Impregnated Cutting Structure Densification for Drill Bit Wear

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Solution Overview

Problem

Conventional superabrasive-impregnated drill bits wear down quickly due to the faster degradation of the matrix material and binder, leading to exposure and loss of superabrasive particles, which reduces their effectiveness and operational life when drilling hard rock formations.

Innovation Solution

The formation of impregnated cutting structures using a powder mixture of diamond particles and a metal binder subjected to high temperature high pressure (HTHP) conditions, eliminating diamond-to-diamond bonds and carbides, resulting in a composite material with increased density, strength, and improved adhesion between superabrasive particles and the binder, which slows down wear and extends the drill bit's operational life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional superabrasive-impregnated drill bits are used with matrix material and binder, then the cutting structures can be formed, but the matrix material and binder wear away faster than the superabrasive particles, leading to particle exposure and loss

Engineering Contradiction:

Improveoperational life of drill bitVSAvoidloss of superabrasive particles

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the physical and chemical parameters of the binder material by using a metal alloy binder (such as cobalt, nickel, or iron-based alloys) instead of conventional organic binders. This parameter change allows the binder to maintain its structural integrity at higher temperatures and exhibit wear resistance comparable to superabrasive particles, thereby preventing premature particle exposure and loss during drilling operations

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material structure where superabrasive particles (diamond or cubic boron nitride) are embedded in a metal alloy matrix. This composite design creates a synergistic effect where both the superabrasive particles and the metal binder contribute to cutting performance and wear resistance, eliminating the differential wear problem between binder and particles

Inventive Principle:

Principle #40Composite materials

2Strength

If high temperature high pressure conditions are applied to densify the powder mixture, then the density and strength of the impregnated cutting structure increase, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvestrength of impregnated cutting structureVSAvoidease of forming cutting structure

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent utilizes phase transition phenomena during the HTHP processing, where the metal alloy binder undergoes solidification and densification at controlled temperatures and pressures. This phase transition allows the powder mixture to transform into a dense, strong monolithic structure with the superabrasive particles firmly embedded in the metal matrix, achieving high strength while following established metallurgical processes

Inventive Principle:

Principle #36Phase transitions

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 impregnated cutting structures exhibit enhanced hardness, strength, reduced porosity, and improved wear resistance, leading to extended operational life and improved performance in drilling hard rock formations compared to conventional methods.

Implementation Method 1

subjecting the powder mixture to a pressure greater than about 4.0 GPa and a temperature greater than about 1,200° C. to densify the powder mixture and form an impregnated cutting structure

Methodology Applied

Scientific EffectHigh temperature high pressure densification: Hot Isostatic Pressing

Implementation Method 2

subjecting the powder mixture to a pressure greater than about 4.0 GPa and a temperature greater than about 1,200° C. to densify the powder mixture and form an impregnated cutting structure comprising the diamond particles dispersed in a continuous phase comprising the metal binder, wherein the impregnated cutting structure is substantially free of diamond-to-diamond bonds and of carbides

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS10605009B2Impregnated cutting structures, earth-boring tools including the impregnated cutting structures, and related methods

Publication Date: 2020.03.31 BAKER HUGHES CO

AI summary

A method of forming an impregnated cutting structure for an earth-boring tool comprises providing a powder mixture comprising diamond particles and a metal binder in a press and subjecting the powder mixture to a pressure greater than about 4.0 GPa and a temperature greater than about 1,200° C. to densify the powder mixture and form an impregnated cutting structure comprising the diamond particles dispersed in a continuous phase comprising the metal binder, wherein the impregnated cutting structure is substantially free of diamond-to-diamond bonds and of carbides. Related methods of forming an earth-boring tool and a related earth-boring tool including the impregnated cutting structure.