COMPOSITE STRUCTURE HAVING A NON-PLANAR INTERFACE AND METHOD OF MAKING SAME

• US 20060237236A1
• Filed: 04/26/2005
• Published: 10/26/2006
• Est. Priority Date: 04/26/2005
• Status: Abandoned Application

• Current Assignee: ReedHycalog LP (NOV, Inc.)
• Original Assignee: ReedHycalog LP (NOV, Inc.)
• Inventors: Drake, Eric F., Sreshta, Harold
• Application Number:
  US10/908,040
• Publication Number:
  US 20060237236A1
• Time in Patent Office: Days
• US Class Current: 175/426
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/02 Compacting only
• CPC Class Codes: B22F 3/26 Impregnating making ferrous alloys by impregnation C22C33/0242
• CPC Class Codes: B22F 7/02 of composite layers B22F7/002 takes precedence
• CPC Class Codes: B22F 7/04 with one or more layers not made from powder, e.g. made from solid metal
• CPC Class Codes: C22C 1/1036 starting from a melt
• CPC Class Codes: E21B 10/5735 Interface between the substrate and the cutting element

Abstract

A composite structure includes a first portion comprising a first metallic material, a monolayer of particles extending into and bonded with the first portion, and a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles. A method for fabricating a composite structure includes bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion and bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.

Claims

1. A composite structure, comprising:

a first portion comprising a first metallic material;

a monolayer of particles extending into and bonded with the first portion; and

a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles.

2. A composite structure, according to claim 1, wherein at least some of the particles and the first portion define recesses exhibiting negative draft angles into which the second portion extends.

3. A composite structure, according to claim 1, wherein the monolayer of particles is co-sintered with the first portion.

4. A composite structure, according to claim 1, wherein the monolayer of particles is bonded to the first portion by metallurgical neck bonds.

5. A composite structure, according to claim 1, wherein the monolayer of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.

6. A composite structure, according to claim 1, wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a diamond composite material, a metal, and a metal alloy.

7. A composite structure, according to claim 1, wherein the monolayer of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.

8. A composite structure, according to claim 1, wherein the first portion is harder than the second portion.

9. A composite structure, according to claim 1, wherein the first portion is softer than the second portion.

10. A composite structure, according to claim 1, further comprising a second monolayer of particles extending into and bonded with the first portion and a third portion comprising a third material, the third portion bonded with the second monolayer of particles and extending into interstices between the particles of the second monolayer of particles.

11. A composite structure, according to claim 1, wherein the second portion comprises a densified powder.

12. A composite structure, according to claim 1, wherein the second portion comprises a solidified metal or metal alloy.

13. An insert for a rock bit, comprising:

a substrate comprising a first metallic material;

a plurality of particles bonded with the substrate; and

a densified portion comprising a second material, the densified portion bonded with the plurality of particles and extending into interstices between the particles.

14. An insert, according to claim 13, wherein at least some of the plurality of particles and the substrate define recesses exhibiting negative draft angles into which the densified portion extends.

15. An insert, according to claim 13, wherein the plurality of particles is co-sintered with the substrate.

16. An insert, according to claim 13, wherein the plurality of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.

17. An insert, according to claim 13, wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a diamond composite material, a metal, and a metal alloy.

18. An insert, according to claim 13, wherein the plurality of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.

19. A composite pick, comprising:

a tip comprising a first metallic material;

a plurality of particles bonded with the tip; and

a densified portion comprising a second material, the densified powder bonded with the plurality of particles and extending into interstices between the particles.

20. A composite pick, according to claim 19, wherein the tip defines an undulant surface and the plurality of particles is bonded with the undulant surface.

21. A composite pick, according to claim 19, wherein at least some of the plurality of particles and the tip define recesses exhibiting negative draft angles into which the second portion extends.

22. A composite pick, according to claim 19, wherein the plurality of particles is co-sintered with the substrate.

23. A composite pick, according to claim 19, wherein the plurality of particles comprises one of the first metallic material, a chemical variant of the first metallic material, a metallurgical variant of the first metallic material, a metal, and a metal alloy.

24. A composite pick, according to claim 19, wherein the first metallic material comprises a first cemented carbide and the second material comprises one of a second cemented carbide, a cemented carbide and steel mixture, a metal, and a metal alloy.

25. A composite pick, according to claim 20, wherein the plurality of particles comprises at least one of spherical particles, oblate spherical particles, cylindrical particles, rod-shaped particles, and irregular shaped particles.

26. A method for fabricating a composite structure, comprising:

bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion; and

bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.

27. A method, according to claim 26, wherein bonding the monolayer of particles further comprises co-sintering the monolayer of particles with the first portion.

28. A method, according to claim 26, wherein bonding the second portion further comprises:

filling the interstices with a powder; and

pressure densifying the powder.

29. A method, according to claim 26, wherein bonding the second portion further comprises:

infiltrating the interstices with a liquid metal; and

allowing the liquid metal to solidify.

30. A method, according to claim 26, further comprising extending the second portion into recesses defined by the particles and the first portion.

31. A method, according to claim 30, wherein the recesses exhibit negative draft angles.

32. A method, according to claim 26, further comprising:

bonding a second monolayer of particles to a first portion, such that the second monolayer of particles extends into the first portion; and

bonding a third portion comprising a third material to the second monolayer of particles, such that the third portion extends into interstices between the particles of the second monolayer of particles.