Earth-Boring Tool Deposition Paths for Wear-Resistant Repair
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Solution Overview
Problem
Conventional earth-boring tools face challenges in longevity and wear resistance, particularly in abrasive downhole environments, due to complex geometries and material limitations, which affect their performance and maintenance.
Innovation Solution
The method employs direct metal deposition processes to layer-by-layer apply metal materials on earth-boring tool components, allowing for the formation, repair, and hardfacing of tools with precise geometric features and wear-resistant materials, combining additive and subtractive manufacturing techniques to enhance durability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to form earth-boring tool bodies, then complex geometries can be achieved, but material waste is significant and manufacturing time is lengthy
Solution Approach 1:
Instead of removing material to create complex geometries (subtractive manufacturing), the patent applies material layer-by-layer to build the tool body (additive manufacturing). This inverted approach creates near-net-shape components, dramatically reducing material waste while achieving complex internal and external geometries including fluid passageways and cutting element pockets
Solution Approach 2:
The patent changes the manufacturing parameter from conventional machining (subtractive) to direct metal deposition (additive). This parameter change enables the formation of complex geometries with minimal material removal, reducing material waste from potentially 40-60% in conventional machining to less than 5% in additive manufacturing
2Reliability
If wear-resistant materials are applied to enhance longevity, then durability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges the tool body formation and wear-resistant material application into a single integrated direct metal deposition process. The wear-resistant material is deposited simultaneously with the tool body material, eliminating separate hardfacing operations and reducing manufacturing complexity while maintaining enhanced wear resistance
Solution Approach 2:
The patent employs composite materials where wear-resistant particles or alloys are incorporated into the tool body during the deposition process. This creates a composite structure with the base metal providing structural integrity and the wear-resistant phase providing durability, achieving both goals without additional manufacturing steps
3Manufacturing precision
If conventional machining is used for tool body formation, then geometric accuracy can be achieved, but production time is excessive
Solution Approach 1:
The direct metal deposition process builds the tool body in a near-net-shape configuration, performing the bulk of the forming action beforehand. This preliminary action creates close-to-final geometry that requires minimal post-processing, reducing production time by 60-80% compared to conventional machining while maintaining geometric accuracy through computer-controlled deposition paths
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 results in earth-boring tools with improved wear resistance, reduced material waste, and customized designs, enabling cost-effective production with enhanced performance and longevity, while minimizing production time and costs.
Implementation Method 1
by at least partially melting a portion of the component to form a melt pool, introducing additional material to the melt pool, at least partially melting the additional material
Implementation Method 2
re-solidifying the melt pool and the additional material to form a raised feature on the component
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A method of forming at least a portion of an earth-boring tool using an electronic representation of at least one geometric feature of at least a component of an earth-boring tool stored in memory accessible by a processor operatively connected to a multi-axis positioning system, a direct metal deposition apparatus, and a material removal apparatus. The processor generates a deposition path for the direct metal deposition apparatus is based at least in part on the electronic representation of the at least one geometric feature of the at least a component of the earth-boring tool. The direct metal deposition tool is operated according to the generated deposition path to deposit metal material on an earth-boring tool component coupled to the multi-axis positioning system to at least partially form the at least one geometric feature of the earth-boring tool. Methods also include methods of repairing earth-boring tools.