Manufacturing Process for Matrix Drill Bits

• US 20130312927A1
• Filed: 05/24/2013
• Published: 11/28/2013
• Est. Priority Date: 05/24/2012
• Status: Abandoned Application

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Thomas, Jeffrey G.
• Application Number:
  US13/901,919
• Publication Number:
  US 20130312927A1
• Time in Patent Office: Days
• US Class Current: 164/108
• CPC Class Codes: B22D 19/02 for making reinforced articles B22D19/14 takes precedence
• CPC Class Codes: B22D 19/06 for manufacturing or repairing tools
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: C22C 29/06 based on carbides, but not containing other metal compounds
• CPC Class Codes: E21B 10/00 Drill bits specially adapted for deflecting the direction of boring E21B7/064; with means for collecting substances E21B27/00

Abstract

A process for reducing inclusions during manufacturing of a matrix drill bit comprises placing at least a first layer of a first matrix material in a matrix bit body mold. At least a second layer of a second matrix material is placed in the mold. A binder material is placed in the mold with the binder material disposed proximate the second layer of matrix material and a metal a blank. A graphite lid is placed on the mold. The mold and the materials disposed therein are heated to a selected temperature to cause the binder material to melt and to allow the hot, liquid binder material to infiltrate the second matrix material and the first matrix material, with the second matrix material operable to improve infiltration of the first matrix material by the hot, liquid binder material without using a flux material.

Claims

1. A fluxless process for manufacturing a matrix drill bit comprising:

placing at least a first layer of a first matrix material in a matrix bit body mold;

placing a metal blank in the mold;

placing at least a second layer of a second matrix material in the mold;

placing a binder material in the mold with the binder material disposed proximate the second layer of matrix material and the metal blank;

placing a graphite lid on the mold;

heating the mold and the materials disposed therein to a selected temperature to melt the binder material and to allow the melted binder material to infiltrate the second matrix material and the first matrix material, with the second matrix material operable to improve infiltration of the first matrix material by the melted binder material;

starting solidification of the hot, liquid binder material with the first matrix material before the hot, liquid binder material solidifies with the second matrix material; and

cooling the mold and the materials disposed therein to form a coherent composite matrix bit body securely engaged with the metal blank.

2. The process of claim 1 wherein the first matrix material is chosen from the group consisting, of:

a cemented carbide material and a spherical carbide material.

3. The process of claim 1 wherein the second matrix material is chosen from the group consisting of a microcrystalline tungsten carbide material and a cast carbide material.

4. The process of claim 1 wherein the second matrix material is operable to improve infiltration of the hot, liquid hinder material throughout the first matrix material to minimize incomplete infiltration of the first matrix material by the hot, liquid binder material.

5. A process for reducing inclusions during manufacturing of a matrix drill bit comprising:

placing at least a first layer of a first matrix material in a matrix bit body mold;

placing a metal blank in the mold;

placing at least a second layer of a second matrix material in the mold;

placing a binder material in the mold with the binder material disposed proximate the second layer of matrix material and the metal blank;

placing a graphite lid on the mold;

heating the mold and the materials disposed therein to a selected temperature to cause the binder material to melt and to allow the hot, liquid binder material to infiltrate the second matrix material and the first matrix material, with the second matrix material operable to improve infiltration of the first matrix material by the hot, liquid binder material without using a flux material;

starting solidification of the hot, liquid binder material with the first matrix material before the hot, liquid binder material solidifies with the second matrix material; and

cooling the mold and the materials disposed therein to form a coherent composite matrix bit body securely engaged with the metal blank.

6. The process of claim 5 wherein the first matrix material is chosen from the group consisting of:

a cemented carbide material and a spherical carbide material.

7. The process of claim 5 wherein the second matrix material is chosen from the group consisting of a microcrystalline tungsten carbide material and a cast carbide material.

8. The process of claim 5 wherein the second matrix material is operable to improve infiltration of the hot, liquid binder material throughout the first matrix material to minimize incomplete infiltration of the first matrix material by the hot, liquid binder material.