Abstract:
A drill bit formed of a binder comprising a copper nickel manganese alloy is disclosed. The binder has an increased content of manganese, which improves the strength and toughness of the drill bit. Manganese forms a solid solution with copper in the alloy, as well as forming an intermetallic with the nickel constituent. The formation of the MnNi inter-metallic also serves to improve the erosion resistance of the binder alloy and thus the overall erosion resistance of the MMC.
Abstract:
An example mold assembly system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.
Abstract:
An example mold assembly system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.
Abstract:
Continuous fiber-reinforced hard composites may be useful in mitigating crack propagation in downhole tools. In some instances, a wellbore tool may be formed at least in part by a continuous fiber-reinforced hard composite portion that includes a binder material continuous phase with reinforcing particles and continuous fibers contained therein, wherein the continuous fibers have an aspect ratio at least 15 times greater than a critical aspect ratio (Ac), wherein Ac=σf/(2Tc, σf is an ultimate tensile strength of the continuous fibers, and Tc is a lower of (1) an interfacial shear bond strength between the continuous fibers and the binder material and (2) a yield stress of the binder material.
Abstract:
An example drill bit for subterranean drilling operations includes a drill bit body with a blade. The drill bit may further include a cutting element and an alloy affixing the cutting element to the blade. The alloy may include a particulate phase, such as ceramic material or an intermetallic material, that increases the strength of the alloy without significantly affecting the melting point of the alloy.
Abstract:
A system of repairing and protecting a surface of a drill bit includes forming a drill bit body that includes a magnetized material or is otherwise magnetizable. The drill bit includes at least one cutting element and is operable to generate a magnetic field. A drilling fluid that includes magnetizable, regenerative particles is circulated through a drill string and wellbore in which the drill bit is deployed. The magnetic field attracts the regenerative particles to the surface of the drill bit body to occupy cracks and chips formed in the surface of the drill bit body, and to form a protective layer of the regenerative particles over the surface of the drill bit body.
Abstract:
Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.
Abstract:
A mold assembly and method for fabricating an infiltrated drill bit may comprise a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, an infiltration chamber defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated drill bit, a displacement core arranged within the infiltration chamber and having one or more legs that extend therefrom, a metal blank arranged about the displacement core within the infiltration chamber, and one or more thermal elements. A method may comprise providing a mold assembly having component parts that include a mold that forms a bottom of the mold assembly and a funnel operatively coupled to the mold, imparting thermal energy to the infiltration chamber with one or more thermal element, and heating contents contained within the infiltration chamber.
Abstract:
Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.
Abstract:
A low surface friction body for a drill bit includes a matrix drill bit body. The body includes a particulate phase having a friction-reducing additive, and a binding material that bonds the particulate phase using a suitable manufacturing process such as selective laser sintering. The particulate phase may include tungsten carbide, the friction-reducing additive may be polytetrafluoroethylene, and the binder material may be copper or cobalt. The friction-reducing additive is distributed throughout at least a portion of the drill bit body that includes the surface that will come into contact with drill cuttings and drilling fluid during operation. The molecular properties of the friction-reducing additive result in a drill bit body having a surface that is resistant to sticking even after enduring chipping and other types of wear.