Earth-boring tools and methods for forming earth-boring tools using shape memory materials

Patent metadata

Field	Value
Publication number	US-10280479-B2
Application number	US-201615002211-A
Country	US
Kind code	B2
Filing date	Jan 20, 2016
Priority date	Jan 20, 2016
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

An earth-boring tool includes a tool body, at least one cutting element, and a retaining member comprising a shape memory material (e.g., alloy, polymer, etc.) located between a surface of the tool body and a surface of the cutting element. The shape memory material is configured to transform, responsive to application of a stimulus, from a first solid phase to a second solid phase. The retaining member comprises the shape memory material in the second solid phase, and at least partially retains the at least one cutting element adjacent the tool body. The shape memory material may be trained in a first phase to a first shape, and trained in a second phase to a second shape. The retaining member may be at least partially within a cavity in the first phase, then transformed to the second phase to apply a force securing the cutting element to the tool body.

First claim

What is claimed is:

1. An earth-boring tool, comprising:
a tool body;
at least one cutting element;
a filler material; and
a retaining member comprising a shape memory material configured to transform, responsive to application of a stimulus, from a first solid phase to a second solid phase, the retaining member located adjacent the filler material and between a surface of the tool body and a surface of the at least one cutting element, the retaining member comprising the shape memory material in the second solid phase and at least partially retaining the at least one cutting element adjacent the tool body;
wherein the filler material is configured to at least substantially fill an annular cavity between the retaining member and at least one of the surface of the at least one cutting element and the surface of the tool body when the shape memory material is in the first solid phase.

2. The earth-boring tool of claim 1 , wherein the retaining member comprises at least one annular sleeve.

3. The earth-boring tool of claim 2 , wherein the at least one annular sleeve surrounds the at least one cutting element.

4. The earth-boring tool of claim 1 , wherein the shape memory material is configured to transform from the second solid phase to the first solid phase to release the at least one cutting element responsive to another stimulus.

5. The earth-boring tool of claim 1 , wherein the filler material comprises at least one material selected from the group consisting of Bi, Sb, Sn, a Sn-based alloy, a Pb-based alloy, an In-based alloy, a Cd-based alloy, a Bi-based alloy, and an Sb-based alloy.

6. The earth-boring tool of claim 1 , wherein a first portion of the retaining member is located within a second cavity defined within the at least one cutting element.

7. The earth-boring tool of claim 6 , wherein a second portion of the retaining member is located within a third cavity defined within the tool body.

8. A method of forming an earth-boring tool, comprising:
disposing a retaining member comprising a shape memory material in a space between a cutting element and a tool body to form an annular cavity in the space between the retaining member and at least one of a surface of the cutting element and a surface of the tool body;
disposing a filler material adjacent the retaining member to at least substantially fill the annular cavity; and
transforming the shape memory material from a first solid phase to a second solid phase by application of a stimulus to cause the retaining member to create a mechanical interference between the cutting element, the retaining member, the filler material, and the tool body to secure the cutting element to the tool body.

9. The method of claim 8 , wherein disposing a retaining member in a space between a cutting element and a tool body comprises disposing the retaining member in a cavity within the cutting element.

10. The method of claim 8 , wherein disposing a retaining member in a space between a cutting element and a tool body comprises disposing the retaining member in a cavity within the tool body.

11. The method of claim 8 , wherein disposing a retaining member in a space between a cutting element and a tool body comprises disposing at least one annular sleeve in the space.

12. The method of claim 11 , wherein disposing at least one annular sleeve in the space comprises disposing the at least one annular sleeve around the cutting element.

13. The method of claim 8 , wherein disposing a retaining member in a space between a cutting element and a tool body comprises disposing at least one cylindrical retaining member in the space.

14. The method of claim 8 , further comprising applying another stimulus to the shape memory material to release the at least one cutting element from the tool body.

15. The method of claim 8 , further comprising training the shape memory material before disposing the retaining member in the space.

16. The method of claim 8 , wherein transforming the shape memory material from a first solid phase to a second solid phase by application of a stimulus comprises applying a thermal stimulus to the shape memory material.

17. The method of claim 8 , wherein the shape memory material comprises an alloy, and wherein transforming the shape memory material from a first solid phase to a second solid phase by application of a stimulus comprises converting the alloy from a martensitic phase to an austenitic phase.

18. The earth-boring tool of claim 8 , wherein the cutting element and the tool body define a gap between an exterior surface of the cutting element and a second surface of the tool body.

19. A method of forming an earth-boring tool, comprising:
training a shape memory material in a first solid phase to a first shape;
training the shape memory material in a second solid phase to a second shape such that a retaining member comprising the shape memory material exhibits a dimension larger in at least one direction than in the at least one direction when in the first solid phase;
transforming the shape memory material to the first solid phase;
disposing the retaining member comprising the shape memory material in the first solid phase at least partially within a space between a cutting element and a tool body to form an annular cavity in the space between the retaining member and at least one of a surface of the cutting element and a surface of the tool body;
disposing a filler material adjacent the retaining member to at least substantially fill the annular cavity; and
transforming the shape memory material to the second solid phase to secure the cutting element to the tool body.

20. The method of claim 19 , wherein transforming the shape memory material to the second solid phase comprises causing the retaining member to apply a force normal to the surface of each of the cutting element and the tool body.

Assignees

• Baker Hughes Inc
• Baker Hughes A Ge Co Llc

Inventors

• Yu Bo
• Huang Xu
• Bilen Juan Miguel
• Stevens John H
• Sullivan Eric C

Classifications

• C21D2201/01

  Shape memory effect · CPC title

• E21B10/567

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title

• C21D10/00 Primary

  Modifying the physical properties by methods other than heat treatment or deformation · CPC title

• C21D2211/001

  Austenite · CPC title

• C22F1/006

  Resulting in heat recoverable alloys with a memory effect · CPC title