Microwave sintering

a technology of microwave sintering and tungsten carbide, which is applied in the direction of drill bits, drilling accessories, earthwork drilling and mining, etc., can solve the problems of residual stresses induced on composite materials, material sintering under high pressure and high temperature, and tungsten carbide cutting elements tend to fail by excessive wear, etc., to achieve rapid consolidation process

Inactive Publication Date: 2007-07-05
SMITH INT INC
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AI Technical Summary

Problems solved by technology

Tungsten carbide cutting elements tend to fail by excessive wear because of their softness.
During manufacture of the cutting elements, the materials are typically subjected to sintering under high pressures and high temperatures.
These manufacturing conditions can lead to potential problems involving dissimilar elements being bonded to each other and the diffusion of various components, resulting in residual stresses induced on the composites.
The residual stress induced composites can often result in insert breakage, fracture or delamination under drilling conditions.
Additionally, the combination of the high temperature and high pressure for the length of time necessary to form the cutting elements inherently result in grain growth and thus larger carbide grain sizes.
However, the use of grain growth inhibitors typically produces undesirable side effects by altering the physical characteristics of the sintered carbide product, especially when the carbide product is to be brazed to a diamond layer or crown.

Method used

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Embodiment Construction

[0031] In one aspect, embodiments of the invention relate to wear resistant elements and carbide composites having nano-scale carbide particles. In another aspect, embodiments of the invention relate to microwave sintered composites. Microwave sintering may provide for a process of forming a hard composite. As compared to a conventional high temperature, high pressure (HTHP) sintering process, such as that disclosed in U.S. Pat. Nos. 4,694,918; 5,370,195; and 4,525,178, sintering using microwave energy may reduce the pressures used, decrease the applied temperature, and reduce the sintering time. The microwave sintering process may be applied to a number of composite materials and may thus form composites having greater wear resistant properties. Tungsten carbide, polycrystalline diamond, thermally stable polycrystalline diamond, silicon carbide, etc, are among the materials suitable for microwave sintering.

[0032] In one embodiment, a microwave sintered composite made in accordance...

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Abstract

A carbide composite that includes carbide particles having an average particle size of less than about 100 nanometers and a metallic binder disposed around the carbide particles is disclosed. The carbide composite may also include carbide particles having an average particle size ranging from 3 to 10 microns.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority, pursuant to § 119(e), of U.S. Patent Provisional Ser. No. 60 / 739,703 filed on Nov. 23, 2005, which is herein incorporated by reference in its entirety.BACKGROUND OF INVENTION [0002] 1. Field of the Invention [0003] The invention relates generally to applications for microwave sintering. More specifically, the invention relates to microwave sintered cutting elements for use in drilling applications. [0004] 2. Background Art [0005] Drill bits used to drill wellbores through earth formations generally are made within several broad categories of bit structures, including roller cone bits, and drag or fixed cutter bits. [0006] Roller cone rock bits include a bit body adapted to be coupled to a rotatable drill string and include at least one “cone” that is rotatably mounted to the bit body. A plurality of cutting elements are positioned on each cone. Within the category of roller cone bits, there are two furt...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E21B10/36
CPCB22F2003/1054B22F2005/001B22F2998/00C22C29/08E21B10/52E21B10/55B22F3/105B22F3/08B22F3/04B22F3/087B22F3/10B22F7/06
Inventor SLUTZ, DAVIDKESHAVAN, MADAPUSI K.GRIFFO, ANTHONY
Owner SMITH INT INC
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