Hardfacing materials including PCD particles, welding rods and earth-boring tools including such materials, and methods of forming and using same

• US 8,079,428 B2
• Filed: 07/02/2009
• Issued: 12/20/2011
• Est. Priority Date: 07/02/2009
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Lyons, Nicholas J., Scott, Danny E.
• Primary Examiner(s): Neuder, William P
• Assistant Examiner(s): HUTCHINS, CATHLEEN R
• Application Number:
  US12/497,420
• Publication Number:
  US 20110000715A1
• Time in Patent Office: 901 Days
• Field of Search: 752/43, 175/374, 175/425, 175/434, 428/323, 428/408, 428/698, 428/704
• US Class Current: 175/374
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B23K 35/0261 Rods, electrodes, wires
• CPC Class Codes: B23K 35/24 Selection of soldering or welding materials proper B23K35/34 takes precedence
• CPC Class Codes: B23K 35/36 Selection of non-metallic compositions, e.g. coatings, fluxes B23K35/34 takes precedence; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest selection of soldering or welding materials proper B23K35/24
• CPC Class Codes: B23K 35/365 Selection of non-metallic compositions of coating materials either alone or conjoint with selection of soldering or welding materials
• CPC Class Codes: B24D 3/10 for porous or cellular structure, e.g. for use with diamonds as abrasives
• CPC Class Codes: C22C 26/00 Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: E21B 10/42 Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62
• 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
• CPC Class Codes: E21B 10/55 with preformed cutting elements
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to form diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material.

Claims

1. A hardfacing material, comprising:

a metal matrix material; and

particles of polycrystalline diamond material embedded within the metal matrix material, the particles of polycrystalline diamond material comprising a plurality of inter-bonded diamond grains, the particles of polycrystalline diamond material comprising fragmented portions of one or more layers of polycrystalline diamond material.

2. The hardfacing material of claim 1, wherein the fragmented portions of the one or more layers of polycrystalline diamond material are at least substantially planar.

3. The hardfacing material of claim 1, wherein interstitial spaces between the plurality of inter-bonded diamond grains within the particles of polycrystalline diamond material are at least substantially free of catalyst material used to catalyze formation of diamond-to-diamond bonds between the plurality of inter-bonded diamond grains.

4. The hardfacing material of claim 1, wherein the particles of polycrystalline diamond material are encapsulated within a coating comprising a metal.

5. The hardfacing material of claim 4, wherein the coating further comprises at least one of a carbide material, a boride material, a nitride material, and non-polycrystalline diamond grit.

6. The hardfacing material of claim 1, wherein interstitial spaces between the plurality of inter-bonded diamond grains within the particles of polycrystalline diamond material are at least substantially free of catalyst material used to catalyze formation of diamond-to-diamond bonds between the plurality of inter-bonded diamond grains, and wherein the particles of polycrystalline diamond material are encapsulated within a coating comprising a metal.

7. The hardfacing material of claim 1, wherein the particles of polycrystalline diamond material are at least substantially planar, have an average particle diameter between about 0.25 millimeter and about 7.0 millimeters, and have an average particle thickness between about 0.1 millimeter and about 5.0 millimeters.

8. An earth-boring tool, comprising:

a body;

at least one cutting element on the body; and

hardfacing material on at least a portion of a surface of the body, the hardfacing material comprising;

a metal matrix material; and

particles of polycrystalline diamond material embedded within the metal matrix material, the particles of polycrystalline diamond material comprising a plurality of inter-bonded diamond grains, the particles of polycrystalline diamond material comprising fragmented portions of one or more layers of polycrystalline diamond material.

9. The earth-boring tool of claim 8, wherein the body comprises a bit body of a fixed-cutter rotary drill bit, and wherein the at least one cutting element comprises a polycrystalline diamond compact (PDC) cutting element fixedly attached to the bit body.

10. The earth-boring tool of claim 8, wherein the body comprises a bit leg of a roller cone rotary drill bit, and wherein the at least one cutting element comprises a roller cone cutter.

11. The earth-boring tool of claim 8, wherein the body comprises a roller cone cutter of a roller cone rotary drill bit, and wherein the at least one cutting element comprises a cutting insert or a cutting tooth on the roller cone cutter.

12. The earth-boring tool of claim 8, wherein interstitial spaces between the plurality of inter-bonded diamond grains within the particles of polycrystalline diamond material are at least substantially free of catalyst material used to catalyze formation of diamond-to-diamond bonds between the plurality of inter-bonded diamond grains, and wherein the particles of polycrystalline diamond material are encapsulated within a coating comprising a metal.

13. A method of hardfacing an earth-boring tool, comprising:

embedding particles of polycrystalline diamond material comprising fragmented portions of one or more layers of polycrystalline diamond material including a plurality of inter-bonded diamond grains in a metal matrix material on a surface of a body of an earth-boring tool to form hardfacing on the surface of the earth-boring tool, the earth-boring tool including at least one cutting element on the body.

14. The method of claim 13, wherein embedding the particles of polycrystalline diamond material in a metal matrix material on the surface of the earth-boring tool comprises:

using a welding torch to at least partially melt the metal matrix material;

applying the at least partially molten metal matrix material and the particles of polycrystalline diamond material to the surface of the earth-boring tool; and

allowing the at least partially molten metal matrix material to cool and solidify on the surface of the earth-boring tool.