Magnetic positioning of reinforcing particles when forming metal matrix composites

Patent metadata

Field	Value
Publication number	US-10655399-B2
Application number	US-201515751145-A
Country	US
Kind code	B2
Filing date	Sep 22, 2015
Priority date	Sep 22, 2015
Publication date	May 19, 2020
Grant date	May 19, 2020

Abstract

A metal matrix composite (MMC) may be formed with two or more portions each having different reinforcing particles that enhance strength, wear resistance, or both of their respective portions of the MMC. Selective placement of the different reinforcing particles may be achieved using magnetic members. For example, in some instances, forming an MMC may involve placing reinforcement materials within an infiltration chamber of a mold assembly, the reinforcement materials comprising magnetic reinforcing particles and non-magnetic reinforcing particles; positioning one or more magnetic members relative to the mold assembly to selectively locate the magnetic reinforcing particles within the infiltration chamber with respect to the non-magnetic reinforcing particles; and infiltrating the reinforcement materials with a binder material to form a hard composite.

First claim

What is claimed is:

1. A method comprising:
placing reinforcement materials within an infiltration chamber of a mold assembly, the reinforcement materials comprising magnetic reinforcing particles and non-magnetic reinforcing particles;
positioning one or more magnetic members relative to the mold assembly to selectively locate the magnetic reinforcing particles within the infiltration chamber with respect to the non-magnetic reinforcing particles; and
infiltrating the reinforcement materials with a binder material to form a hard composite after selectively locating the magnetic reinforcing particles within the infiltration chamber.

2. The method of claim 1 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members within a portion of the mold assembly or a component thereof and thereby locating the magnetic reinforcing particles along inner surfaces of the infiltration chamber.

3. The method of claim 1 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members external to the mold cavity and thereby locating the magnetic reinforcing particles along inner surfaces of the infiltration chamber.

4. The method of claim 1 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members within one or more displacements arranged within the infiltration chamber, wherein the one or more displacements are selected from the group consisting of a nozzle displacement, a junk slot displacement, a central displacement, and a cutter-pocket displacement.

5. The method of claim 1 , wherein the non-magnetic reinforcing particles are first non-magnetic reinforcing particles, and wherein the magnetic reinforcing particles comprise second non-magnetic particles at least partially coated with a magnetic material.

6. A method comprising:
positioning one or more magnetic members relative to a mold assembly;
placing first reinforcing particles within an infiltration chamber of the mold assembly between a magnetic partitioning barrier positioned within the infiltration chamber and the one or more magnetic members;
adding second reinforcing particles to the infiltration chamber opposite the magnetic partitioning barrier from the first reinforcing particles; and
infiltrating the first and second reinforcing particles with a binder material to form a hard composite.

7. The method of claim 6 further comprising:
removing the magnetic partitioning barrier once a volume of the second reinforcing particles can physically maintain the first reinforcing particles in position.

8. The method of claim 6 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members external to the mold cavity and the method further comprising positioning the magnetic partitioning barrier proximal to an inner surface of the infiltration chamber, thereby locating the first reinforcing particles along the inner surface of the infiltration chamber.

9. The method of claim 6 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members as a portion of the mold assembly or a component thereof and thereby locating the magnetic reinforcing particles along inner surfaces of the infiltration chamber.

10. The method of claim 6 , wherein positioning the one or more magnetic members relative to the mold assembly comprises positioning the one or more magnetic members within one or more displacements arranged within the infiltration chamber, wherein the one or more displacements are selected from the group consisting of a nozzle displacement, a junk slot displacement, a central displacement, and a cutter-pocket displacement, and the method further comprising positioning the magnetic partitioning barrier proximal to a surface of the one or more displacements, thereby locating the first reinforcing particles along surfaces of the one or more displacements.

11. A metal matrix composite (MMC) tool comprising:
a body having a hard composite portion that comprises a first portion and a second portion that comprises magnetic reinforcing particles and non-magnetic reinforcing particles at least partially coated with a magnetic material, and non-magnetic reinforcing particles in the first portion and the second portion dispersed in a binder material.

12. The MMC tool of claim 11 , wherein the MMC tool is a drill bit and the body is a bit body at least partially formed of the hard composite portion, the MMC tool further comprising: a plurality of cutting elements coupled to an exterior portion of the bit body.

13. The MMC tool of claim 12 further comprising:
a fluid cavity defined within the bit body;
at least one flow passageway extending from the fluid cavity to the exterior portion of the bit body, wherein the first portion of the hard composite portion includes surfaces of the flow passageway and the first reinforcing particles are larger than the second reinforcing particles; and
at least one nozzle opening defined by an end of the at least one flow passageway proximal to the exterior portion of the matrix bit body.

14. The MMC tool of claim 12 further comprising:
a fluid cavity defined within the bit body, wherein the first portion of the hard composite portion includes surfaces of the fluid cavity and the first reinforcing particles are larger than the second reinforcing particles;
at least one flow passageway extending from the fluid cavity to the exterior portion of the bit body; and
at least one nozzle opening defined by an end of the at least one flow passageway proximal to the exterior portion of the matrix bit body.

15. The MMC tool of claim 12 further comprising:
a plurality of cutter blades formed on an exterior portion of the matrix bit body, the plurality of cutting elements being arranged on the plurality of cutter blades; and
a plurality of pockets formed in the plurality of cutter blades, wherein the first portion of the hard composite portion includes surfaces of the pockets and the first reinforcing particles are larger than the second reinforcing particles.

16. The MMC tool of claim 12 further comprising:
a plurality of cutter blades formed on an exterior portion of the matrix bit body, the plurality of cutting elements being arranged on the plurality of cutter blades; and
a plurality of pockets formed in the plurality of cutter blades, wherein the first portion of the hard composite portion includes surfaces of the pockets and the second reinforcing particles comprise fibers.

Assignees

• Halliburton Energy Services Inc

Inventors

• Cook Iii Grant O
• Thomas Jeffrey G
• Olsen Garrett T
• Anderle Seth Garrett

Classifications

• B22F2202/05

  Use of magnetic field · CPC title

• E21B10/55

  with preformed cutting elements · CPC title

• E21B10/602 Primary

  the bit being a rotary drag type bit with blades · CPC title

• B22F2007/066

  using impregnation · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title