MATRIX DRILL BIT WITH DUAL SURFACE COMPOSITIONS AND METHODS OF MANUFACTURE
1 Assignment
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Accused Products
Abstract
Matrix drill bits and other downhole tools may be formed with one or more layers of hard materials disposed on exterior portions thereof. Exterior portions of used rotary drill bits or other downhole tools may be measured using three dimensional (3D) scanning techniques or other techniques to determine specific locations of undesired abrasion, erosion and/or wear. During the design of a new rotary drill bit or other downhole tool, computational flow analysis techniques may be used to determine potential locations for excessive erosions, abrasion, wear, impact and/or fatigue on exterior portions of the rotary drill bit or other downhole tools. One or more layers of hard material may be disposed at such locations on exterior portions of matrix bit bodies and other matrix bodies based on analyzing exterior portions of used downhole tools and/or computational flow analysis.
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Citations
71 Claims
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1-22. -22. (canceled)
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24. A method of making a matrix drill bit comprising:
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determining potential locations for excessive erosion, abrasion and/or wear of exterior portions of a matrix bit body; placing layers of hard material at selected locations on interior portions of a matrix bit body mold corresponding with the potential locations for excessive erosion, abrasion and/or wear of exterior portions of the associated matrix bit body; placing a hollow bit blank in the matrix bit body mold; placing at least one matrix material selected from the group consisting of cemented carbides, composite carbides, spherical carbides, macrocrystalline tungsten carbide and cast carbide and formulates thereof in the mold; placing a binder material in the mold with the binder material disposed proximate the matrix material and the hollow bit blank; heating the mold and the materials disposed therein to a selected temperature to allow the binder material to melt and infiltrate the matrix material and the layers of hard material and associated tungsten carbide pellets with hot, liquid binder material; and cooling the mold and materials disposed therein to form a matrix bit body with multiple layers of hard material disposed proximate selected locations on exterior portions of the matrix bit body. - View Dependent Claims (56, 57, 58, 59, 60, 61, 62, 63)
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24-1. The method of claim 23 further comprising forming interior portions of the matrix bit body with more than one matrix material.
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25. The method of claim 23 further comprising forming multiple layers of tungsten carbide pellets at selected locations on exterior portions of the matrix bit body associated with engaging and removing downhole formation materials during formation of a wellbore.
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26. The method of claim 23 further comprising forming multiple layers of crushed sintered tungsten carbide at selected locations on exterior portions of the matrix bit body associated with engaging and removing downhole formation materials during formation of a wellbore.
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27. (canceled)
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28. The method of claim 23 further comprising forming the layers of the hard material with respective dimensions including thickness selected to minimize erosion, abrasion and/or wear proximate the corresponding selected location on exterior portions of the matrix bit body.
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29. A method of making a matrix drill bit comprising:
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determining potential locations for excessive erosion, abrasion and/or wear of exterior portions of a matrix bit body; placing first layers of adhesive material at selected locations on interior portions of a matrix bit body mold corresponding with the potential locations for excessive erosion, abrasion and/or wear of exterior portions of a matrix bit body; placing tungsten carbide pellets in each first layer of adhesive material; placing a respective second layer of adhesive material on each first layer of adhesive material and associated tungsten carbide pellets; placing additional tungsten carbide pellets in each second layer of adhesive material; placing a hollow bit blank in the matrix bit body mold; placing at least one matrix material selected from the group consisting of cemented carbides, composite carbides, spherical carbides, macrocrystalline tungsten carbide and cast carbide and formulates thereof in the mold; placing a binder material in the mold with the binder material disposed proximate the matrix material and the hollow bit blank; heating the mold and the materials disposed therein to a selected temperature to allow the binder material to melt and infiltrate the matrix material and the layers of adhesive material and associated tungsten carbide pellets with hot, liquid binder material; and cooling the mold and materials disposed therein to form a matrix bit body with multiple layers of tungsten carbide pellets disposed proximate selected locations on exterior portions of the matrix bit body. - View Dependent Claims (30, 31, 33, 34, 35, 36, 64, 65, 66, 67, 68, 69, 70, 71)
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32. (canceled)
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37-55. -55. (canceled)
Specification