Methods of making and attaching tsp material for forming cutting elements, cutting elements having such tsp material and bits incorporating such cutting

Drill bit inserts enhanced with polycrystalline diamond

Drill bit inserts enhanced with polycrystalline diamond

Drill bit inserts enhanced with polycrystalline diamond

Methods of making and attaching TSP material for forming cutting elements, cutting elements having such TSP material and bits incorporating such elements

A method of forming one or more TSP compacts is provided. The method includes placing one or more TSP material layers in an enclosure and surrounding each TSP material layer with at least one of a pre-sintered tungsten carbide powder, pre-cemented tungsten carbide powder, tungsten carbide powder, or partially sintered tungsten carbide substrates. The method also includes exposing the enclosure to a high temperature high pressure process wherein the at least one of a pre-sintered tungsten carbide powder, pre-cemented tungsten carbide powder, tungsten carbide powder, or partially sintered tungsten carbide substrates bond to the TSP material layers forming a stack of TSP material layers including the TSP material layers one over the other with tungsten carbide bonded to each of the TSP material layers and encapsulating each of the TSP material layers.

Drill Bit Inserts Enhanced with Polycrystalline Diamond

Ultra-hard constructions with enhanced second phase

Ultra-hard constructions include an ultra-hard body having a first region including a polycrystalline matrix first phase and a second phase material interposed therein. The first region is substantially free of a catalyst material used to form the first phase. The body is formed by removing the catalyst material and then replacing it with the second phase material. A second region is disposed within the body and includes the polycrystalline matrix first phase and a catalyst material used to form the first phase. The second phase material has a thermal characteristic that is more closely matched to the matrix first phase than the catalyst material. The body may be joined to a substrate, and the ultra-hard body may consist entirely of the first region. The second phase material can include non-refractory metals, ceramics, silicon, silicon-containing compounds, diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof.

Ultra-hard constructions with enhanced second phase

An ultra-hard construction is disclosed that is prepared by a method comprising the steps of treating a material microstructure having a polycrystalline matrix first phase material and a second phase material from at least a partial region of the material microstructure, wherein the second phase material is disposed within interstitial regions of the material microstructure, and wherein removal of the second phase material creates a porous material microstructure characterized by a plurality of empty voids and replacing the removed second phase material with a replacement material having a thermal characteristic that more closely matched polycrystalline matrix first phase that the second phase material.

Solid state processing of materials through friction stir processing and friction stir mixing

Solid state processing is performed on a workpiece by using a tool capable of friction stir processing, friction stir mixing, or friction stir welding, wherein solid state processing modifies characteristics of a workpiece while substantially maintaining a solid phase in some embodiments, allowing some elements to pass through a liquid phase in other embodiments, and wherein modified characteristics of the material include, but are not limited to, microstructure, macrostructure, toughness, hardness, grain boundaries, grain size, the distribution of phases, ductility, superplasticity, change in nucleation site densities, compressibility, expandability, coefficient of friction, abrasion resistance, corrosion resistance, fatigue resistance, magnetic properties, strength, radiation absorption, and thermal conductivity.

ULTRA-HARD CONSTRUCTIONS WITH ENHANCED SECOND PHASE

Ultra-hard constructions include an ultra-hard body having a first region including a polycrystalline matrix first phase and a second phase material interposed therein. The first region is substantially free of a catalyst material used to form the first phase. The body is formed by removing the catalyst material and then replacing it with the second phase material. A second region is disposed within the body and includes the polycrystalline matrix first phase and a catalyst material used to form the first phase. The second phase material has a thermal characteristic that is more closely matched to the matrix first phase than the catalyst material. The body may be joined to a substrate, and the ultra-hard body may consist entirely of the first region. The second phase material can include non-refractory metals, ceramics, silicon, silicon-containing compounds, diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof.

Friction stirring and its application to drill bits, oil field and mining tools, and components in other industrial applications

Solid state processing is performed on a workpiece that operates alone or is a component of equipment used in various demanding, harsh and wearing environments in which failure of a product could compromise safety or the environment or otherwise result in significant cost for repair or replacement, wherein the solid state processing performed by using a tool capable of friction stir processing, friction stir mixing, or friction stir welding results in a workpiece that offers a longer life-cycle and/or improved performance and/or improved reliability as a result of the solid state processing.

FRICTION STIRRING AND ITS APPLICATION TO DRILL BITS, OIL FIELD AND MINING TOOLS, AND COMPONENTS IN OTHER INDUSTRIAL APPLICATIONS

Solid state processing is performed on a workpiece that operates alone or is a component of equipment used in various demanding, harsh and wearing environments in which failure of a product could compromise safety or the environment or otherwise result in significant cost for repair or replacement, wherein the solid state processing performed by using a tool capable of friction stir processing, friction stir mixing, or friction stir welding results in a workpiece that offers a longer life-cycle and/or improved performance and/or improved reliability as a result of the solid state processing. 1. A method for manufacturing an apparatus to improve performance , reliability , or useful life thereof , said method comprising the steps of:identifying at least one portion of the apparatus that experiences stress; andfriction stirring the at least one portion to thereby improve performance, reliability or useful life thereof by modifying the residual compressive stress of the at least one portion through contact with a rotating friction stirring spindle tool comprising a shank, a shoulder and a pin, by forming an area with increased residual compressive stress within the at least one portion as a result of the friction stirring by the rotating friction stirring spindle tool, wherein the friction stirring comprises plunging the pin of the rotating friction stirring spindle tool into the least one portion and transversely moving the rotating friction stirring spindle tool across the at least one portion to thereby impart increased residual compressive stress within the at least one portion.2. The method as defined in wherein the step of friction stirring is selected from the group of friction stirring processes including friction stir welding claim 1 , friction stir processing claim 1 , and friction stir mixing.3. The method as defined in wherein the apparatus is selected from the group of drilling tools and components including a drill bit claim 2 , a roller cone drill bit ...

ULTRA-HARD CONSTRUCTIONS WITH ENHANCED SECOND PHASE

An ultra-hard construction is disclosed that is prepared by a method comprising the steps of treating a material microstructure having a polycrystalline matrix first phase material and a second phase material from at least a partial region of the material microstructure, wherein the second phase material is disposed within interstitial regions of the material microstructure, and wherein removal of the second phase material creates a porous material microstructure characterized by a plurality of empty voids and replacing the removed second phase material with a replacement material having a thermal characteristic that more closely matched polycrystalline matrix first phase that the second phase material.

FRICTION STIRRING AND ITS APPLICATION TO DRILL BITS, OIL FIELD AND MINING TOOLS, AND COMPONENTS IN OTHER INDUSTRIAL APPLICATIONS

A method of processing a downhole tool includes friction stirring at least a portion of a steel surface of the downhole tool. 1. A method for processing a downhole tool , comprising:friction stirring at least a portion of a steel surface of a downhole tool.2. The method of claim 1 , further comprising:heat treating at least a portion of the downhole tool.3. The method of claim 1 , wherein the friction stirring comprises welding two components together.4. The method of claim 1 , wherein the friction stirring comprises stirring a first additive component into the portion of the steel surface.5. The method of claim 4 , wherein the additive component comprises at least one of tungsten carbide claim 4 , silicon carbide claim 4 , aluminum oxide claim 4 , cubic boron nitride claim 4 , or diamond.6. The method of claim 4 , further comprising friction stirring a second additive component into a portion of the steel at a depth less than the first additive component.7. The method of claim 1 , wherein the portion of the steel surface comprises a wear area on the surface of the downhole tool.8. The method of claim 1 , wherein the portion of the steel surface comprises a fluid erosion area on the surface of the downhole tool.9. The method of claim 1 , wherein the downhole tool comprises a drill bit.10. The method of claim 1 , wherein the downhole tool comprises a hole opener.11. The method of claim 1 , wherein the downhole tool comprises a stabilizer.12. The method of claim 1 , wherein the downhole tool comprises a reamer.13. The method of claim 1 , wherein the downhole tool comprises a downhole motor.14. The method of claim 1 , wherein the downhole tool comprises a drill collar15. The method of claim 1 , wherein the downhole tool comprises a sub.16. The method of claim 1 , wherein the downhole tool comprises a jar. This application is a divisional application of U.S. application Ser. No. 14/046,769, filed on Oct. 4, 2013. U.S. application Ser. No. 14/046,769 is a continuation ...

Drill bit inserts enhanced with polycrystalline diamond

A drill bit has means at one end for connecting the bit to a drill string and a plurality of inserts at the other end for crushing the rock to be drilled. The inserts have a cemented tungsten carbide body partially embedded in the drill bit and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and particles of carbide or carbonitride of elements selected from the group consisting of W, Ti, Ta, Cr, Mo, Cb, V, Hf and Zr. The remaining layers adjacent the polycrystalline diamond layer are transition layers each comprising a composite containing diamond crystals, particles of tungsten carbide, and particles of titanium carbonitride. The average size of the diamond particles in the polycrystalline diamond layer is greater than the average size of the carbide or carbonitride particles; and the average size of the diamond particles in the transition layers is greater than the average sizes of the carbide and carbonitride particles. In particular, the transition layers contain particles of carbide and/or carbonitride with average grain sizes of less than one micrometer. The outermost layer of polycrystalline diamond extends along at least a portion of the length of the grip portion of the carbide body embedded in the drill bit.

Drill bit inserts enhanced with polycrystalline diamond

A drill bit has means at one end for connecting the bit to a drill string and a plurality of inserts at the other end for crushing the rock to be drilled. The inserts have a cemented tungsten carbide body partially embedded in the drill bit and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and particles of carbide or carbonitride of elements selected from the group consisting of W, Ti, Ta, Cr, Mo, Cb, V, Hf and Zr. The remaining layers adjacent the polycrystalline diamond layer are transition layers each comprising a composite containing diamond crystals, particles of tungsten carbide, and particles of titanium carbonitride. The average size of the diamond particles in the polycrystalline diamond layer is greater than the average size of the carbide or carbonitride particles; and the average size of the diamond particles in the transition layers is greater than the average sizes of the carbide and carbonitride particles. In particular, the transition layers contain particles of carbide and/or carbonitride with average grain sizes of less than one micrometer. The outermost layer of polycrystalline diamond extends along at least a portion of the length of the grip portion of the carbide body embedded in the drill bit.

Whisker or fiber reinforced polycrystalline cubic boron nitride and diamond

Drill bit inserts enhanced with polycrystalline diamond

A drill bit has means at one end for connecting the bit to a drill string and a plurality of inserts at the other end for crushing the rock to be drilled. The inserts have a cemented tungsten carbide body partially embedded in the drill bit and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and particles of carbide or carbonitride of elements selected from the group consisting of W, Ti, Ta, Cr, Mo, Cb, V, Hf and Zr. The remaining layers adjacent the polycrystalline diamond layer are transition layers each comprising a composite containing diamond crystals, particles of tungsten carbide, and particles of titanium carbonitride. The average size of the diamond particles in the polycrystalline diamond layer is greater than the average size of the carbide or carbonitride particles; and the average size of the diamond particles in the transition layers is greater than the average sizes of the carbide and carbonitride particles. in particular, the transition layers contain particles of carbide and/or carbonitride with average grain sizes of less than one micrometer. The outermost layer of polycrystalline diamond extends along at least a portion of the length of the grip portion of the carbide body embedded in the drill bit.

Solid state processing of materials through friction stir processing and friction stir mixing

Solid state processing is performed on a workpiece (16) by using a tool (10) capable of friction stir processing, friction stir mixing, or friction stir welding, wherein solid state processing modifies characteristics of a workpiece while substantially maintaining a solid phase in some embodiments, allowing some elements to pass through a liquid phase in other embodiments, and wherein modified characteristics of the material include, but are not limited to, microstructure, macrostructure, toughness, hardness, grain boundaries, grain size, the distribution of phases, ductility, superplasticity, change in nucleation site densities, compressibility, expandability, coefficient of friction, abrasion resistance, corrosion resistance, fatigue resistance, magnetic properties, strength, radiation absorption, and thermal conductivity.

Behandling av faste materialer med fiksjonsagitering og friksjonssammenflytting

Fasttilstandbehandling gjennomføres på et arbeidsemne ved bruk av et verktøy som kan gi en friksjonsagitering, fiiksjonssammenflyting eller friksjonssveising, hvilken fasttilstandbehandling gir en modiflsering av egenskaper i et arbeidsemne samtidig som det bibeholdes en fastfase i noen utførelser, mens noen elementer tillates å gå gjennom en flytfase, og hvor materialets modifiserte egenskaper innbefatter, uten begrensning, mikrostruktur, makrostruktur, seighet, hardhet, komgrenser, korntørrelse, fasefordeling, duktilitet, superplastisitet, endring av kjemestedstettheter, kompressibilitet, ekspanderbarhet, friksj onskoeffisient, abrasj onsmotstand, korrosjonsmotstand, utmattingsmotstand, magnetiske egenskaper, styrke, sfrålingsabsorpsjon og termisk ledningsevne.

Solid state processing of materials through friction stir processing and friction stir mixing

Solid state processing is performed on a workpiece (16) by using a tool (10) capable of friction stir processing, friction stir mixing, or friction stir welding, wherein solid state processing modifies characteristics of a workpiece while substantially maintaining a solid phase in some embodiments, allowing some elements to pass through a liquid phase in other embodiments, and wherein modified characteristics of the material include, but are not limited to, microstructure, macrostructure, toughness, hardness, grain boundaries, grain size, the distribution of phases, ductility, superplasticity, change in nucleation site densities, compressibility, expandability, coefficient of friction, abrasion resistance, corrosion resistance, fatigue resistance, magnetic properties, strength, radiation absorption, and thermal conductivity.