Erosion Resistant Hard Composite Materials

• US 20130000982A1
• Filed: 12/23/2011
• Published: 01/03/2013
• Est. Priority Date: 06/25/2010
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Olsen, Garrett T.
• Granted Patent: US 9,138,832 B2
• Time in Patent Office: Days
• US Class Current: 175/57
• CPC Class Codes: B22F 1/05 Metallic powder characterised by the size or surface area of the particles
• CPC Class Codes: B22F 1/052 characterised by a mixture of particles of different sizes or by the particle size distribution
• CPC Class Codes: B22F 1/054 Nanosized particles
• CPC Class Codes: B22F 1/0547 Nanofibres or nanotubes
• CPC Class Codes: B22F 1/0549 Hollow particles, including tubes and shells
• CPC Class Codes: B22F 1/062 Fibrous particles
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/0655 Hollow particles
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 35/0261 Rods, electrodes, wires
• CPC Class Codes: B23K 35/327 comprising refractory compounds, e.g. carbides
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C04B 2235/427 Diamond
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/5454 nanometer sized, i.e. below 100 nm
• CPC Class Codes: C04B 2235/5472 Bimodal, multi-modal or multi-fraction
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/5607 : based on refractory metal carbides
• CPC Class Codes: C04B 35/5611 : based on titanium carbides
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/563 : based on boron carbide
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/5831 : based on cubic boron nitrides or Wurtzitic boron nitrides, including crystal structure transformation of powder
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C22C 1/0433 : Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 29/062 : based on B4C
• CPC Class Codes: C22C 29/065 : based on SiC
• CPC Class Codes: C22C 29/08 : based on tungsten carbide
• CPC Class Codes: C22C 29/10 : based on titanium carbide
• CPC Class Codes: C22C 29/12 : based on oxides
• CPC Class Codes: C22C 29/16 : based on nitrides containing cubic BN or wurtzitic BN and diamond C22C26/00
• CPC Class Codes: C22C 32/0015 : with only single oxides as main non-metallic constituents
• CPC Class Codes: C22C 32/0026 : Matrix based on Ni, Co, Cr or alloys thereof
• CPC Class Codes: C22C 32/0052 : only carbides
• CPC Class Codes: C22C 32/0057 : based on B4C
• CPC Class Codes: C22C 32/0063 : based on SiC
• CPC Class Codes: C22C 32/0068 : only nitrides
• CPC Class Codes: C22C 32/0084 : carbon or graphite as the main non-metallic constituent
• CPC Class Codes: C22C 33/02 : by powder metallurgy working metallic powder B22F
• CPC Class Codes: E21B 10/46 : characterised by wear resisting parts, e.g. diamond inserts
• CPC Class Codes: E21B 10/50 : the bit being of roller type
• CPC Class Codes: E21B 10/54 : the bit being of the rotary drag type, e.g. fork-type bits

Abstract

A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima.

Claims

1. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 30 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

2. The composition of claim 1 wherein the first local maxima is at a particle size of about 0.5 nm to about 1 μ

m.

3. The composition of claim 1 wherein the first local maxima is at a particle size of about 1 μ

m to about 10 μ

m.

4. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

a carbide, a nitride, a natural diamond, a synthetic diamond, predominantly carbon structures, iron oxides, steels, stainless steels, austenitic steels, ferritic steels, martensitic steels, precipitation-hardening steels, duplex stainless steels, iron alloys, nickel alloys, chromium alloys, and any combination thereof.

5. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one particle selected from the group consisting of:

a whisker, a rod, a nanorod, a wire, a nanowire, a lobal particle, a nanostar, a nanosphere, and a nanorice.

6. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

stoichiometric tungsten carbide, cemented tungsten carbide, cast tungsten carbide, and any combination thereof.

7. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

molybdenum carbide, titanium carbide, tantalum carbide, niobium carbide, chromium carbide, vanadium carbide, silicon carbide, boron carbide, solid solutions thereof, and any combination thereof.

8. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

silicon nitride, cubic boron nitride, and any combination thereof.

9. The composition of claim 1 wherein the polymodal blend of matrix powder has a second local maxima at a particle size of 30 μ

m less and/or a second local maxima at a particle size of 200 μ

m or more.

10. The composition of claim 1 wherein the binder comprises at least one material selected from the group consisting of:

copper, cobalt, nickel, iron, zinc, manganese, any alloys of these elements, and any combinations thereof.

11. The composition of claim 1 wherein the composition has an erosion rate of less than 0.06% volume per hour based on a “

Specific Slurry Erosion Test Procedure”

disclosed herein.

12. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder comprising at least two particles, wherein a first particle has an aspect ratio of about 5 or greater.

13. The hard composite composition of claim 12 wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 1 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

14. The hard composite composition of claim 12 wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 1 μ

m to about 10 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

15. A drill bit comprising:

a bit body; and

at least one cutting element for engaging a formation;

wherein at least a portion of the bit body comprises a hard composite material comprising;

a binder;

a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 30 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

16. The drill bit of claim 15 wherein the drill bit is a fixed cutter drill bit.

17. The drill bit of claim 15 wherein the drill bit is a rotary cone drill bit.

18. The drill bit of claim 15 wherein the first local maxima is at a particle size of about 0.5 nm to about 1 μ

m.

19. The drill bit of claim 15 wherein the first local maxima is at a particle size of about 1 μ

m to about 10 μ

m.

20. The drill bit of claim 15 wherein the polymodal blend of matrix powder comprises at least one particle selected from the group consisting of:

a whisker, a rod, a nanorod, a wire, a nanowire, a lobal particle, a nanostar, a nanosphere, and a nanorice.

21. A method comprising:

providing a drill bit comprising;

a bit body comprising;

a binder;

a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 30 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima; and

at least one cutting element for engaging a formation; and

drilling a well bore in a subterranean formation with the drill bit.