Hardfacing compositions, methods of applying the hardfacing compositions, and tools using such hardfacing compositions

Patent metadata

Field	Value
Publication number	US-9353578-B2
Application number	US-72893210-A
Country	US
Kind code	B2
Filing date	Mar 22, 2010
Priority date	Mar 20, 2009
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

A hardfacing composition comprising an iron-based binder alloy; and a carbide phase comprising a sintered carbide and a cast tungsten carbide, wherein the cast carbide is present in a quantity of at least 22% by weight, based on the total weight of the carbide phase, and the cast carbide comprises particles having sizes in the range of from 30 to 60 mesh. Also provided is a hardfacing composition comprising an iron-based binder alloy; and a carbide phase comprising a super dense sintered carbide and one or more additional carbide materials, wherein the super dense sintered carbide is present in a quantity of at least 10 percent by weight (% w), based on the total weight of the carbide phase, and comprises particles having sizes in the range of from 16 to 40 mesh. Included are methods of manufacturing such hardfacing compositions and downhole tools having such improved hardfacing compositions applied thereon.

First claim

What is claimed is:

1. A hardfacing composition comprising:
an iron-based binder alloy; and
a carbide phase comprising a sintered carbide and a cast tungsten carbide, wherein the cast carbide is present in a quantity of at least 22% and no greater than 40% by weight, based on the total weight of the carbide phase, wherein the cast carbide comprises particles having sizes in the range of from 30 to 60 mesh, and wherein the sintered carbide comprises particles having sizes in the range of from 16 to 50 mesh, and wherein only a portion of the sintered carbide particles comprise a super dense sintered carbide having a predominantly closed porosity or are free of pores, and wherein a first quantity of the super dense sintered carbide particles have sizes in the range of from 16 to 25 mesh (−16/+25 mesh) and a second quantity of the super dense sintered carbide particles have sizes in the range of from 25 to 50 mesh (−25/+50 mesh).

2. The hardfacing composition of claim 1 , wherein the cast tungsten carbide comprises crushed cast tungsten carbide.

3. The hardfacing composition of claim 1 , wherein the quantity of cast carbide is in the range of from 22.5% to 40% by weight, based on the total weight of the carbide phase.

4. The hardfacing composition of claim 1 , wherein the particles of cast carbide have sizes in the range of from 40 to 60 mesh.

5. The hardfacing composition of claim 1 , wherein the cast tungsten carbide has a core of cast tungsten carbide and a shell of monotungsten carbide.

6. The hardfacing composition of claim 5 , wherein said cast carbide comprises tungsten carbide particles having a bound carbon content in the range from 4% by weight to 6% by weight based on a total weight of the particles.

7. The hardfacing composition of claim 1 , wherein the quantity of sintered carbide is in the range of from 10% to 70% by weight, based on the total weight of the carbide phase.

8. The hardfacing composition of claim 1 , wherein the quantity of sintered carbide is in the range of from 30% to 65% by weight, based on the total weight of the carbide phase, and has particles with sizes in the range of from 16 to 40 mesh.

9. The hardfacing composition of claim 1 , wherein the carbide phase further comprises a filler carbide in a quantity of from 5% to 15% by weight, based on the total weight of the carbide phase, and the filler carbide particles have sizes in the range of from 200 to 625 mesh.

10. The hardfacing composition of claim 1 , wherein the amount of cast carbide is at least 1% w greater than the second quantity of sintered carbide, based on the weight percentages calculated based on the total weight of the carbide phase.

11. The hardfacing composition of claim 1 , wherein the first quantity and second quantity of sintered carbide is super dense sintered carbide having a predominantly closed porosity or is free of pores.

12. The hardfacing composition of claim 11 , wherein the first quantity of sintered carbide has particles with sizes in the range of from 16 to 20 mesh (−16/+20 mesh) and a second quantity of sintered carbide has particles with sizes in the range of from 30 to 40 mesh (−30/+40 mesh).

13. The hardfacing composition of claim 1 , wherein the carbide phase is present in an amount of from 50% to 75% by weight, based on the total weight of the hardfacing composition.

14. The hardfacing composition of claim 1 , wherein the binder alloy is present in an amount of from 25% to 50% by weight, based on the total weight of the hardfacing composition.

15. The hardfacing composition of claim 1 , wherein the sintered carbide is spherical and comprises tungsten carbide and cobalt.

16. The hardfacing composition of claim 1 , wherein the cast carbide is present in a quantity of 25% to 40% by weight.

17. The hardfacing composition of claim 1 , wherein the cast carbide is present in a quantity of 25% to 35% by weight.

18. The hardfacing composition of claim 1 , wherein the cast carbide is present in a quantity of 24% to 34% by weight.

19. A hardfacing composition comprising:
an iron-based binder alloy; and
a carbide phase comprising a super dense sintered carbide and one or more additional carbides, wherein the super dense sintered carbide comprises particles having sizes in the range of from 16 to 40 mesh, wherein the carbide phase comprises a first quantity of super dense sintered carbide having particles with sizes in the range of from 16 to 25 mesh, said first quantity of super dense sintered carbide being in the range of 10% w to 70% w of the total weight of the carbide phase, and a second quantity of super dense sintered carbide having a particles with sizes of at least 25 mesh.

20. The hardfacing composition of claim 19 , wherein the second quantity of super dense sintered carbide has particles with sizes in the range of from 25 to 75 mesh.

21. The hardfacing composition of claim 20 , wherein the first quantity is greater than the second quantity by no greater than 15%.

22. A hardfacing composition comprising:
an iron-based binder alloy; and
a carbide phase comprising a sintered carbide phase including a super dense sintered carbide and wherein the carbide phase comprises one or more additional carbides, wherein the sintered carbide phase comprises a first quantity of the sintered carbide particles have sizes in the range of from 16 to 25 mesh (−16/+25 mesh) and a second quantity of the sintered carbide particles have sizes in the range of from 25 to 50 mesh (−25/+50 mesh), wherein the first quantity of sintered carbide is present in an amount of at least 10% w, wherein the first quantity larger than the second quantity, and wherein the super dense sintered carbide is present in a quantity of 22.5% w to 47.5% w based on the total weight of the carbide phase.

Assignees

• Xia Sike
• Yong Zhou
• Smith International

Inventors

• Xia Sike
• Yong Zhou

Classifications

• C22C29/08

  based on tungsten carbide · CPC title

• C22C29/005

  comprising a particular metallic binder · CPC title

• B22F2005/001

  Cutting tools, earth boring or grinding tool other than table ware · CPC title

• E21B10/50 Primary

  the bit being of roller type · CPC title