CA2668192A1 - Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits - Google Patents

Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits Download PDF

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Publication number
CA2668192A1
CA2668192A1 CA002668192A CA2668192A CA2668192A1 CA 2668192 A1 CA2668192 A1 CA 2668192A1 CA 002668192 A CA002668192 A CA 002668192A CA 2668192 A CA2668192 A CA 2668192A CA 2668192 A1 CA2668192 A1 CA 2668192A1
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CA
Canada
Prior art keywords
aluminum
rotary drill
drill bit
boron carbide
based alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002668192A
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French (fr)
Other versions
CA2668192C (en
Inventor
Heman Choe
John H. Stevens
James C. Westhoff
Jimmy W. Eason
James L. Overstreet
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Baker Hughes Holdings LLC
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Individual
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Application filed by Individual filed Critical Individual
Publication of CA2668192A1 publication Critical patent/CA2668192A1/en
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Publication of CA2668192C publication Critical patent/CA2668192C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts

Abstract

Rotary drill bits (10) for drilling subterranean formations include a bit body (12) and at least one cutting structure (34) disposed on a face (18) t hereof. The bit body includes a crown region (14) comprising a particle-matr ix composite material (52) that includes a plurality of boron carbide partic les (50) dispersed throughout an aluminum or aluminum-based alloy matrix mat erial. In some embodiments, the matrix material may include a continuous sol id solution phase and a discontinuous precipitate phase. Methods of manufact uring rotary drill bits for drilling subterranean formations include infiltr ating a plurality of boron carbide particles with a molten aluminum or alumi num-based material. In additional methods, a green powder component is provi ded that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based allo y material. The green powder component is at least partially sintered to pro vide a bit body, and a shank is attached to the bit body.

Claims (18)

1. A rotary drill bit for drilling a subterranean formation, the drill bit comprising:
a bit body including a crown region comprising a particle-matrix composite material, the composite material comprising a plurality of boron carbide particles dispersed throughout an aluminum or an aluminum-based alloy matrix material;
and at least one cutting structure disposed on a face of the bit body;
the rotary drill bit characterized in that the aluminum or aluminum-based alloy matrix material comprises at least 75% by weight aluminum and at least trace amounts of at least one of copper, iron, lithium, magnesium, manganese, nickel, scandium, silicon, tin, zirconium, and zinc.
2. The rotary drill bit of claim 1, wherein the crown region of the bit body is predominantly comprised of the particle-matrix composite material.
3. The rotary drill bit of claim 1, wherein the crown region of the bit body comprises a plurality of blades, the at least one cutting structure being disposed on at least one blade of the plurality of blades.
4. The rotary drill bit of claim 1, wherein the bit body further includes a blank at least partially embedded in the particle-matrix composite material, the blank comprising a metal or metal alloy material and including at least one surface configured for attaching the rotary drill bit to a drill string.
5. The rotary drill bit of claim 1, wherein the aluminum or aluminum-based alloy matrix material comprises at least 90% by weight aluminum and at least about 3%
by weight of at least one of copper, iron, lithium, magnesium, manganese, nickel, scandium, silicon, tin, zirconium, and zinc.
6. The rotary drill bit of claim 5, wherein the aluminum or aluminum-based alloy matrix material comprises a solid solution.
7. The rotary drill bit of claim 6, wherein the aluminum or aluminum-based alloy matrix material of the composite material further includes regions comprising at least one precipitate phase dispersed through the solid solution.
8. The rotary drill bit of claim 7, wherein the at least one precipitate phase comprises a metastable phase.
9. The rotary drill bit of claim 8, wherein the at least one precipitate phase comprises an intermetallic compound.
10. The rotary drill bit of claim 9, wherein the intermetallic compound comprises CuAl2.
11. The rotary drill bit of claim 1, wherein the plurality of boron carbide particles comprises a plurality of -20 ASTM Mesh boron carbide particles.
12. The rotary drill bit of claim 1, wherein the plurality of boron carbide particles includes a multi-modal particle size distribution.
13. The rotary drill bit of claim 1, wherein the at least one cutting structure comprises a plurality of polycrystalline diamond compact cutters disposed on the face of the bit body.
14. The rotary drill bit of claim 1, wherein the plurality of boron carbide particles comprises between about 40% and about 60% by weight of the particle-matrix composite material, and wherein the aluminum or aluminum-based alloy matrix material comprises between about 60% and about 40% by weight of the particle-matrix composite material.
15. A method of forming an earth-boring rotary drill bit, the method comprising:
forming a bit body including a crown region comprising a particle-matrix composite material comprising a plurality of boron carbide particles dispersed throughout an aluminum or aluminum-based alloy matrix material; and securing at least one cutting structure to a face of the bit body;
the method characterized in that forming the bit body comprises causing the aluminum or aluminum-based alloy matrix material to comprise at least 75% by weight aluminum and at least trace amounts of at least one of copper, iron, lithium, magnesium, manganese, nickel, scandium, silicon, tin, zirconium, and zinc.
16. The method of claim 15, wherein forming a bit body comprises:
forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of the bit body;
infiltrating the plurality of boron carbide particles with a molten aluminum or aluminum-based material; and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles.
17. The method of claim 15, wherein forming a bit body comprises:
providing a green powder component comprising a plurality of particles each comprising boron nitride and a plurality of particles each comprising an aluminum or an aluminum-based alloy material; and at least partially sintering the green powder component.
18. The method of claim 17, wherein providing a green powder component comprises:
providing a first region having a first composition substantially comprised by the plurality of particles each comprising boron carbide and the plurality of particles each comprising an aluminum or aluminum-based alloy material; and providing a second region having a second composition that differs from the first composition.

hardness of the matrix material.
CA2668192A 2006-09-29 2007-09-28 Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits Expired - Fee Related CA2668192C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US11/540,912 2006-09-29
US11/540,912 US7913779B2 (en) 2005-11-10 2006-09-29 Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits
PCT/US2007/021070 WO2008042328A1 (en) 2006-09-29 2007-09-28 Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits

Publications (2)

Publication Number Publication Date
CA2668192A1 true CA2668192A1 (en) 2008-04-10
CA2668192C CA2668192C (en) 2012-05-15

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2668192A Expired - Fee Related CA2668192C (en) 2006-09-29 2007-09-28 Earth-boring rotary drill bits including bit bodies having boron carbide particles in aluminum or aluminum-based alloy matrix materials, and methods for forming such bits

Country Status (8)

Country Link
US (2) US7913779B2 (en)
EP (1) EP2079898B1 (en)
CN (1) CN101542067A (en)
AT (1) ATE531894T1 (en)
CA (1) CA2668192C (en)
PL (1) PL2079898T3 (en)
RU (1) RU2464403C2 (en)
WO (1) WO2008042328A1 (en)

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ATE531894T1 (en) 2011-11-15
EP2079898B1 (en) 2011-11-02
WO2008042328A1 (en) 2008-04-10
CN101542067A (en) 2009-09-23
RU2009118255A (en) 2010-11-20
US20070102200A1 (en) 2007-05-10
RU2464403C2 (en) 2012-10-20
US7913779B2 (en) 2011-03-29
US8230762B2 (en) 2012-07-31
PL2079898T3 (en) 2012-04-30
CA2668192C (en) 2012-05-15
WO2008042328B1 (en) 2008-06-12
US20110142707A1 (en) 2011-06-16

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