nanotubes · CPC title