Additive Manufacturing Drill Bit with Graded Alloys

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional earth-boring drill bits experience wear and fatigue, leading to reduced lifespan and increased costs due to the complexity of materials and operations, particularly at greater depths, where removing and replacing bits is time-consuming and costly.

Innovation Solution

The use of additive manufacturing to deposit different steel, copper, and nickel alloys in precise regions of the drill bit, allowing for customized mechanical properties and eliminating the need for welding, thereby enhancing precision and reducing thermal effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional subtractive manufacturing or infiltration methods are used to make drill bits, then the manufacturing process is well-established, but the drill bit lifespan is limited due to wear and fatigue

Engineering Contradiction:

Improvedrill bit lifespanVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental manufacturing parameter from subtractive manufacturing to additive manufacturing. This enables precise control over material distribution and microstructure, creating drill bits with optimized mechanical properties that extend lifespan while managing manufacturing complexity through digital design capabilities.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent produces drill bits with composite material structures by depositing different alloys in specific regions. This creates functionally graded materials where each region has optimized properties for its specific function, improving overall reliability and wear resistance.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If drill bits are made with multiple materials using infiltration methods, then material properties can be optimized for different regions, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improvematerial property optimizationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by depositing different steel, copper, and nickel alloys in specific regions of the drill bit using additive manufacturing. Each region receives materials optimized for its specific functional requirements, achieving superior adaptability while simplifying the manufacturing process compared to conventional infiltration methods.

Inventive Principle:

Principle #3Local quality

3Productivity

If drill bits are removed and replaced frequently due to wear, then cutting performance is maintained, but time and cost increase significantly

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidbit removal and replacement time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent incorporates wear-resistant materials and optimized microstructures during the additive manufacturing process itself, providing beforehand protection against wear and fatigue. This prevents premature failure and extends drill bit lifespan, reducing the frequency of replacements and minimizing loss of time.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Manufacturing precision

If conventional manufacturing methods are used, then production is straightforward, but welding is required which introduces thermal effects and reduces precision

Engineering Contradiction:

Improvematerial placement precisionVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical welding process with additive manufacturing, where materials are deposited and bonded in a controlled manner without the thermal effects of welding. This achieves superior manufacturing precision for material placement while managing process complexity through automated deposition systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach extends the downhole time of drill bits by optimizing mechanical properties for various regions, improving wear resistance, corrosion resistance, and erosion resistance, reducing the need for frequent replacements and associated costs.

Implementation Method 1

drill bits, or portions thereof, formed by additive manufacturing

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS12103086B2Earth-boring drill bit formed by additive manufacturing

Publication Date: 2024.10.01 HALLIBURTON ENERGY SERVICES INC

AI summary

The present disclosure relates to an earth-boring drill bit including a shank, an internal region formed from at least a first alloy using additive manufacturing and secured to the shank, and an exterior region formed from at least a second alloy using additive manufacturing and secured to the internal region using additive manufacturing. The first alloy and the second alloy have a different modulus of elasticity, yield strength, resilience, ductility, hardness, fracture toughness, wear resistance, corrosion resistance, or erosion resistance. The disclosure further includes a method of manufacturing such an earth-boring drill by depositing a plurality of layers according to a drill bit specification using additive manufacturing.