Earth-boring tools including replaceable hardfacing pads and related methods

Patent metadata

Field	Value
Publication number	US-10415320-B2
Application number	US-201715633530-A
Country	US
Kind code	B2
Filing date	Jun 26, 2017
Priority date	Jun 26, 2017
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

Earth-boring tools may include a body having blades protruding therefrom and at least one hardfacing pad secured to at least one blade. The at least one hardfacing pad may be located at least partially within a recess extending at least into the at least one blade body around a circumference of a gage region of the body and may include a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that the plate is spaced from the body by at least a thickness of the at least one spacer. A braze material may secure the at least one hardfacing pad to the at least one blade, the braze material extending around the at least one spacer and located between the plate and the body.

First claim

What is claimed is:

1. An earth-boring tool, comprising:
a body having blades protruding therefrom;
at least one hardfacing pad secured to at least one blade, the at least one hardfacing pad located at least partially within a recess extending into at least the at least one blade around a circumference of a gage region of the body, the at least one hardfacing pad comprising a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that the plate is spaced from the body by at least a thickness of the at least one spacer; and
a braze material securing the at least one hardfacing pad to the body, the braze material extending around the at least one spacer and located between the plate and the body.

2. The earth-boring tool of claim 1 , wherein the at least one hardfacing pad comprises a notch located in the plate, the notch configured to receive a lever for removal of the at least one hardfacing pad from the body.

3. The earth-boring tool of claim 1 , wherein the thickness of the at least one spacer is between about 0.003 inch and about 0.005 inch.

4. The earth-boring tool of claim 1 , wherein a greatest lateral dimension of a surface of the plate facing the abrasion-resistant material is between about 0.5 inch and about 8 inches.

5. The earth-boring tool of claim 1 , wherein the body comprises a particle-matrix composite material comprising particles of a ceramic material in a matrix of a metal or metal alloy material.

6. The earth-boring tool of claim 5 , wherein a melting temperature of the metal or metal alloy material is greater than a melting temperature of the braze material.

7. The earth-boring tool of claim 6 , further comprising at least one cutting element secured partially within a pocket extending into at least one of a blade and the body by another braze material, wherein a melting temperature of the other braze material is less than the melting temperature of the braze material.

8. The earth-boring tool of claim 1 , wherein a surface of the abrasion-resistant material facing away from the plate exhibits an arcuate shape.

9. The earth-boring tool of claim 1 , wherein the abrasion-resistant material of the at least one hardfacing pad comprises a hardfacing material.

10. The earth-boring tool of claim 1 , wherein the plate of the at least one hardfacing pad comprises a metal or metal alloy material.

11. A method of making an earth-boring tool, comprising:
placing a braze material within a recess extending at least into a blade protruding from a body of the earth-boring tool around a circumference of a gage region of the body;
placing at least one hardfacing pad at least partially within the recess, the at least one hardfacing pad comprising a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that a gap is located between the plate and the body;
temporarily securing the at least one hardfacing pad in place by placing a retention member around the hardfacing pads;
exposing the body, the braze material, and the at least one hardfacing pad to an elevated temperature, at least partially flowing the braze material; and
solidifying the braze material in response to cooling the braze material from the elevated temperature, the braze material securing the at least one hardfacing pad to the body of the earth-boring tool.

12. The method of claim 11 , wherein the body comprises a particle-matrix composite material comprising particles of a ceramic material in a matrix of a metal or metal alloy material and wherein the exposing the body, the braze material, and the at least one hardfacing pad to the elevated temperature, at least partially flowing the braze material, comprises exposing the body, the braze material, and the at least one hardfacing pad to the elevated temperature less than a melting temperature of the metal or metal alloy material, at least partially flowing the braze material.

13. The method of claim 11 , wherein placing the at least one hardfacing pad at least partially within the recess comprises placing a surface of the plate of the at least one hardfacing pad located opposite the abrasion-resistant material between about 0.003 inch and about 0.005 inch from the body.

14. The method of claim 11 , wherein temporarily securing the at least one hardfacing pad in place by placing a retention member around the at least one hardfacing pad comprises aligning at least one rigid member of the retention member with the at least one hardfacing pad, aligning at least one flexible member of the retention member with a junk slot, and temporarily securing the flexible securing members to the rigid members utilizing a latch.

15. The method of claim 11 , further comprising grinding a surface of the abrasion-resistant material facing away from the plate to an arcuate shape.

16. The method of claim 15 , wherein grinding the surface of the abrasion-resistant material comprises removing between about 0.25 inch and 0.5 inch of the abrasion-resistant material as measured from the surface before grinding.

17. A method of repairing an earth-boring tool, comprising:
removing at least one hardfacing pad from within a recess extending into a blade protruding from a body of the earth-boring tool around a circumference of a gage region of the body;
replacing the at least one hardfacing pad with at least another hardfacing pad located at least partially within the recess, the at least another hardfacing pad comprising a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that a gap is located between the plate and the body;
temporarily securing the at least another hardfacing pad in place by placing a retention member in contact with the at least another hardfacing pad around the gage region;
exposing the body, a braze material located proximate the at least another hardfacing pad, and the at least another hardfacing pad to an elevated temperature, at least partially flowing the braze material; and
solidifying the braze material in response to cooling the braze material from the elevated temperature, the braze material securing the at least another hardfacing pad to the body of the earth-boring tool.

18. The method of claim 17 , wherein removing the at least one hardfacing pad comprises inserting at least a portion of a lever into a notch located in a plate of the at least one hardfacing pad and prying the at least one hardfacing pad away from the body.

19. The method of claim 17 , further comprising grinding a surface of the abrasion-resistant material facing away from the plate to an arcuate shape.

20. The method of claim 19 , wherein grinding the surface of the abrasion-resistant material comprises rendering a diameter of the gage region after grinding different from a diameter of the gage region before removal of the at least one hardfacing pad.

Assignees

• Baker Hughes A Ge Co Llc

Inventors

• Savage Michael T

Classifications

• B23K2101/002

  Drill-bits · CPC title

• E21B10/54 Primary

  the bit being of the rotary drag type, e.g. fork-type bits · CPC title

• B23K1/0008 Primary

  specially adapted for particular articles or work · CPC title

• B23K1/008

  Soldering within a furnace (B23K1/012 takes precedence) · CPC title

• E21B10/43

  characterised by the arrangement of teeth or other cutting elements · CPC title