Cemented carbide composite for a downhole tool

Patent metadata

Field	Value
Publication number	US-2016230470-A1
Application number	US-201615131186-A
Country	US
Kind code	A1
Filing date	Apr 18, 2016
Priority date	Apr 4, 2013
Publication date	Aug 11, 2016
Grant date	—

Abstract

A carbide composite for a downhole tool may be formed by depositing a first layer on a substrate, and a second layer at least partially adjacent to the first layer. The first and second layers may each include carbides, metal binders, organic binders, or a combination thereof. The first and second carbide layers may have a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another.

First claim

What is claimed is:

1 . A carbide composite for a downhole tool, comprising:
a carbide layer, the carbide layer comprising tungsten carbide and cobalt; and a second layer at least partially adjacent to and bound to the carbide layer, the second layer comprising one or more carbides, metal binders, organic binders, or a combination thereof, the carbide layer and second layer having a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another.

2 . The carbide composite of claim 1 , wherein the second layer comprises diamond particles.

3 . The carbide composite of claim 1 , wherein the second layer comprises a carbide selected from the group consisting of titanium carbide, vanadium carbide, chromium carbide, zirconium carbide, niobium carbide, molybdenum carbide, hafnium carbide, tantalum carbide, tungsten carbide, and combinations thereof.

4 . The carbide composite of claim 1 , wherein the second layer comprises a metal binder selected from the group consisting of magnesium, ruthenium, osmium, iron, cobalt, nickel, copper, molybdenum, tantalum, tungsten, rhenium, and combinations thereof.

5 . The carbide composite of claim 1 , wherein the carbide layer is from about 0.0005 cm to about 0.06 cm thick.

6 . The carbide composite of claim 1 , wherein the second layer is from about 0.0005 cm to about 0.06 cm thick.

7 . The carbide composite of claim 1 , further comprising a polycrystalline diamond layer.

8 . The carbide composite of claim 1 , wherein the carbide composite has a density from about 75% to about 85% based on a theoretical density of the carbide composite.

9 . The carbide composite of claim 1 , wherein the organic binder is selected from the group consisting of polyolefins, polyol ether-esters, chlorinated naphthalenes, hydrocarbon waxes, and combinations thereof.

10 . The carbide composite of claim 1 , wherein the second layer comprises a metal binder selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and combinations thereof.

11 . A carbide composite for a downhole tool, formed by a method comprising:
depositing a first layer on a substrate, the first layer comprising one or more first carbides, the first layer being from about 0.0005 cm to about 0.06 cm thick; depositing a second layer at least partially adjacent the first layer, the second layer comprising one or more second carbides, metal binders, organic binders, or a combination thereof, the second layer being from about 0.0005 cm to about 0.06 cm thick, and wherein the first and second layers have a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another; and binding the first and second layers to form the carbide composite, wherein the first and second layers are formed by additive manufacturing using a CAD assembly.

12 . The carbide composite of claim 11 , wherein the method further comprises heating and pressing the carbide composite.

13 . The carbide composite of claim 11 , wherein the method further comprises milling one or more components of the first or second layers before depositing the first and second layers.

14 . The carbide composite of claim 13 , wherein milling coats the first carbide with a second organic binder or the second carbide with the organic binder.

15 . The carbide composite of claim 11 , wherein the method further comprises granulating the components of the first or second layers before depositing the first and second layers to facilitate flow of the components.

16 . The carbide composite of claim 11 , wherein the method further comprises pre-sintering the carbide composite to remove at least a portion of the organic binder contained therein.

17 . The carbide composite of claim 11 , wherein the CAD assembly includes a digital design.

18 . A carbide composite for a downhole tool, formed by a method comprising:
depositing a carbide layer on a substrate, the carbide layer comprising tungsten carbide and cobalt, the carbide layer being from about 0.0005 cm to about 0.06 cm thick; depositing a second layer at least partially on the carbide layer, the second layer comprising one or more carbides, metal binders, organic binders, diamond particles, or a combination thereof, the second layer being from about 0.0005 cm to about 0.06 cm thick, and wherein the carbide layer and the second layer have a different particle size, particle shape, carbide concentration, metal binder concentration, diamond particle concentration, or organic binder concentration from one another; binding the carbide layer and second layers to form the carbide composite; and sintering the carbide composite to form a polycrystalline diamond insert, wherein the carbide layer and the second layer are formed by additive manufacturing using a CAD assembly.

19 . The carbide composite of claim 18 , wherein sintering the carbide composite comprises heating and pressing the carbide composite.

20 . The carbide composite of claim 19 , wherein sintering the carbide composite comprises vacuum sintering the carbide composite or hot isostatic pressing the carbide composite.

Assignees

• Smith International

Inventors

• Keshavan Madapusi K

Classifications

• B24D3/10 Primary

  for porous or cellular structure, e.g. for use with diamonds as abrasives · CPC title

• E21B10/567 Primary

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

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B24D18/0009

  using moulds or presses · CPC title