Composite constructions with oriented microstructure

• US 7,264,879 B2
• Filed: 09/30/2004
• Issued: 09/04/2007
• Est. Priority Date: 08/01/1996
• Status: Expired due to Fees

• Current Assignee: Smith International Incorporated (Schlumberger NV)
• Original Assignee: Smith International Incorporated (Schlumberger NV)
• Inventors: Fang, Zhigang, Rai, Ghanshyam, Sue, J. Albert
• Primary Examiner(s): McNeil; Jennifer
• Assistant Examiner(s): Savage; Jason L.
• Application Number:
  US10/957,326
• Publication Number:
  US 20050112396A1
• Time in Patent Office: 1,069 Days
• Field of Search: 428/469, 428/408, 428/698, 175/425, 175/426, 175/434
• US Class Current: 428/411.1
• CPC Class Codes: B22F 1/09 Mixtures of metallic powders
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 2005/002 Tools other than cutting tools
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/10 Sintering only
• CPC Class Codes: B22F 3/20 by extruding
• CPC Class Codes: B22F 7/04 with one or more layers not made from powder, e.g. made from solid metal
• 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 47/00 Making alloys containing metallic or non-metallic fibres or filaments
• CPC Class Codes: C22C 47/025 Aligning or orienting the fibres
• CPC Class Codes: C22C 47/04 by coating, e.g. with a protective or activated covering
• CPC Class Codes: C22C 47/068 Aligning wires
• CPC Class Codes: C22C 47/14 by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
• CPC Class Codes: C22C 49/00 Alloys containing metallic or non-metallic fibres or filaments
• CPC Class Codes: E21B 10/52 with chisel- or button-type inserts
• CPC Class Codes: E21B 10/56 Button-type inserts E21B10/52 takes precedence
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
• CPC Class Codes: Y10T 428/12035 Fiber, asbestos, or cellulose in or next to particulate component
• CPC Class Codes: Y10T 428/12465 having magnetic properties, or preformed fiber orientation coordinate with shape
• CPC Class Codes: Y10T 428/12486 : Laterally noncoextensive components [e.g., embedded, etc.]
• CPC Class Codes: Y10T 428/249927 : Fiber embedded in a metal matrix
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

Abstract

In one embodiment, composite constructions of the invention are in the form of a plurality of coated fibers bundled together to produce a fibrous composite construction in the form of a rod. Each fiber has a core formed from a hard phase material, that is surrounded by a shell formed from a binder phase material. In another embodiment of the invention, monolithic sheets of the hard phase material and the binder phase material are stacked and arranged to produce a swirled composite in the form of a rod. In still another embodiment of the invention, sheets formed from coated fibers are arranged to produce a swirled composite. Inserts for use in such drilling applications as roller cone rock bits and percussion hammer bits, and shear cutters for use in such drilling applications as drag bits, that are manufactured using conventional methods from these composite constructions exhibit increased fracture toughness due to the continuous binder phase around the hard phase of the composites. These binder phases increase the overall fracture toughness of the composite by blunting or deflecting the tip of a propagating crack.

Claims

1. A composite construction having an ordered arrangement of first and second material phases, the construction being formed by the process of:

combining one or more precursor materials selected from the group consisting of ceramics, metals, diamond, cubic boron nitride, and mixtures thereof to form a green-state first material phase part;

combining one or more materials to form a green-state second material phase part, wherein one of the first or second material phase parts does not include a ceramic material;

joining together a number of the first and second green-state material phase parts to form a green-state assembly, wherein at least one of the first and second green-state material phase parts are commonly oriented within the assembly; and

consolidating and sintering the green-state assembly at high pressure/high temperature conditions to form the composite construction;

wherein the sintered first material phase has a hardness that is relatively greater than the sintered second material phase in the composite construction.

2. The composite construction as recited in claim 1 wherein the composite construction comprises a material microstructure characterized by a plurality of the first material phases disposed within a continuous matrix of the second material phase.

3. The composite construction as recited in claim 2 wherein the plurality of first material phases are aligned with an axis perpendicular to a working surface of the composite construction.

4. The composite construction as recited in claim 1 wherein the materials used to form the second green-state material phase parts are selected from the group consisting of ceramics, Co, Ni, Fe, W, Mo, Cu, Al, Nb, Ti, Ta, and alloys thereof.

5. An insert for use in a subterranean drill bit, the insert having a wear surface comprising the composite construction of claim 1.

6. A shear cutter for use in a subterranean drill bit, the shear cutter having a wear surface comprising the composite construction of claim 1.