WO2011146760A4 - Methods of forming at least a portion of earth-boring tools, and articles formed by such methods - Google Patents

Methods of forming at least a portion of earth-boring tools, and articles formed by such methods Download PDF

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Publication number
WO2011146760A4
WO2011146760A4 PCT/US2011/037223 US2011037223W WO2011146760A4 WO 2011146760 A4 WO2011146760 A4 WO 2011146760A4 US 2011037223 W US2011037223 W US 2011037223W WO 2011146760 A4 WO2011146760 A4 WO 2011146760A4
Authority
WO
WIPO (PCT)
Prior art keywords
metal
hard material
eutectic
phase
article
Prior art date
Application number
PCT/US2011/037223
Other languages
French (fr)
Other versions
WO2011146760A2 (en
WO2011146760A3 (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 CN201180033765XA priority Critical patent/CN102985197A/en
Priority to CA2799911A priority patent/CA2799911A1/en
Priority to EP11784268.2A priority patent/EP2571648A4/en
Priority to MX2012013455A priority patent/MX2012013455A/en
Priority to RU2012155100/02A priority patent/RU2012155100A/en
Publication of WO2011146760A2 publication Critical patent/WO2011146760A2/en
Publication of WO2011146760A3 publication Critical patent/WO2011146760A3/en
Publication of WO2011146760A4 publication Critical patent/WO2011146760A4/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
    • E21B10/56—Button-type 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
    • 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
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • 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
    • C22C1/1068—Making hard metals based on borides, carbides, nitrides, oxides or silicides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/12—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on oxides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—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
    • 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
    • C22C32/0052—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 only carbides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Manufacturing & Machinery (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • External Artificial Organs (AREA)
  • Powder Metallurgy (AREA)

Abstract

Methods of forming at least a portion of an earth-boring tool include providing at least one insert in a mold cavity, providing particulate matter in the mold cavity, melting a metal and the hard material to form a molten composition, and casting the molten composition. Other methods include coating at least one surface of a mold cavity with a coating material having a composition differing from a composition of the mold, melting a metal and a hard material to form a molten composition, and casting the molten composition. Articles comprising at least a portion of an earth-boring tool include at least one insert and a solidified eutectic or near-eutectic composition including a metal phase and a hard material phase. Other articles include a solidified eutectic or near-eutectic composition including a metal phase and a hard material phase and a coating material in contact with the solidified eutectic or near-eutectic composition.

Claims

1
AMENDED CLAIMS
received by the International Bureau on 06 January 2012 (06.01.2012).
What is claimed is: L A method of forming at least a portion of an earth-boring tool, comprising:
providing at least one insert in a mold cavity;
providing particulate matter comprising a hard material in the mold cavity;
melting a metal and the hard material to form a molten composition comprising a eutectic or near-eutectic composition of the metal and the hard material; and casting the molten composition within the mold cavity.
2. The method of claim 1, further comprising providing an inoculant within the mold cavity to control grain growth as the molten composition comprising the eutectic or near eutectic composition of the metal and the hard material solidifies.
3. The method of claim 1 or claim 2, further comprising adjusting a stoichiometry of at least one hard material phase of the at least a portion of the earth-boring tool.
4. The method of claim 1 or claim 2, wherein melting a metal and a hard material to form a molten composition comprises forming a eutectic or near-eutectic composition of cobalt and tungsten carbide. 5. The method of claim 1 or claim 2, wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising from about 40% to about 90% cobalt or cobalt-based alloy by weight and from about 0.
5% to about 3.8% carbon by weight, wherein a balance of the mixture is at least substantially comprised of tungsten. 2
6. The method of claim 1 or claim 2, wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising about 69% cobalt or cobalt-based alloy by weight, about 1.9% carbon by weight, and about 29.1% tungsten by weight
7. The method of claim 1 or claim 2, wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising about 75% cobalt or cobalt-based alloy by weight, about 1.53% carbon by weight, and about 23.47% tungsten by weight.
8. The method of claim 1 or claim 2, wherein providing the at least one insert in the mold cavity comprises providing a less than fully sintered body,
9. An article comprising at least a portion of an earth-boring tool, the article comprising:
at least one insert; and
a solidified eutectic or near-eutectic composition including a metal phase, a hard
material phase, and an inoculant.
10. The article of claim 9, wherein the inoculant comprises a material selected from the group consisting of a transition metal aluminate, a transition metal metasilicate, and a transition metal oxide.
1 1. The article of claim 9 or claim 10, wherein the metal phase comprises at least one of cobalt, iron, nickel, and alloys thereof.
12. The article of claim 9 or claim 10, wherein the hard material phase comprises a ceramic compound selected from the group consisting of carbides, borides, nitrides, and mixtures thereof.
13. The article of claim 9 or claim 10, further comprising a composite microstructure that includes regions of the metal phase and the hard material phase. 3
14. The article of claim 9 or claim 10, wherein the hard material phase comprises a metal carbide phase including at least one of an MC phase and an M2C phase, wherein M is at least one metal element and C is carbon.
15. The article of claim 9 or claim 10, wherein the at least one insert comprises a particle-matrix composite material exhibiting a wear-resistance greater than a wear resistance of the solidified eutectic or near-eutectic composition.
16. The article of claim 9 or claim 10, wherein the at least one insert comprises at least one of a cutting surface and a bearing surface of the at least a portion of an earth-boring tool.
17. The article of claim 9 or claim 10, wherein the at least one insert is at least partially embedded in the eutectic or near-eutectic composition.
PCT/US2011/037223 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods WO2011146760A2 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CN201180033765XA CN102985197A (en) 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods
CA2799911A CA2799911A1 (en) 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods
EP11784268.2A EP2571648A4 (en) 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods
MX2012013455A MX2012013455A (en) 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods.
RU2012155100/02A RU2012155100A (en) 2010-05-20 2011-05-19 METHOD FOR FORMING A LESS PART OF A DRILLING TOOL AND FORMED PRODUCT THEREOF

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US34672110P 2010-05-20 2010-05-20
US61/346,721 2010-05-20
US40825310P 2010-10-29 2010-10-29
US61/408,253 2010-10-29

Publications (3)

Publication Number Publication Date
WO2011146760A2 WO2011146760A2 (en) 2011-11-24
WO2011146760A3 WO2011146760A3 (en) 2012-01-12
WO2011146760A4 true WO2011146760A4 (en) 2012-03-01

Family

ID=44972709

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2011/037223 WO2011146760A2 (en) 2010-05-20 2011-05-19 Methods of forming at least a portion of earth-boring tools, and articles formed by such methods

Country Status (7)

Country Link
US (3) US8905117B2 (en)
EP (1) EP2571648A4 (en)
CN (1) CN102985197A (en)
CA (1) CA2799911A1 (en)
MX (1) MX2012013455A (en)
RU (1) RU2012155100A (en)
WO (1) WO2011146760A2 (en)

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