Metal matrix composite material for additive manufacturing of downhole tools

Patent metadata

Field	Value
Publication number	US-2019128072-A1
Application number	US-201816175920-A
Country	US
Kind code	A1
Filing date	Oct 31, 2018
Priority date	Oct 31, 2017
Publication date	May 2, 2019
Grant date	—

Abstract

A downhole cutting tool includes a tool body with a cutting element or cutting element pocket thereon. At least a portion of the tool body or an attachment thereto is a metal matrix composite formed from metal carbide particles dispersed in a continuous metal matrix. The metal carbide particles make up less than 45 wt % of the metal matrix composite and/or less than 30 vol % of the metal matrix composite. The continuous metal matrix may also be formed from a metal or metal alloy other than Ni—Si—B and/or have a transverse rupture strength greater than 150 ksi and a fracture toughness over 22 ksi*in 0.5 .

First claim

What is claimed is:

1 . A downhole cutting tool, comprising:
a tool body including a cutting element or cutting element pocket thereon, at least a portion of the tool body including a metal matrix composite formed from spherical cast carbide particles dispersed in a continuous metal matrix formed from a metal binder, wherein:
a density ratio of spherical cast carbide particles to the metal binder is between 1.7 and 2.1;
the spherical cast carbide particles compose up to 27 vol % or up to 40 wt % of the metal matrix composite; and
the metal binder makes up at least 75 vol % or at least 60 wt % of the metal matrix composite.

2 . The downhole cutting tool of claim 1 , the metal binder consisting essentially of transition metals or transition metal alloys.

3 . The downhole cutting tool of claim 2 , the metal binder consisting essentially of iron, nickel, copper, or alloys thereof.

4 . The downhole cutting tool of claim 1 , the at least a portion of the tool body including an attached tool body segment.

5 . The downhole cutting tool of claim 1 , the at least a portion of the tool body including the metal matrix composite being formed using a high energy fusion additive manufacturing process.

6 . The downhole cutting tool of claim 1 , the metal matrix composite having a transverse rupture strength greater than 150 ksi and a fracture toughness over 22 ksi*in 0.5 .

7 . The downhole cutting tool of claim 6 , the metal matrix composite having an erosion rate of less than 0.1 g/lb. sand.

8 . The downhole cutting tool of claim 6 , the metal matrix composite having a transverse rupture strength greater than 180 ksi and a fracture toughness over 25 ksi*in 0.5 .

9 . A downhole cutting tool, comprising:
a tool body including a cutting element or cutting element pocket thereon, at least a portion of the tool body including a metal matrix composite formed from hard particles dispersed in a continuous metal matrix formed from a metal binder, wherein: a density ratio of the hard particles to the metal binder is between 0.5 and 1.2; and the hard particles make up less than 60 vol % of the metal matrix composite.

10 . The downhole cutting tool of claim 9 , the hard particles having a density of less than 5 g/cm 3 .

11 . The downhole cutting tool of claim 10 , the metal binder consisting essentially of transition metals or transition metal alloys.

12 . The downhole cutting tool of claim 11 , the metal binder consisting essentially of iron, nickel, copper, or alloys thereof.

13 . The downhole cutting tool of claim 12 , the metal binder consisting essentially of copper alloys.

14 . The downhole cutting tool of claim 9 , the metal binder including titanium, and the density ratio being between 0.85 and 1.15.

15 . The downhole cutting tool of claim 9 , the at least a portion of the tool body including the metal matrix composite being formed using a high energy fusion additive manufacturing process.

16 . A downhole cutting tool, comprising:
a tool body including a cutting element or cutting element pocket thereon, at least a portion of the tool body including a metal matrix composite formed from hard particles dispersed in a continuous metal matrix formed from a metal binder, wherein:
a density ratio of hard particles to the metal binder is between 0.9 and 1.1;
the hard particles make up less than 55 vol % or less than 40 wt % of the metal matrix composite;
the hard particles are a transition metal carbide or boride including SiC, TiB 2 , or other borides; and
the metal binder consists essentially of Al, Ni, Si, Ti, B, or alloys thereof.

17 . The downhole cutting tool of claim 16 , the continuous metal matrix consisting essentially of transition metals or transition metal alloys.

18 . The downhole cutting tool of claim 17 , the continuous metal matrix consisting essentially of titanium, iron, nickel, copper, or alloys thereof.

19 . The downhole tool of claim 16 , the continuous metal matrix consisting essentially of iron or nickel base alloys containing an alloying component that reduces the melting temperature of the metal binder.

20 . The downhole cutting tool of claim 16 , the continuous metal matrix having a melting point below 1,200° C.

21 . The downhole cutting tool of claim 16 , the at least a portion of the tool body including the metal matrix composite being formed using a high energy fusion additive manufacturing process.

22 . A downhole cutting tool, comprising:
a tool body including a cutting element or cutting element pocket thereon, at least a portion of the tool body including a metal matrix composite formed from metallic hard particles dispersed in a continuous metal matrix formed from a metal binder, wherein:
a density ratio of the metallic hard particles to the metal binder is between 0.5 and 1.2;
the metallic hard particles make up less than 60 vol % of the metal matrix composite;
the metallic hard particles have a hardness between 500 and 800 VHN, and a density that is less than 9 g/cm 3 ; and
the continuous metal matrix surrounding the metallic hard particles has a hardness that is less than 500 VHN.

23 . The downhole cutting tool of claim 22 , the at least a portion of the tool body including the metal matrix composite being formed using a high energy fusion additive manufacturing process.

24 . The downhole cutting tool of claim 22 , the metallic hard particles having a melting point below 1,700° C.

Assignees

• Smith International

Inventors

• Griffo Anthony
• Keshavan Madapusi K
• Zhang Youhe

Classifications

• B23K15/0086

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• E21B10/54 Primary

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

• C22C32/0052

  only carbides · CPC title

• E21B10/32

  with expansible cutting tools · CPC title