Abstract:
An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold. An infiltration chamber is 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 downhole tool. One or more thermal elements are positioned within at least one of the mold and the funnel, and the one or more thermal elements are in thermal communication with the infiltration chamber.
Abstract:
Drill bits for use in drilling well bores in subterranean formations, and associated systems and methods of making and using such drill bits, are provided. In certain embodiments, the drill bits comprise: a body; a plurality of blades on the body; a plurality of cutting elements on at least one of the plurality of blades; a reinforcement material forming portions of the body and the plurality of blades; a binder material infiltrated through the reinforcement material to form a composite material and forming portions of the body and the plurality of blades; and at least one interior displacement element located in an interior region of the body that is surrounded by the composite material.
Abstract:
An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold and having an inner wall, an outer wall, and a cavity defined between the inner and outer walls. An infiltration chamber is defined at least partially by the mold and the funnel. The inner wall faces the infiltration chamber and the outer wall forms at least a portion of an outer periphery of the mold assembly.
Abstract:
A wellbore tool may be formed, at least in part, by a fiber-reinforced hard composite portion. The fiber-reinforced hard composite portion can include reinforcing particles and reinforcing fibers dispersed in a binder, wherein the reinforcing fibers have an aspect ratio ranging from 1 to 15 times a critical aspect ratio (Ac). The critical aspect ratio can be determined using the equation Ac=σf/(2τc), wherein σf is an ultimate tensile strength of the reinforcing fibers, and τc is an interfacial shear bond strength between the reinforcing fiber and the binder or a yield stress of the binder, whichever is lower.
Abstract:
An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold and having an inner wall, an outer wall, and a cavity defined between the inner and outer walls. An infiltration chamber is defined at least partially by the mold and the funnel. The inner wall faces the infiltration chamber and the outer wall forms at least a portion of an outer periphery of the mold assembly.
Abstract:
A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.
Abstract:
A metal matrix composite tool that includes a hard composite portion comprising a reinforcement material infiltrated with a binder material, wherein the reinforcement material comprises a refractory metal component dispersed with reinforcing particles, wherein a surface roughness of the reinforcing particles is at least two times greater than the refractory metal component, wherein the refractory metal component has a failure strain of at least 0.05 and a shear modulus of 200 GPa or less, and wherein the reinforcing particles have a failure strain of 0.01 or less but at least five times less than the failure strain of the refractory metal component, and the reinforcing particles have a shear modulus of greater than 200 GPa and at least two times greater than the shear modulus of the refractory metal component. The reinforcing particles may comprise an intermetallic, a boride, a carbide, a nitride, an oxide, a ceramic, and/or a diamond.
Abstract:
A mold transfer assembly includes a transfer housing providing an interior defined by one or more sidewalls and a top. The transfer housing is sized to receive and encapsulate a mold as the mold is moved between a furnace and a thermal heat sink. An arm is coupled to the transfer housing to move the transfer housing and the mold encapsulated within the transfer housing between the furnace and a thermal heat sink. The transfer housing exhibits one or more thermal properties to control a thermal profile of the mold.
Abstract:
An example mold assembly for fabricating an infiltrated downhole tool includes a mold forming a bottom of the mold assembly, and a funnel operatively coupled to the mold. An infiltration chamber is 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 downhole tool. One or more thermal elements are positioned within at least one of the mold and the funnel, and the one or more thermal elements are in thermal communication with the infiltration chamber.
Abstract:
An example insulation enclosure includes a support structure having a top end, a bottom end, and an opening defined at the bottom end for receiving a mold within an interior of the support structure, and a thermal mass arranged at the top end of the support structure to thermally communicate with a top of the mold and resist heat flow from the top of the mold in an axial direction.