Drilling Tools Having Matrices With Carbide-Forming Alloys, And Methods Of Making And Using Same

Patent metadata

Field	Value
Publication number	US-2016201398-A1
Application number	US-201614993550-A
Country	US
Kind code	A1
Filing date	Jan 12, 2016
Priority date	Jan 12, 2015
Publication date	Jul 14, 2016
Grant date	—

Abstract

Drilling tools, such as drill bits, having a shank, a crown, and a plurality of abrasive cutting elements. In the case of impregnated drilling tools, the abrasive cutting elements are dispersed throughout at least a portion of the crown. In the case of surface-set drilling tools, the abrasive cutting media is secured to and projects from a cutting face of the crown. The matrix of the crown of the drilling tools includes a carbide-forming alloy that forms a direct carbide bond with at least one cutting element of the plurality of abrasive cutting elements.

First claim

What is claimed is:

1 . A drilling tool, comprising:
a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component; a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a cutting face, and a crown body between the cutting face and the shank; and a plurality of abrasive cutting elements secured at least partially within the crown body, wherein the carbide-forming alloy forms a direct bond with the hard particulate material of the matrix, and wherein the carbide-forming alloy forms a direct carbide bond with at least one abrasive cutting element of the plurality of abrasive cutting elements.

2 . The drilling tool as recited in claim 1 , wherein the carbide-forming alloy comprises chromium.

3 . The drilling tool as recited in claim 1 , wherein the carbide-forming alloy comprises titanium.

4 . The drilling tool as recited in claim 1 , wherein the carbide-forming alloy comprises aluminum.

5 . The drilling tool as recited in claim 1 , wherein the carbide-forming alloy comprises vanadium.

6 . The drilling tool as recited in claim 1 , wherein the plurality of abrasive cutting elements comprises a plurality of synthetic diamonds.

7 . The drilling tool as recited in claim 1 , wherein the plurality of abrasive cutting elements comprises a plurality of thermally stable polycrystalline diamonds.

8 . The drilling tool as recited in claim 1 , wherein the plurality of abrasive cutting elements comprises natural diamond.

9 . The drilling tool as recited in claim 1 , wherein the crown has an annular shape, a longitudinal axis, an inner surface, and an outer surface, wherein the inner surface of the crown defines an interior space about the longitudinal axis, and wherein the interior space is configured to receive a core sample.

10 . The drilling tool as recited in claim 1 , wherein at least one abrasive cutting element of the plurality of abrasive cutting elements extends outwardly from the cutting face.

11 . The drilling tool as recited in claim 1 , wherein the hard particulate material of the matrix of the crown comprises at least one of tungsten and tungsten carbide.

12 . The drilling tool as recited in claim 1 , wherein the drilling tool is a drill bit.

13 . The drilling tool as recited in claim 12 , wherein the drill bit is a full-face drill bit.

14 . The drilling tool as recited in claim 12 , wherein the drill bit is an all-cast drill bit.

15 . The drilling tool as recited in claim 1 , wherein the drilling tool is a reamer.

16 . The drilling tool as recited in claim 1 , wherein the drilling tool is an impregnated drilling tool, and wherein the plurality of abrasive cutting elements are dispersed throughout at least a portion of the crown body.

17 . The drilling tool as recited in claim 16 , wherein the impregnated drilling tool is an impregnated drill bit.

18 . The drilling tool as recited in claim 16 , wherein at least a portion of the plurality abrasive cutting elements are dispersed within the crown body proximate the cutting face.

19 . The drilling tool as recited in claim 16 , further comprising a plurality of fibers dispersed in an unorganized arrangement throughout at least a portion of the crown body.

20 . The drilling tool as recited in claim 1 , wherein the drilling tool is a surface-set drilling tool, and wherein the plurality of abrasive cutting elements are secured to and project from the cutting face of the crown.

21 . The drilling tool as recited in claim 20 , wherein the surface-set drilling tool is a surface-set drill bit.

22 . The drilling tool as recited in claim 1 , wherein the plurality of abrasive cutting elements comprises at least one abrasive cutting element that is not configured to form a carbide bond with the carbide-forming alloy.

23 . The drilling tool as recited in claim 1 , wherein the drilling tool is infiltrated with a binder, and wherein the binder does not comprise a carbide-forming material.

24 . The drilling tool as recited in claim 23 , wherein the abrasive cutting elements are not coated, and wherein the carbide-forming alloy forms direct carbide bonds with the uncoated abrasive cutting elements.

25 . The drilling tool as recited in claim 1 , wherein the plurality of abrasive cutting elements comprise a plurality of diamond cutting elements, and wherein the carbide-forming alloy is configured to convert the diamond cutting elements to a carbide to form the direct carbide bonds between the carbide-forming alloy and the diamond cutting elements.

26 . A drilling system, comprising:
a drill string configured for rotation; and a drilling tool, wherein the drilling tool comprises:
a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;
a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a cutting face, and a crown body between the cutting face and the shank; and
a plurality of abrasive cutting elements secured at least partially within the crown body,
wherein the carbide-forming alloy forms a direct bond with the hard particulate material of the matrix, and wherein the carbide-forming alloy forms a direct carbide bond with at least one abrasive cutting element of the plurality of abrasive cutting elements.

27 . The drilling system as recited in claim 26 , further comprising a drill rig, wherein the drill string is adapted to be secured to and rotated by the drill rig.

28 . The drilling system as recited in claim 26 , further comprising a down-hole motor, wherein the drill string is adapted to be secured to and rotated by the down-hole motor.

29 . The drilling system as recited in claim 26 , wherein the drilling tool is infiltrated with a binder, and wherein the binder does not comprise a carbide-forming material.

30 . The drilling system as recited in claim 29 , wherein the abrasive cutting elements are not coated, and wherein the carbide-forming alloy forms direct carbide bonds with the uncoated abrasive cutting elements.

31 . The drilling system as recited in claim 26 , wherein the plurality of abrasive cutting elements comprise a plurality of diamond cutting elements, and wherein the carbide-forming alloy is configured to convert the diamond cutting elements to a carbide to form the direct carbide bonds between the carbide-forming alloy and the diamond cutting elements.

32 . A method of drilling, comprising:
securing a drilling tool to a drill string, wherein the drilling tool comprises:
a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;
a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a cutting face, and a crown body between the cutting face and the shank; and
a plurality of abrasive cutting elements secured at least partially within the crown body,
wherein the carbide-forming alloy forms a direct bond with the hard particulate material of the matrix, and wherein the carbide-forming alloy forms a direct carbide bon

Assignees

• Longyear Tm Inc

Inventors

• Pearce Cody A
• Rupp Michael D
• Lambert Christian M

Classifications

• B22F2999/00

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

• B24D3/06

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• B24D18/0027 Primary

  by impregnation · CPC title

• C22C49/00

  Alloys containing metallic or non-metallic fibres or filaments · CPC title

• C04B2235/3826

  Silicon carbides · CPC title