CN101292054A - 包括镍基基体材料和硬质颗粒的复合材料,包括这种材料的工具以及使用这种材料的方法 - Google Patents
包括镍基基体材料和硬质颗粒的复合材料,包括这种材料的工具以及使用这种材料的方法 Download PDFInfo
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- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
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- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
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- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
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Abstract
耐磨材料包括基体、烧结碳化钨颗粒和铸造碳化钨细粒。在钻探地层中使用的装置包括利用粘结材料固定到第二结构上的第一结构。耐磨材料覆盖所述粘结材料。第一结构包括钻头体,第二结构包括切削元件。用于将耐磨材料施加到钻头上的方法包括提供钻头、使烧结碳化钨颗粒和铸造碳化钨细粒在基体材料中混合以提供使用前材料、使使用前材料加热以熔化基体材料、将使用前材料施加到钻头上,以及固化所述材料。用于将切削元件固定到钻头体上的方法包括给钻头表面提供耐磨材料,所述耐磨材料覆盖布置于切削元件和钻头体之间的钎焊合金。
Description
技术领域
本发明通常涉及钻地钻头和用于钻凿地层的其它工具,并且涉及在这种钻地钻头表面上使用的耐磨表面硬化材料。本发明还涉及用于给钻地钻头的表面施加耐磨表面硬化材料的方法,并且涉及用于将切削元件固定到钻地钻头上的方法。
背景技术
用于钻凿地层的典型的固定牙轮式或″切削型″旋转钻头包括具有表面区域的钻头体,在所述表面区域上支承用于切入地层的切削元件。钻头体可以固定到硬化钢杆上,所述硬化钢杆具有用于将钻头附接到钻柱上的螺纹销连接,所述钻柱包括在钻头和其它钻孔设备之间首尾相联的管状管段。例如回转工作台或顶部驱动装置的设备可用于使管状管和钻头旋转。可选地,钻杆可以直接联接到井下马达的驱动轴上以使钻头旋转。
典型地,钻头的钻头体由钢或嵌入在基体材料中的钢坯复合材料制成,所述基体材料包括渗有例如铜合金的粘合剂的硬质颗粒材料,所述硬质颗粒材料例如为碳化钨。钢杆可以在已经形成钻头体之后固定到钻头体上。可以在钻头体上或钻头体内的选定位置设置结构特征以方便钻探过程。这种结构特征例如可以包括径向和纵向延伸的刀翼、切削元件凹窝、突脊、槽脊(lands)、喷嘴排量(displacements)、和钻井流体路径和通道。切削元件通常固定在凹窝内,所述切削元件机加工成位于钻头体表面区域上的刀翼。
通常,固定牙轮式钻头的每个切削元件包括切削表面,其包括硬质超耐磨材料,例如相互粘结的多晶金刚石颗粒。这种″聚晶金刚石复合片″(PDC)牙轮已经在油气井钻探工业中的固定牙轮式旋转钻头上使用了几十年。
图1显示了通常根据上述说明的传统的固定牙轮式旋转钻头10。旋转钻头10包括联接到钢杆14上的钻头体12。纵向穿过钻头10的一部分形成有孔(未显示),以便在钻井操作期间通过喷嘴19给钻头10的表面20输送钻井流体。切削元件22(典型地,聚晶金刚石复合片(PDC)切削元件)通常通过例如铜焊、粘结或机械固定的方法结合到钻头体12的钻头面20上。
钻头10可以多次使用以进行连续的钻井操作,在所述钻井操作期间,钻头体12的表面和切削元件22在钻头10的切削元件22切削下面的地层时会经受非常大的作用力和应力。。极大的作用力和应力导致切削元件22和钻头体12的表面磨损。最终,切削元件22和钻头体12的表面会磨损到钻头10不再适于使用的程度。
图2是与固定到钻头体12上的图1所示类似的PDC切削元件22的放大图。切削元件22通常不与钻头体12整体形成。典型地,切削元件22与钻头体12分开制造并且固定在形成于钻头体12的外表面上形成的凹窝21中。如前所述,可以使用粘结材料24将切削元件22固定到钻头体12上,所述粘结材料例如为粘合剂,更典型地,为钎焊合金。而且,如果切削元件22为PDC牙轮,切削元件22可以包括固定到切削元件主体或基底23上的聚晶金刚石复合台28,所述切削元件可以是整体的或者包括粘结在一起的两个部件。
典型地,粘结材料24与钻头10和切削元件22的其它部分和表面相比更不耐磨损。在使用期间,由于磨损,在粘结材料24的暴露表面上可能产生小晶簇、砂眼或其它缺陷。充满固体的钻井流体和在钻井过程中产生的地层残余物可能使粘结材料24上的小晶簇和砂眼进一步腐蚀、磨损和扩大。如果去除足够多的粘结材料24,整个切削元件22可能在钻井操作期间与钻头主体12分离。在钻井操作期间,切削元件22的损耗会导致其它切削元件的迅速磨损及整个钻头10的突然失效。因此,在本领域需要有效的方法来防止切削元件在钻井操作期间的损耗。
理想钻头的材料必须非常坚硬以在没有过度磨损的情况下切削下面的地层。由于钻头在钻井操作期间经受的极大作用力和应力,理想钻头的材料必须同时具有高抗裂韧性。但是,实际上,具有极高硬度的材料相对易碎并且不具有高抗裂韧性,但具有高抗裂韧性的材料相对较软并且不具有高硬度。因此,当选择用于钻头的材料时,必须兼顾硬度和抗裂韧性。
为了同时提高钻地钻头的硬度和抗裂韧性,已经将复合材料应用于经受极大磨损的钻头表面。这些复合材料通常称作″表面硬化″材料,并且典型地包括具有较高硬度的至少一个相和具有较高抗裂韧性的另一个相。
图3是传统的表面硬化材料的抛光和腐蚀面的显微放大。表面硬化材料包括大体上随机分布在基体材料46的铁基基体上的碳化钨颗粒40。碳化钨颗粒40具有较高硬度,而基体材料46具有较高抗裂韧性(fracture toughness)。
表面硬化材料中使用的碳化钨颗粒40可以包括一个或多个铸造碳化钨颗粒、烧结碳化钨颗粒和粗结晶碳化钨颗粒。碳化钨系统包括两个化学计量化合物,WC和W2C,其间具有连续的合成范围。铸造碳化钨通常包括WC和W2C化合物的共熔混合物。烧结碳化钨颗粒包括由基体材料结合在一起的较小的WC颗粒。钴和钴合金通常用作烧结碳化钨颗粒中的基体材料。烧结碳化钨颗粒可以通过使包括较小碳化钨颗粒的第一粉末和包括钴颗粒的第二粉末混合在一起而形成。粉末混合物形成为″未加工″状态。未加工粉末混合物随后在接近钴颗粒的熔融温度的温度下烧结以形成围绕碳化钨颗粒的钴材料基体,从而形成烧结碳化钨颗粒。最后,粗结晶碳化钨颗粒通常由WC的单结晶构成。
可以使用本领域公知的各种方法将例如图3所示的表面硬化材料施加到钻头表面上。钻杆可以配置为空心圆柱管,其由充满碳化钨颗粒的表面硬化材料制成的基体材料形成。可以密封空心圆柱管的至少一端。管的密封端随后可以熔融或焊接到钻头的希望表面上。当管熔化时,当熔融基体材料沉积在钻头上时,空心圆柱管内的碳化钨颗粒与所述熔融基体材料混合。可选方法包括形成表面硬化材料制铸棒,使用电弧或焊枪将设置于铸杆端部的表面硬化材料施加或焊接到钻头的希望表面上。
还可以使用电弧焊方法将表面硬化材料施加到钻头表面上。例如,在电极和希望施加表面硬化材料的钻头表面的区域之间会产生等离子转移弧。包括碳化钨颗粒和基体材料颗粒的粉末混合物随后可以通过或紧邻等离子转移弧而被导向钻头表面区域。由电弧产生的热量至少熔化基体材料颗粒以形成钻头表面上的焊池,其随后凝固以形成钻头表面上的表面硬化材料层。
当表面硬化材料施加到钻头表面上时,利用较高温度使至少基体材料熔化。在这种较高温度下,在碳化钨颗粒和基体材料之间可能发生原子扩散。换句话说,在施加表面硬化材料之后,在围绕碳化钨颗粒的基体材料中会发现原本包含于碳化钨颗粒中的至少一部分原子(例如钨和碳)。另外,在碳化钨颗粒中会发现原本包含于基体材料中的至少一部分原子(例如,铁)。图4是图3所示碳化钨颗粒40的放大图。在紧紧围绕碳化钨颗粒40的基体材料46的区域47中会发现原本包含于碳化钨颗粒40中的至少一部分原子(例如,钨和碳)。区域47粗略地包括围绕在假想线48内的基体材料46的区域。另外,在碳化钨颗粒40的外周或外部区域41内会发现原本包含于基体材料46中的至少一部分原子(例如,铁)。外部区域41粗略地包括位于假想线42以外的碳化钨颗粒40的区域。
碳化钨颗粒40和基体材料46之间的原子扩散可以使包围碳化钨颗粒40的区域47中的基体材料46脆化,并且降低外部区域41中的碳化钨颗粒40的硬度,降低表面硬化材料的总效用。因此,在本领域中存在对耐磨表面硬化材料的需要,所述耐磨表面硬化材料包括允许将碳化钨颗粒和基体材料之间的原子扩散最小化的基体材料。在本领域中还需要施加这种耐磨表面硬化材料的方法以及包括这种材料的钻头和钻具。
发明内容
在一个方面,本发明包括耐磨材料,其包括基体材料、多个-20ASTM(美国材料试验协会)目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒。碳化钨球粒和细粒大体上随机分布在基体材料中。基体材料包括至少75%重量比的镍,并且具有低于大约1100℃的熔点。每个烧结碳化钨球粒包括利用熔点高于1200℃的粘结合金结合在一起的多个碳化钨颗粒。就使用前比率而言,基体材料包括大约20%到大约60%重量比的耐磨材料,所述多个烧结碳化钨球粒包括大约30%到大约55%重量比的耐磨材料,所述多个铸造碳化钨细粒包括小于大约35%重量比的耐磨材料。在一些实施例中,例如,基体材料可以包括大约20%到大约50%重量比的耐磨材料,所述多个-40ASTM目铸造碳化钨细粒可以包括多个-100ASTM目铸造碳化钨球粒,所述多个-100ASTM目铸造碳化钨球粒可以包括大约15%到大约35%重量比耐磨材料。
在另一方面,本发明包括供钻探地层使用的装置。所述装置包括第一结构、沿交界固定到所述结构上的第二结构以及布置在第一结构和第二结构之间交界处的粘结材料。粘结材料将第一和第二结构固定在一起。所述装置进一步包括布置在该装置表面上的耐磨材料。耐磨材料的至少连续部分结合到第一结构的表面和第二结构的表面上。耐磨材料的所述连续部分至少在第一结构和第二结构之间的交界区域上延伸并且覆盖粘结材料。耐磨材料包括熔融温度低于大约1100℃的基体材料、大体上随机分布在基体材料中的多个烧结碳化钨球粒以及大体上随机分布在基体材料中的多个铸造碳化钨细粒。
在其它方面,本发明包括用于钻探地层的旋转钻头,其包括钻头体和沿交界固定到所述钻头体上的至少一个切削元件。当在此使用时,术语″钻头″包括和包含任何配置的钻具,包括取芯钻头、偏心钻、双中心钻头、铰刀、铣刀、切削型钻头、牙轮钻头和本领域已知的其它这类结构。钎焊合金布置在钻头体和所述至少一个切削元件之间的交界处并且将所述至少一个切削元件固定到钻头体上。就使用前比率而言,耐磨材料包括基体材料、多个-20ASTM目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒,所述基体材料包括大约20%到大约60%重量比的耐磨材料,所述烧结碳化钨球粒包括大约30%到大约55%重量比的耐磨材料,所述铸造碳化钨细粒包括小于大约35%重量比的耐磨材料。碳化钨球粒和细粒大体上随机分布在基体材料中。基体材料包括至少75%重量比的镍,并且具有低于大约1100℃的熔点。每个烧结钨球粒包括利用熔点高于1200℃的粘结合金结合在一起的多个碳化钨颗粒。
在另一个方面,本发明包括将耐磨材料施加到用于钻探地层的钻头表面上的方法。所述方法包括:提供包括具有外表面的钻头体的钻头,使多个-20ASTM目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒在基体材料中混合以提供使用前的耐磨材料,以及熔化基体材料。熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到钻头的至少一部分外表面上,并且使熔化的基体材料固化。基体材料包括至少75%重量比的镍,并且具有低于大约1100℃的熔点。每个烧结钨球粒包括利用熔点高于1200℃的粘结合金结合在一起的多个碳化钨颗粒。基体材料包括大约20%到大约60%重量比的使用前耐磨材料,所述多个烧结碳化钨球粒包括大约30%到大约55%重量比的使用前耐磨材料,所述多个铸造碳化钨细粒包括小于大约35%重量比的使用前耐磨材料。在一些实施例中,使多个-20ASTM目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒在基体材料中混合可以包括使多个-20ASTM目烧结碳化钨球粒和多个-100ASTM目铸造碳化钨球粒在基体材料中混合以提共使用前耐磨材料,其中,所述基体材料可以包括大约20%到大约50%重量比的使用前耐磨材料,所述多个烧结碳化钨球粒可以包括大约30%到大约55%重量比的使用前耐磨材料,所述多个铸造碳化钨球粒可以包括大约15%到大约35%重量比的使用前耐磨材料。
在另一方面,本发明包括用于将切削元件固定到旋转钻头的钻头体上的方法。所述方法包括:提供包括具有外表面的钻头体的旋转钻头,所述外表面包括位于其中的凹窝,所述凹窝配置为接收切削元件,以及使切削元件定位在所述凹窝内。提供钎焊合金,使所述前焊合金熔化并施加到切削元件的相邻表面和位于凹窝内的钻头体外表面上,随后凝固,其中所述凹窝界定了所述表面之间的交界。耐磨材料施加到钻头表面上。至少耐磨材料的连续部分结合到切削元件的表面上和钻头体外表面的一部分上。所述连续部分在切削元件和钻头体外表面之间的至少交界区域上延伸并覆盖钎焊合金。就使用前比率而言,耐磨材料包括粘结材料、多个烧结碳化钨球粒和多个铸造碳化钨细粒。基体材料包括至少75%重量比的镍,并且具有低于大约1100℃的熔点。碳化钨球粒大体上随机分布在基体材料中。而且,每个烧结钨球粒包括利用熔点高于大约1200℃的粘结合金结合在一起的多个碳化钨颗粒。
对于本领域的技术人员来说,通过结合附图考虑下列详细说明,本发明的特征、优点和可选方面将变得显而易见。
附图说明
尽管说明书末尾的权利要求特别指出和清楚主张了本发明的范围,但是在结合附图阅读本发明的下列说明的情况下,本发明的优点将变得易于确定:
图1是包括切削元件的旋转式钻头的透视图;
图2是图1所示钻头的切削元件的放大图;
图3是包括碳化钨颗粒的耐磨材料的显微放大图,其中,所述碳化钨颗粒大体上随机分布在基体材料中;
图4是图3所示碳化钨颗粒的放大图;
图5是耐磨材料的显微放大图,其中,所述耐磨材料体现本发明的教导并且包括大体上随机分布在基体材料中的碳化钨颗粒;
图6是图5所示碳化钨颗粒的放大图;
图7A是体现本发明教导的钻头的切削元件的放大图;
图7B是图7A所示切削元件沿剖面线7B-7B剖开的横向剖视图;
图7C是图7A所示切削元件沿剖面线7C-7C剖开的纵向剖视图;
图8A是与图7B类似的横向剖视图,显示了体现本发明教导的钻头的另一切削元件;
图8B是图8A所示切削元件的纵向剖视图;和
图9是耐磨材料的显微放大图,其中,所述耐磨材料体现本发明的教导并且包括大体上随机分布在基体中的碳化钨颗粒。
具体实施方式
除图9之外,这里显示的示例不表示任何特殊材料、设备、系统或方法的实际视图,而仅是用于描述本发明的理想化表示。另外,附图之间共有的元件可以保持相同的数字编号。
图5显示了体现本发明教导的耐磨材料54的抛光和腐蚀面。图9是体现本发明教导的耐磨材料的抛光和腐蚀面的实际显微放大图。参照图5,耐磨材料54包括大体上随机分布在基体材料60中的多个烧结碳化钨球粒56和多个铸造碳化钨细粒58。每个烧结碳化钨球粒56可以具有通常球形球粒构造。在此使用的术语″球粒″表示具有通常球形形状的任何颗粒。球粒不是真正的球形,而是缺少通常在压碎及其它非球形碳化钨颗粒中发现的角、锋利边缘和角状突起。在本发明的一些实施例中,铸造碳化钨细粒可以是或包括铸造碳化钨球粒,如图9所示。
角、锋利边缘和角状突起可以产生残余应力,其可能导致在耐磨材料54施加到钻头表面上的时候,紧邻残余应力的颗粒区域内的碳化钨材料在较低温度下熔化。碳化钨材料在使用期间熔化或部分熔化会有利于碳化钨颗粒和周围基体材料之间的原子扩散。如先前所讨论的,基体材料60和烧结碳化钨球粒56以及铸造碳化钨细粒58之间的原子扩散会使碳化钨球粒56、58周围区域内的基体材料60脆化,并且降低碳化钨球粒56、58在其外部区域中的硬度。这种原子扩散可以削弱耐磨材料54的整体物理性质。使用烧结碳化钨球粒56(可选择地,和铸造碳化钨球粒58)来代替包括角、锋利边缘和角状突起的传统碳化钨颗粒可以减少这种原子扩散,从而在耐磨材料54施加到钻头及其它工具表面上的时候,保持基体材料60和烧结碳化钨球粒56(可选择地,和铸造碳化钨球粒58)的物理性质。
基体材料60可以包括大约20%到大约60%重量比的耐磨材料54。在一些实施例中,基体材料60可以包括大约30%到大约50%重量比的耐磨材料54。更特别地,基体材料60可以包括大约35%到45%重量比的耐磨材料54。所述多个烧结碳化钨球粒56可以包括大约30%到大约55%重量比的耐磨材料54。而且,所述多个铸造碳化钨细粒58可以包括小于大约35%重量比的耐磨材料54。更特别地,所述多个铸造碳化钨细粒58可以包括大约10%到大约35%重量比的耐磨材料54。例如,基体材料60可以是大约40%重量比的耐磨材料54,所述多个烧结碳化钨球粒56可以是大约48%重量比的耐磨材料54,所述多个铸造碳化钨细粒58可以是大约12%重量比的耐磨材料。在其它实施例中,所述多个铸造碳化钨细粒58可以包括大约15%到大约35%重量比的耐磨材料54。
烧结碳化钨球粒56可以在尺寸上大于铸造碳化钨细粒58。而且,每单位体积耐磨材料54中的铸造碳化钨细粒56的数目可以高于每单位体积耐磨材料54中的烧结碳化钨球粒58的数目。
烧结碳化钨球粒56可以包括-20ASTM目球粒。当在此使用时,短语″-20ASTM目球粒″是指能够穿过ASTM No.20美国标准试验筛的球粒。这种烧结碳化钨球粒具有小于大约850微米的平均直径。烧结碳化钨球粒56的平均直径为铸造碳化钨细粒58的平均直径的大约1.1倍到大约5倍。铸造碳化钨细粒58可以包括-40ASTM目细粒。当在此使用时,短语″-40ASTM目细粒″是指能够穿过ASTM No.40美国标准试验筛的细粒。在一些实施例中,铸造碳化钨细粒58可以包括-100ASTM目铸造碳化钨球粒。当在此使用时,短语″-100ASTM目球粒″是指能够穿过ASTM No.100美国标准试验筛的球粒。这种铸造碳化钨细粒具有小于大约150微米的平均直径。
举例来说,烧结碳化钨球粒56可以包括-60/+80ASTM目球粒,铸造碳化钨细粒58可以包括-100/+270ASTM目细粒。当在此使用时,短语″-60/+80ASTM目球粒″是指能够穿过ASTM No.60美国标准试验筛,但不能穿过ASTM No.80美国标准试验筛的球粒。这种烧结碳化钨球粒可以具有小于大约250微米且大于大约180微米的平均直径。而且,当在此使用时,短语″-100/+270ASTM目细粒″是指能够穿过ASTM No.100美国标准试验筛,但不能穿过ASTM No.270美国标准试验筛的细粒。这种铸造碳化钨细粒58可以具有大约50微米到大约150微米的平均直径。
作为另一实例,所述多个烧结碳化钨球粒56可以包括多个-60/+80ASTM目烧结碳化钨球粒和多个-120/+270ASTM目烧结碳化钨球粒。所述多个-60/+80ASTM目烧结碳化钨球粒可以包括大约30%到大约40%重量比的耐磨材料54,所述多个-120/+270ASTM目烧结碳化钨球粒可以包括大约15%到大约25%重量比的耐磨材料54。当在此使用时,短语″-120/+270ASTM目球粒″是指能够穿过ASTM No.120美国标准试验筛,但不能穿过ASTM No.270美国标准试验筛的球粒。这种烧结碳化钨球粒56可以具有大约50微米到大约125微米的平均直径。
在一个特定实施例中,仅仅举例说明,耐磨材料54可以包括大约40%重量比的基体材料60、大约48%重量比的-20/+30ASTM目烧结碳化钨球粒56和大约12%重量比的-140/+325ASTM目铸造碳化钨细粒58。当在此使用时,短语″-20/+30ASTM目球粒″是指能够穿过ASTM No.20美国标准试验筛,但不能穿过ASTM No.30美国标准试验筛的球粒。类似地,短语″-140/+325ASTM目球粒″是指能够穿过ASTM No.140美国标准试验筛,但不能穿过ASTM No.325美国标准试验筛的球粒。基体材料60可以包括镍基合金,其还可以包括一种或多种例如铬、硼和硅的添加元素。基体材料60还可以具有低于大约1100℃的熔点,并且在洛氏硬度C标下具有大约35到大约60的硬度。更特别地,基体材料60在洛氏硬度C标下具有大约40到大约55的硬度。例如,基体材料60在洛氏硬度C标下具有大约40的硬度。
还可以使用除了碳化钨之外的碳化物铸造细粒和烧结球粒来提供体现本发明教导的耐磨材料。其它这类碳化物包括但不限于碳化铬、碳化钼、碳化铌、碳化钽、碳化钛和碳化钒。
基体材料60可以包括熔点低于大约1100℃的金属合金材料。而且,多个烧结碳化钨球粒56中的每个烧结碳化钨球粒56可以包括利用熔点高于大约1200℃的粘结合金(binder alloy)结合在一起的多个碳化钨颗粒。例如,粘结合金可以包括熔点高于大约1200℃的钴基金属合金材料或镍基合金材料。在这种构造中,基体材料60在将耐磨材料54施加到钻具(例如,钻头)表面上的时候大体上熔化,但铸造碳化钨细粒58、或粘结合金或烧结碳化钨球粒56的碳化钨颗粒大体上不熔化。这能够使耐磨材料54在较低温度下施加到钻具表面上,从而使烧结碳化钨球粒56和基体材料60之间以及铸造碳化钨细粒58和基体材料60之间的原子扩散减到最小。
如先前所讨论的,将基体材料60与烧结碳化钨球粒56以及铸造碳化钨细粒58之间的原子扩散减到最小有助于在将耐磨材料54施加到钻头及其它钻具的表面上的时候保持基体材料60、烧结碳化钨球粒56和铸造碳化钨细粒58的化学成分和物理性质。
基体材料60还可以包括较少数量的其它元素,例如碳、铬、硅、硼、铁和镍。而且,基体材料60还可以包括例如硅锰合金的助熔剂、例如铌的合金元素、以及例如聚合物材料的结合剂。
图6是图5所示烧结碳化钨球粒56的放大图。烧结碳化钨球粒56的硬度在整个球粒中大体上相同。例如,烧结碳化钨球粒56可以包括烧结碳化钨球粒56的外周或外部区域57。外部区域57可以粗略地包括位于假想线64以外的烧结碳化钨球粒56的区域。烧结碳化钨球粒56在由假想线64包围的球粒的中心区域具有第一平均硬度,在位于假想线64以外的球粒的外周区域57内的部位具有第二平均硬度。烧结碳化钨球粒56的第二平均硬度可以高于烧结碳化钨球粒56的第一平均硬度的大约99%。举例来说,第一平均硬度在洛氏硬度A标下为大约91,第二平均硬度在洛氏硬度A标下为大约90。此外,位于紧邻烧结碳化钨球粒56并由假想线66包围的区域61内的基体材料60的抗裂韧性与位于假想线66以外的基体材料60的抗裂韧性大体上相似。
Rancho Cucamonga,California的Broco,Inc.出售商标为40和50的市售金属合金材料可用作耐磨材料54中的基体材料60。Barchfeld,Germany的Sulzer MetcoWOKA GmbH出售可在耐磨材料54中使用的市售烧结碳化钨球粒56和铸造碳化钨细粒58。
烧结碳化钨球粒56相对于铸造碳化钨细粒58而言具有较高的抗裂韧性,而铸造碳化钨细粒58相对于烧结碳化钨球粒56而言具有较高的硬度。通过使用此处描述的基体材料60,在将耐磨材料54施加到钻头或其它钻具上时,在耐磨材料54中可以保持烧结碳化钨球粒56的抗裂韧性和铸造碳化钨细粒58的硬度,从而提供相对于本领域已知耐磨材料性能提高的耐磨材料54。
体现本发明教导的耐磨材料(例如图5-6所示的耐磨材料54)可以施加给旋转钻头(例如图1所示旋转钻头10)、滚动切削钻头(通常称作″牙轮钻头″)、以及经受磨损的其它钻具(例如扩钻刀具及可扩张的扩眼器刀翼)的表面上的选定区域,所有这些及其它设备包括在先前所述的术语″钻头″的范围内。
钻头表面上的某些位置可能需要较高硬度,而钻头表面上的其它位置可能需要较高的抗裂韧性。可以有选择地改变基体材料60、所述多个烧结碳化钨球粒56和所述多个铸造碳化钨细粒58的相对重量百分比,从而提供具有适合于特定工具或工具表面上特定区域的物理性质的耐磨材料54。例如,除了摩擦类型的研磨或磨削力之外,滚动切削刀具型钻头上的切齿表面可能经受较大的冲击力。因此,施加到切齿表面上的耐磨材料54可以包括较大重量百分比的烧结碳化钨球粒56以便提高耐磨材料54的抗裂韧性。相反,钻头保径面可能经受较小的冲击力,但是经受较大的摩擦类型的研磨或磨削力。因此,施加到钻头保径面上的耐磨材料54可以包括较大重量百分比的铸造碳化钨细粒58以便提高耐磨材料54的硬度。
除了施加到经受磨损的钻头和钻具的表面上的选定区域上之外,体现本发明教导的耐磨材料可用于保护更易受到磨损的钻头和钻具的构造细部或材料。
图7A显示了体现本发明教导的典型旋转钻头50的一部分。旋转钻头50在结构上类似于图1所示的旋转钻头10,并且包括多个切削元件22,所述切削元件22定位并固定于设置在钻头体12的外表面上的凹窝内。如图7A所示,每个切削元件22可以沿其与钻头体12之间的交界固定到钻头50的钻头体12上。例如粘合剂或钎焊合金的粘结材料24可以布置在交界处,并用于将每个切削元件22固定和附接到钻头体12上。粘结材料24不如钻头体12和切削元件22的材料耐磨损。每个切削元件22可以包括沿交界附接和固定到切削元件主体或基底23上的聚晶金刚石复合台28。
旋转钻头50还包括布置在钻头50的表面上的耐磨材料54。此外,耐磨材料54的区域可以构造为保护粘结材料24的暴露表面。
图7B是图7A所示切削元件22沿剖面线7B-7B剖开的横向剖视图。如图7B所示,耐磨材料54的连续部分可以结合到钻头体12的外表面区域和切削元件22的侧表面上,并且每个连续部分可以在钻头体12和切削元件22的侧表面之间的至少一部分交界区域上延伸。
图7C是图7A所示切削元件22沿剖面线7C-7C剖开的纵向剖视图。如图7C所示,耐磨材料54的另一连续部分可以结合到钻头体12的外表面区域和切削元件22的侧表面上,并且可以在钻头体12和与聚晶金刚石复合台28相对的切削元件22的纵向端面之间的至少一部分交界区域上延伸。耐磨材料54的又一连续部分可以结合到钻头体12的外表面区域和聚晶金刚石复合台28的一部分暴露表面上,并且可以在钻头体12和与聚晶金刚石复合台28的表面之间的至少一部分交界区域上延伸。
在这种构造中,耐磨材料54的连续部分可以覆盖布置于切削元件22和钻头体12之间的至少一部分粘结材料24并防止其在钻井操作期间磨损。通过防止粘结材料24在钻井操作中受到磨损,耐磨材料54有助于防止切削元件22和钻头体12在钻井操作期间分离、损坏钻头体12以及旋转钻头50突然失效。
覆盖和保护粘结材料24的暴露表面的耐磨材料54的连续部分可以构造为沿着钻头体12和切削元件22的交界面的边缘并于其上设置的耐磨材料54的焊珠。
图8A和8B显示了体现本发明教导的另一典型旋转钻头50′的切削元件22的横向剖视图。旋转钻头50′在结构上类似于图1所示的旋转钻头10,并且包括多个切削元件22,所述切削元件22定位并固定于设置在钻头体12′的外表面上的凹窝内。如先前相对于图7A-7C所示旋转钻头50所讨论的,旋转钻头50′的切削元件22还包括沿着钻头体12′和切削元件22的交界面边缘覆盖和保护粘结材料24的暴露表面的耐磨材料54的连续部分。
但是,如图8A所示,凹槽70设置在钻头体12′的外表面上并与其中固定有切削元件22的凹窝相邻。在这种构造中,耐磨材料54的焊珠可以沿钻头体12和切削元件22的交界面边缘设置在凹槽70内。通过在凹槽70内提供耐磨材料54的焊珠,耐磨材料54的焊珠从旋转钻头50′的表面伸出的程度可以减到最小。因此,可以减少耐磨材料54的焊珠在钻井操作期间经受的研磨和腐蚀材料及流体。
耐磨材料54可用于覆盖和保护钻头或其它钻具的任意两个结构或部件之间的交界。例如,钻头体和抗磨结或钻头体中的各种硬合金齿(insert)的外周之间的交界。另外,耐磨材料54不局限于在结构或部件之间的交界处使用,并且可以在经受磨损的钻头或钻具的任何表面上的各个部位处使用。
体现本发明教导的耐磨材料(例如耐磨材料54)可以利用本领域已知的各种方法施加到钻头或钻具的选定表面上。例如,体现本发明教导的使用前耐磨材料可以焊条形式提供。焊条可以包括由耐磨材料54构成的固态的铸造或挤压棒材。可选地,焊条可以包括由基体材料60制成并充满多个烧结碳化钨球粒56和多个铸造碳化钨细粒58的中空圆柱管。可以使用氧乙炔喷枪或任何其他类型的焊枪将焊条的至少一部分加热到高于基体材料60的熔点且低于大约1200℃的温度,从而使基体材料60熔化。这可以使发生于基体材料60和烧结碳化钨球粒56及铸造碳化钨细粒58之间的原子扩散程度减到最小。
发生于基体材料60和烧结碳化钨球粒56以及铸造碳化钨细粒58之间的原子扩散速率至少部分地与发生原子扩散的温度相关。因此,原子扩散程度至少部分地与发生原子扩散的温度和发生原子扩散的时间两者相关。因此,通过控制喷枪和焊条(或使用前耐磨材料)之间的距离和焊条经受由喷枪产生的热量的时间,可以控制发生于基体材料60和烧结碳化钨球粒56以及铸造碳化钨细粒58之间的原子扩散程度。
氧乙炔和原子氢喷枪能够将材料加热到1200℃以上的温度。有利地是仅仅在将耐磨材料54施加到表面上之前,使将被施加耐磨材料54的钻头或钻具的表面略微熔化。例如,可以使氧乙炔和原子氢喷枪非常接近钻头或钻具的表面,并且使该表面加热到足够高的温度以略微熔化或″熔解(sweat)″表面。包括使用前耐磨材料的焊条随后可以非常接近所述表面,并且喷枪和焊条之间的距离可以调节至将至少一部分焊条加热到高于基体材料60的熔点且低于大约1200℃的温度,从而使基体材料60熔化。熔化的基体材料60、至少一部分烧结碳化钨球粒56和至少一部分铸造碳化钨细粒58可以施加到钻头的表面上,并且熔化的基体材料60可以通过控制冷却而固化。可以控制冷却速率来控制耐磨材料54的微观结构和物理性质。
可选地,耐磨材料54可以利用诸如等离子转移弧焊接方法的电弧焊方法施加到钻头或钻具的表面上。例如,基体材料60可以粉末(基体材料60的小颗粒)形式提供。多个烧结碳化钨球粒56和多个铸造碳化钨细粒58可以与粉末状基体材料60混合,从而提供粉末混合物形式的使用前耐磨材料。随后可以使用等离子转移弧焊机将至少一部分使用前耐磨材料加热到高于基体材料60的熔点且低于大约1200℃的温度,从而使基体材料60熔化。
等离子转移弧焊机典型地包括非自耗电极,所述非自耗电极非常接近将要施加材料的基底(钻头或其它钻具)。等离子合成气体布置在基底和非自耗电极之间,典型地为流动气柱的形式。在电极和基底之间产生电弧以在等离子合成气体中产生等离子。可以利用惰性载气使粉末状使用前耐磨材料穿过等离子并施加到基底表面上。当粉末状使用前耐磨材料穿过等离子时,它被加热至至少一部分耐磨材料将要熔化的温度。当至少部分熔化的耐磨材料已经沉积在基底表面上时,允许耐磨材料固化。这种等离子转移弧焊机在本领域中已知并且可在市场上买到。
通过控制在电极和基底之间流动的电流,可以至少部分地控制当材料穿过等离子时加热使用前耐磨材料的温度。例如,所述电流可以在大电流和小电流之间的选定脉冲频率下波动。小电流可以选择到充分大以使使用前耐磨材料中的至少基体材料60熔化,大电流可以充分大以使基底表面熔化或熔解。可选地,小电流可以选择到过小而不能使所有使用前耐磨材料熔化,并且大电流可以充分大以将至少一部分使用前耐磨材料加热到高于基体材料60的熔点且低于大约1200℃的温度,从而使基体材料60熔化。这可以使发生于基体材料60和烧结碳化钨球粒56以及铸造碳化钨细粒58之间的原子扩散程度减到最小。
例如金属惰性气体(MIG)电弧焊方法、钨极隋性气体(TIG)电弧焊方法和火焰喷焊方法的其它焊接方法在本领域中已知,并且可用于将耐磨材料54施加到钻头或钻具的表面上。
尽管这里已经相对于特定的优选实施例对本发明进行了描述,但是本领域的普通技术人员应当考虑和认识到本发明不限于此。相反,在不脱离如下文要求保护的本发明范围的情况下,可以对优选实施例进行多种增加、删除和改变。另外,一个实施例的特征可以与另一个实施例的特征结合,但仍然处于由本发明人考虑的发明范围内。另外,本发明在具有不同和各种钻头外形及切削型的钻头和取芯钻头中具有实用性。
Claims (20)
1.一种包括具有使用前比率的下列材料的耐磨材料:
基体材料,所述基体材料包括大约20%到大约60%重量比的耐磨材料,所述基体材料包括至少75%重量比的镍,所述基体材料具有低于大约1100℃的熔点;
大体上随机分布在所述基体材料中的多个-20ASTM目烧结碳化钨球粒,所述多个烧结碳化钨球粒包括大约30%到大约55%重量比的耐磨材料,每个烧结碳化钨球粒包括利用粘结合金结合在一起的多个碳化钨颗粒,所述粘结合金具有超过大约1200℃的熔点;和
大体上随机分布在所述基体材料中的多个-40ASTM目铸造碳化钨细粒,所述铸造碳化钨细粒包括小于大约35%重量比的耐磨材料。
2.如权利要求1所述的耐磨材料,其中,所述基体材料包括大约20%到大约50%重量比的耐磨材料,所述多个-40ASTM目铸造碳化钨细粒包括多个-100ASTM目铸造钨球粒,所述多个-100ASTM目铸造钨球粒包括大约15%到大约35%重量比的耐磨材料。
3.如权利要求2所述的耐磨材料,其中,所述多个-20ASTM目烧结碳化钨球粒包括多个-60/+80ASTM目烧结碳化钨球粒和多个-120/+270ASTM目烧结碳化钨球粒,所述多个-60/+80ASTM目烧结碳化钨球粒包括大约30%到大约35%重量比的耐磨材料,所述多个-120/+270ASTM目烧结碳化钨球粒包括大约15%到大约20%重量比的耐磨材料。
4.如权利要求1-3中任意一项所述的耐磨材料,其中,所述耐磨材料布置在一工具上,所述工具包括:
第一结构;
沿交界固定到所述第一结构上的第二结构;和
布置在第一结构和第二结构之间交界处的粘结材料,所述粘结材料将第一结构和第二结构固定在一起;以及
其中,所述耐磨材料布置在所述工具的表面上,所述耐磨材料的至少连续部分结合到第一结构的表面和第二结构的表面上,并且在第一结构和第二结构之间的交界上延伸并覆盖所述粘结材料。
5.如权利要求4所述的耐磨材料,其中,所述第一结构包括旋转钻头的钻头体,所述第二结构包括旋转钻头的切削元件。
6.如权利要求4或5所述的耐磨材料,其中,所述粘结材料包括钎焊合金。
7.如权利要求5所述的耐磨材料,其中,所述旋转钻头的钻头体具有外表面和形成在所述外表面上且与钻头体和切削元件之间的交界相邻的至少一个凹槽,其中,所述耐磨材料的至少一部分布置在所述至少一个凹槽内。
8.如权利要求5-7中任意一项所述的耐磨材料,其中,所述旋转钻头的钻头体具有外表面和位于其上的凹窝,所述切削元件的至少一部分布置在所述凹窝内,所述交界沿着钻头体和切削元件的相邻表面延伸。
9.如权利要求1-8中任意一项所述的耐磨材料,其中,所述耐磨材料还包括铌,所述铌小于所述耐磨材料的大约1%。
10.如权利要求1-9中任意一项所述的耐磨材料,其中,所述耐磨材料的基体材料还包括铬、镍、铁、硼和硅中的至少一种。
11.如权利要求3-10中任意一项所述的耐磨材料,其中,所述耐磨材料中的每个烧结碳化钨球粒在球粒的中心区域具有第一平均硬度,在球粒的周边区域中具有第二硬度,所述第二硬度大于所述第一硬度的大约99%。
12.如权利要求11所述的耐磨材料,其中,所述第一硬度和第二硬度在洛氏硬度A标下高于大约89。
13.一种用于将耐磨材料施加到在钻探地层中使用的工具的表面上的方法,所述方法包括:
提供在钻探地层中使用的工具,所述工具包括具有外表面的第一结构;
使多个-20ASTM目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒在基体材料中混合以提供使用前耐磨材料,所述基体材料包括至少75%重量比的镍,所述基体材料具有低于1100℃的熔点,每个烧结碳化钨球粒包括利用粘结合金结合在一起的多个碳化钨颗粒,所述粘结合金具有高于大约1200℃的熔点,所述基体材料包括大约20%到大约60%重量比的使用前耐磨材料,所述多个烧结碳化钨球粒包括大约30%到大约55%重量比的使用前耐磨材料,所述多个铸造碳化钨细粒包括小于大约35%重量比的使用前耐磨材料;
熔化所述基体材料,熔化基体材料包括将至少一部分使用前耐磨材料加热到高于基体材料的熔点且低于大约1200℃的温度,从而使基体材料熔化;
将熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到所述第一结构的至少一部分外表面上;和
固化熔化的基体材料。
14.如权利要求13所述的方法,其中,使多个-20ASTM目烧结碳化钨球粒和多个-40ASTM目铸造碳化钨细粒在基体材料中混合包括使多个-20ASTM目烧结碳化钨球粒和多个-100ASTM目铸造碳化钨球粒在基体材料中混合以提供使用前耐磨材料,并且其中,所述基体材料包括大约20%到大约50%重量比的使用前耐磨材料,所述多个烧结碳化钨球粒包括大约30%到大约55%重量比的使用前耐磨材料,所述多个铸造碳化钨球粒包括大约15%到大约35%重量比的使用前耐磨材料。
15.如权利要求13或14所述的方法,其中,使至少一部分使用前耐磨材料加热包括利用等离子转移弧加热基体材料、利用电弧加热基体材料和在大体上纯氧中燃烧乙炔来加热基体材料中的至少一种。
16.如权利要求13-15中任意一项所述的方法,其中,提供工具包括提供钻头,所述工具的第一结构包括钻头的钻头体。
17.如权利要求16所述的方法,其中,提供钻头还包括:
提供沿着交界固定到钻头体上的至少一个切削元件;和
在钻头体和所述至少一个切削元件之间的交界处提供钎焊合金,所述钎焊合金将所述至少一个切削元件固定到钻头体上。
18.如权利要求17所述的方法,其中,将熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到至少一部分工具外表面上包括将熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到位于钻头体和所述至少一个切削元件之间的交界处的钎焊合金的暴露表面上。
19.如权利要求17或18所述的方法,其中,提供钻头还包括:
提供位于钻头体外表面上的凹窝;和
在所述凹窝内提供所述至少一个切削元件的至少一部分,所述交界沿钻头体和所述至少一个切削元件的相邻表面延伸。
20.如权利要求17-19中任意一项所述的方法,其中,提供钻头还包括提供位于钻头外表面上且与所述至少一个切削元件相邻的至少一个凹槽,并且其中,将熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到至少一部分工具外表面上包括将熔化的基体材料、至少一部分烧结碳化钨球粒和至少一部分铸造碳化钨细粒施加到位于所述至少一个凹槽内的钻头体的外表面上。
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2009
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Also Published As
Publication number | Publication date |
---|---|
US8758462B2 (en) | 2014-06-24 |
US9506297B2 (en) | 2016-11-29 |
US7597159B2 (en) | 2009-10-06 |
US20090113811A1 (en) | 2009-05-07 |
US20070056776A1 (en) | 2007-03-15 |
US20140284116A1 (en) | 2014-09-25 |
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