WO2010141575A4 - Methods systems and compositions for manufacturing downhole tools and downhole tool parts - Google Patents

Methods systems and compositions for manufacturing downhole tools and downhole tool parts Download PDF

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Publication number
WO2010141575A4
WO2010141575A4 PCT/US2010/037056 US2010037056W WO2010141575A4 WO 2010141575 A4 WO2010141575 A4 WO 2010141575A4 US 2010037056 W US2010037056 W US 2010037056W WO 2010141575 A4 WO2010141575 A4 WO 2010141575A4
Authority
WO
WIPO (PCT)
Prior art keywords
recited
carbide
downhole tool
tool part
cobalt
Prior art date
Application number
PCT/US2010/037056
Other languages
French (fr)
Other versions
WO2010141575A3 (en
WO2010141575A2 (en
Inventor
John H. Stevens
Jimmy W. Eason
Original Assignee
Baker Hughes Incorporated
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Baker Hughes Incorporated filed Critical Baker Hughes Incorporated
Priority to EP19179937.8A priority Critical patent/EP3572164B1/en
Priority to EP10784006.8A priority patent/EP2437903B1/en
Publication of WO2010141575A2 publication Critical patent/WO2010141575A2/en
Publication of WO2010141575A3 publication Critical patent/WO2010141575A3/en
Publication of WO2010141575A4 publication Critical patent/WO2010141575A4/en

Links

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
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/06—Casting in, on, or around objects which form part of the product for manufacturing or repairing tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

Abstract

Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.

Claims

AMENDED CLAIMS received by the International Bureau on 09 March 201 1 (09.03.201 1) What is claimed is:
1. A method of manufacturing a downhole tool part for drilling subterranean material comprising:
fabricating a model having an external peripheral shape of a downhole tool part; applying a mold material to at least a portion of the external periphery of the model; permitting the mold material to harden to form a mold about the model;
eliminating the model from within the mold; and
casting a composite matrix material within the mold.
2. The method as recited in claim 1, wherein the composite matrix material is cast within the mold containing a selectively dispersed particulate material.
3. The method as recited in claim 2, wherein the particulate material comprises at least one constituent selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), macro-crystalline tungsten carbide, cobalt, titanium carbide, tantalum carbide, metal borides, metal oxides, metal nitrides, polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), tungsten, iron, nickel, titanium and boron carbide.
4. The method as recited in claim 2, wherein the particulate material increases at least one of wear resistance, strength and toughness of a selective surface of the downhole tool part formed from casting the composite matrix material within the mold.
5. The method as recited in claim 1, wherein eliminating the model from within the mold includes at least one of burning, melting, vaporizing and dissolving the model.
6. The method as recited in claim 1, wherein the composite matrix material comprises at least two constituents selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), cobalt, tungsten, iron, nickel, titanium and boron carbide.
7. The method as recited in claim 1, wherein casting occurs at or above the eutectic temperature of the composite matrix material.
AMENDED SHEET (ARTICLE 19)
8. The method as recited in claim 1, wherein the composite matrix material is a eutectic composition of at least two constituents.
9. The method as recited in claim 1, wherein the composite matrix material comprises tungsten carbide and cobalt.
10. The method as recited in claim 9, wherein the tungsten carbide content is about 25 atomic percent and the cobalt content is about 75 atomic percent.
11. The method as recited in claim 9, wherein the cobalt content is equal to or greater than about 70 atomic percent.
12. The method as recited in claim 1, wherein the downhole tool part is a drill bit body.
13. The method as recited in claim 12, further comprising positioning a bit body element at the external periphery of the model and then applying the mold material to at least a portion of the external periphery of the model and at least a portion of the bit body element.
14. The method as recited in claim 13, wherein the bit body element is at least one of a cutting element, a bearing structure, a gage trimmer, a nozzle and a cutting control structure.
15. The method as recited in claim 14, wherein the bit body element is fabricated from tungsten carbide and cobalt.
16. The method as recited in claim 15, wherein the cobalt content is less than 20 weight percent.
17. The method as recited in claim 1, wherein the downhole tool part is a roller cone.
18. The method as recited in claim 17, further comprising positioning at least one of a cutting insert and a bearing element within the model and then applying the mold material to at least a portion of the model, and at least a portion of one of the cutting insert and the bearing element.
AMENDED SHEET (ARTICLE 19)
25
19. The method as recited in claim 18, wherein the cutting insert is fabricated from tungsten carbide and cobalt.
20. The method as recited in claim 19, wherein the cobalt content is less than 20 weight percent.
21. The method as recited in claim 1, wherein the casting of the composite matrix material occurs under vacuum conditions.
22. The method as recited in claim 1, wherein the casting of the composite matrix material occurs in a protective atmosphere.
23. The method as recited in claim 22, wherein the protective atmosphere is one of an inert atmosphere and a reducing atmosphere.
24. The method as recited in claim 1, wherein the casting of the composite matrix material occurs in air.
25. A downhole tool part for drilling subterranean material, wherein the downhole tool part is manufactured by casting a composite matrix material within a mold containing a selectively dispersed particulate material.
26. The downhole tool part as recited in claim 25, wherein the particulate material comprises at least one constituent selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), macro-crystalline tungsten carbide, cobalt, titanium carbide, tantalum carbide, metal borides, metal oxides, metal nitrides, polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), tungsten, iron, nickel, titanium and boron carbide.
27. The downhole tool part as recited in claim 25, wherein the particulate material increases at least one of wear resistance, strength and toughness of a selective surface of the downhole tool part formed from casting the composite matrix material within the mold.
AMENDED SHEET (ARTICLE 19)
26
28. The downhole tool part as recited in claim 25, wherein the composite matrix material comprises at least two constituents selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), cobalt, tungsten, iron, nickel, titanium and boron carbide.
29. The downhole tool part as recited in claim 25, wherein the casting occurs at or above the eutectic temperature of the composite matrix material.
30. The downhole tool part as recited in claim 25, wherein the composite matrix material is a eutectic composition of at least two constituents.
31. The downhole tool part as recited in claim 25, wherein the composite matrix material comprises tungsten carbide and cobalt.
32. The downhole tool part as recited in claim 31, wherein the tungsten carbide content is about 25 atomic percent and the cobalt content is about 75 atomic percent.
33. The downhole tool part as recited in claim 31, wherein the cobalt content is equal to or greater than about 70 atomic percent.
34. The downhole tool part as recited in claim 25, wherein the downhole tool part is a bit body.
35. The downhole tool part as recited in claim 25, wherein the downhole tool part is a roller cone.
36. A composition for manufacturing a downhole tool part for drilling subterranean material comprising: a continuous phase and a selectively dispersed particulate phase.
37. The composition as recited in claim 36, wherein the continuous phase comprises at least one constituent selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), cobalt, tungsten, iron, nickel, titanium and boron carbide.
AMENDED SHEET (ARTICLE 19)
27
38. The composition as recited in claim 36, wherein the selectively dispersed particulate phase comprises at least one constituent selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), macro-crystalline tungsten carbide, cobalt, titanium carbide, tantalum carbide, metal borides, metal oxides, metal nitrides, polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), tungsten, iron, nickel, titanium and boron carbide.
39. The composition as recited in claim 36, wherein the continuous phase is cobalt and the selectively dispersed particulate phase is monotungsten carbide (WC).
40. The composition as recited in claim 39, wherein the cobalt content is equal to or greater than about 70 atomic percent.
41. The composition as recited in claim 36, further comprising a eutectic particulate phase.
42. The composition as recited in claim 41, wherein the eutectic particulate phase comprises a eutectic composition of at least two constituents selected from the group comprising: monotungsten carbide (WC), ditungsten carbide (W2C), cobalt, tungsten, iron, nickel, titanium and boron carbide.
43. The composition as recited in claim 36, further comprising a sub-stoiciometric phase having the formula MXC, where M is cobalt or tungsten, C is carbide and x is a number between 1 and 6.
AMENDED SHEET (ARTICLE 19)
28

Statement under Article 19(1)

Pursuant to Article 19(1), Applicant offers the following remarks with regard to the submitted amendments to the claims. The claim amendments do not go beyond the disclosure as filed and do not require changes to the specification or the drawings.

29

PCT/US2010/037056 2009-06-05 2010-06-02 Methods systems and compositions for manufacturing downhole tools and downhole tool parts WO2010141575A2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP19179937.8A EP3572164B1 (en) 2009-06-05 2010-06-02 Method of manufacturing downhole tool part for drilling subterranean material
EP10784006.8A EP2437903B1 (en) 2009-06-05 2010-06-02 Downhole tool parts with composite matrix material of specific composition and manufacturing method thereof

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/479,534 2009-06-05
US12/479,534 US8201610B2 (en) 2009-06-05 2009-06-05 Methods for manufacturing downhole tools and downhole tool parts

Publications (3)

Publication Number Publication Date
WO2010141575A2 WO2010141575A2 (en) 2010-12-09
WO2010141575A3 WO2010141575A3 (en) 2011-03-10
WO2010141575A4 true WO2010141575A4 (en) 2011-05-19

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Family Applications (1)

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PCT/US2010/037056 WO2010141575A2 (en) 2009-06-05 2010-06-02 Methods systems and compositions for manufacturing downhole tools and downhole tool parts

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US (4) US8201610B2 (en)
EP (2) EP3572164B1 (en)
WO (1) WO2010141575A2 (en)

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US20110259647A1 (en) 2011-10-27

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