Flowable Composite Particles for Drill Bit Infiltration
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Solution Overview
Problem
Existing infiltrated metal matrices for subterranean drill bits face challenges in achieving a balance between erosion resistance, strength, and thermal stability, with issues related to particle flowability and the effectiveness of tungsten/copper composite powders.
Innovation Solution
The development of flowable composite particles comprising unfractured and fractured hard particles bonded to a binder alloy, which are then infiltrated with an infiltrant alloy to form an infiltrated article with improved properties, including enhanced erosion resistance and transverse rupture strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional infiltrated metal matrices are used for drill bits, then erosion resistance can be achieved, but transverse rupture strength and thermal stability are compromised
Solution Approach 1:
The invention uses composite particles comprising tungsten carbide (WC) and ditungsten carbide (W2C) in specific ratios (WC: 3-7 wt%, W2C: 93-97 wt%) embedded in a copper-based binder alloy. This composite structure allows the material to achieve both erosion resistance from the hard carbide phases and thermal stability from the controlled composition and distribution of phases within the copper matrix.
Solution Approach 2:
The invention carefully controls compositional parameters including the WC/W2C ratio, copper content (6-12 wt%), and particle size distribution (-80 to -325 mesh). By optimizing these parameters, the material achieves a balance between erosion resistance (from hard carbide particles) and thermal stability (from controlled phase distribution and copper matrix properties).
2Ease of operation
If fine particle size powders are used to improve flowability, then particle flowability improves, but particle strength and handling characteristics deteriorate
Solution Approach 1:
The invention creates composite particles where fine carbide particles (providing flowability) are embedded within a copper-based binder matrix (providing structural integrity). The copper binder holds the fine carbide particles together, maintaining particle strength while preserving the fine size distribution needed for good flowability.
Solution Approach 2:
The particle structure exhibits local quality differentiation: the core contains hard carbide particles for erosion resistance and flowability, while the copper binder matrix provides structural cohesion. This local differentiation allows fine particles to maintain both flowability and adequate strength for handling.
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
The use of flowable composite particles results in an infiltrated article that exhibits a favorable balance of erosion resistance and strength, with improved flowability and microstructural uniformity, addressing the limitations of previous technologies.
Implementation Method 1
an infiltrated article that comprises a particulate mass comprising flowable composite particles wherein prior to infiltration with an infiltrant alloy, each of the flowable composite particles comprising a plurality of bound hard particles and a binder alloy
Data Source
AI summary
A flowable composite particle that includes a plurality of bound hard particles and a binder alloy. The bound hard particles are unfractured bound hard particles and fractured bound hard particles. Each of the bound hard particles is bonded to the binder alloy. The bound hard particles have a particle size of −325 Mesh. The flowable composite particle have a particle size distribution is: (a) between more than about zero weight percent and about 5 weight percent flowable composite particles of a +80 Mesh particle size, (b) between about 60 weight percent and about 95 weight percent flowable composite particles of a −80+325 Mesh particle size, and (c) between more than about zero weight percent and about 35 weight percent flowable composite particles of a −325 Mesh particle size.