Erosion resistant subterranean drill bits having infiltrated metal matrix bodies
First Claim
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1. A subterranean drill bit comprising:
- (a) at least one cutting element, and(b) a bit body having an infiltrated metal matrix, wherein the infiltrated metal matrix comprises;
(i) an infiltrant, and(ii) a matrix powder mixture comprising;
(A) about 30 to about 90 weight percent of a first component powder, the first component powder consisting of particles of cast tungsten carbide of −
30 (600 micron) +140 (106 micron) in particle size;
(B) about 10 to about 70 weight percent of a second component powder, the second component powder consisting of particles of at least one selected from the group consisting of macrocrystalline tungsten carbide, carburized tungsten carbide, and cemented tungsten carbide; and
(C) up to about 12 weight percent of a third component powder, the third component powder consisting of particles of at least one selected from the group consisting of transition metals, main group metals, and alloys and combinations thereof;
wherein the bit body carries the cutting element and the matrix powder mixture contains substantially no particles of the first component powder of −
140 mesh (106 micron) in particle size and particles of the first component powder having a particle size of +100 mesh (150 microns) account for at least 15 weight percent of the matrix powder mixture.
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Abstract
Subterranean drill bits having good erosion resistance, strength, toughness, and thermal stability are disclosed. The drill bits comprise a bit body carrying at least one cutting element and having an infiltrated metal matrix. The infiltrated metal matrix comprises a matrix powder composition bound together by an infiltrant. The matrix powder mixture includes cast tungsten carbide powder having a particle size of −30 (600 micron) +140 mesh (106 micron), a second component powder consisting of one or more other types of tungsten carbide particles, and a metal powder.
33 Citations
20 Claims
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1. A subterranean drill bit comprising:
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(a) at least one cutting element, and (b) a bit body having an infiltrated metal matrix, wherein the infiltrated metal matrix comprises; (i) an infiltrant, and (ii) a matrix powder mixture comprising; (A) about 30 to about 90 weight percent of a first component powder, the first component powder consisting of particles of cast tungsten carbide of −
30 (600 micron) +140 (106 micron) in particle size;(B) about 10 to about 70 weight percent of a second component powder, the second component powder consisting of particles of at least one selected from the group consisting of macrocrystalline tungsten carbide, carburized tungsten carbide, and cemented tungsten carbide; and (C) up to about 12 weight percent of a third component powder, the third component powder consisting of particles of at least one selected from the group consisting of transition metals, main group metals, and alloys and combinations thereof; wherein the bit body carries the cutting element and the matrix powder mixture contains substantially no particles of the first component powder of −
140 mesh (106 micron) in particle size and particles of the first component powder having a particle size of +100 mesh (150 microns) account for at least 15 weight percent of the matrix powder mixture. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A matrix powder mixture comprising:
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a) about 30 to about 90 weight percent of a first component powder, the first component powder consisting of particles of cast tungsten carbide of −
30 (600 micron) +140 (106 micron) in particle size;b) about 10 to about 70 weight percent of a second component powder, the second component powder consisting of particles of at least one selected from the group consisting of macrocrystalline tungsten carbide, carburized tungsten carbide, and cemented tungsten carbide; and c) up to about 12 weight percent of a third component powder, the third component powder consisting of particles of at least one selected from the group consisting of transition metals, main group metals, and alloys and combinations thereof; wherein the matrix powder mixture contains substantially no particles of the first component powder of −
140 mesh (106 micron) in particle size and particles of the first component powder having a particle size of +100 mesh (150 microns) account for at least 15 weight percent of the matrix powder mixture. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
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18. A method of making a subterranean drill bit comprising the steps of:
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a) providing a matrix powder mixture comprising; (A) about 30 to about 90 weight percent of a first component powder, the first component powder consisting of particles of cast tungsten carbide of −
30 (600 micron) +140 (106 micron) in particle size;(B) about 10 to about 70 weight percent of a second component powder, the second component powder consisting of particles of at least one selected from the group consisting of macrocrystalline tungsten carbide, carburized tungsten carbide, and cemented tungsten carbide; and (C) up to about 12 weight percent of a third component powder, the third component powder consisting of particles of at least one selected from the group consisting of transition metals, main group metals, and alloys and combinations thereof; wherein the matrix powder mixture contains substantially no particles of the first component powder of −
140 mesh (106 micron) in particle size and particles of the first component powder having a particle size of +100 mesh (150 microns) account for at least 15 weight percent of the matrix powder mixture;c) confining the matrix powder mixture within a graphite mold; d) infiltrating an infiltrant into the confined matrix powder mixture to form a bit body; e) fixing at least one cutting element to the bit body. - View Dependent Claims (19, 20)
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Specification