Erosion resistant hard composite materials

• US 9,138,832 B2
• Filed: 12/23/2011
• Issued: 09/22/2015
• Est. Priority Date: 06/25/2010
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Olsen, Garrett T.
• Primary Examiner(s): Wyszomierski, George
• Assistant Examiner(s): MAI, NGOCLAN THI
• Application Number:
  US13/336,842
• Publication Number:
  US 20130000982A1
• Time in Patent Office: 1,369 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B22F 1/05 Metallic powder characterised by the size or surface area of the particles
• CPC Class Codes: B22F 1/052 characterised by a mixture of particles of different sizes or by the particle size distribution
• CPC Class Codes: B22F 1/054 Nanosized particles
• CPC Class Codes: B22F 1/0547 Nanofibres or nanotubes
• CPC Class Codes: B22F 1/0549 Hollow particles, including tubes and shells
• CPC Class Codes: B22F 1/062 Fibrous particles
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/0655 Hollow particles
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 35/0261 Rods, electrodes, wires
• CPC Class Codes: B23K 35/327 comprising refractory compounds, e.g. carbides
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C04B 2235/427 Diamond
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/5454 nanometer sized, i.e. below 100 nm
• CPC Class Codes: C04B 2235/5472 Bimodal, multi-modal or multi-fraction
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/5607 : based on refractory metal carbides
• CPC Class Codes: C04B 35/5611 : based on titanium carbides
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/563 : based on boron carbide
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/5831 : based on cubic boron nitrides or Wurtzitic boron nitrides, including crystal structure transformation of powder
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C22C 1/0433 : Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 29/062 : based on B4C
• CPC Class Codes: C22C 29/065 : based on SiC
• CPC Class Codes: C22C 29/08 : based on tungsten carbide
• CPC Class Codes: C22C 29/10 : based on titanium carbide
• CPC Class Codes: C22C 29/12 : based on oxides
• CPC Class Codes: C22C 29/16 : based on nitrides containing cubic BN or wurtzitic BN and diamond C22C26/00
• CPC Class Codes: C22C 32/0015 : with only single oxides as main non-metallic constituents
• CPC Class Codes: C22C 32/0026 : Matrix based on Ni, Co, Cr or alloys thereof
• CPC Class Codes: C22C 32/0052 : only carbides
• CPC Class Codes: C22C 32/0057 : based on B4C
• CPC Class Codes: C22C 32/0063 : based on SiC
• CPC Class Codes: C22C 32/0068 : only nitrides
• CPC Class Codes: C22C 32/0084 : carbon or graphite as the main non-metallic constituent
• CPC Class Codes: C22C 33/02 : by powder metallurgy working metallic powder B22F
• 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

Abstract

A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima.

Claims

1. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has a first local maxima at a particle size of about 0.5 nm to about 30 μ

m, a second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima;

wherein the polymodal blend of matrix powder comprises at least one particle selected from the group consisting of;

a whisker, a rod, a nanorod, a wire, a nanowire, a nanostar, a nanosphere, and a nanorice.

2. The composition of claim 1 wherein the first local maxima is at a particle size of about 0.5 nm to about 1 μ

m.

3. The composition of claim 1 wherein the first local maxima is at a particle size of about 1 μ

m to about 10 μ

m.

4. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

a carbide, a nitride, a natural diamond, a synthetic diamond, predominantly carbon structures, iron oxides, steels, stainless steels, austenitic steels, ferritic steels, martensitic steels, precipitation-hardening steels, duplex stainless steels, iron alloys, nickel alloys, chromium alloys, and any combination thereof.

5. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

stoichiometric tungsten carbide, cemented tungsten carbide, cast tungsten carbide, and any combination thereof.

6. The composition of claim 1 wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of:

molybdenum carbide, titanium carbide, tantalum carbide, niobium carbide, chromium carbide, vanadium carbide, silicon carbide, boron carbide, solid solutions thereof, and any combination thereof.

7. The composition of claim 1 wherein the polymodal blend of matrix powder further has a third local maxima at a particle size of 30 μ

m less, fourth local maxima at a particle size of 200 μ

m or more, or both.

8. The composition of claim 1 wherein the binder comprises at least one material selected from the group consisting of:

copper, cobalt, nickel, iron, zinc, manganese, any alloys of these elements, and any combinations thereof.

9. The composition of claim 1 wherein the composition has an erosion rate of less than 0.06% volume per hour based on a “

Specific Slurry Erosion Test Procedure”

disclosed herein.

10. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder comprising at least two particles, wherein a first particle has an aspect ratio of about 5 or greater, and wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 1 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

11. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder comprising at least two particles, wherein a first particle has an aspect ratio of about 5 or greater, and wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 1 μ

m to about 10 μ

m, at least one second local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.

12. A hard composite composition comprising:

a binder; and

a polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has a first local maxima at a particle size of about 0.5 nm to about 1 μ

m, a local maxima at a particle size of about 200 μ

m to about 10 mm, and at least one local minima between a particle size of about 30 μ

m to about 200 μ

m that has a value that is less than the first local maxima.