Metal-Matrix Composite Reinforcement Blends for Erosion Resistance

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Solution Overview

Problem

Metal-matrix composite (MMC) tools, such as drill bits, face issues with brittleness due to thermal and mechanical stress, leading to stress cracks, which affects their strength, ductility, and erosion resistance.

Innovation Solution

Incorporating a metallic component with optimized sizing and distribution into the reinforcement material blend, where at least 25% of the metallic component has a particle size of 50 microns or less, dispersed within the reinforcement material and infiltrated with a binder material, improves the strength, ductility, and erosion resistance of the resulting MMC tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional reinforcement material blends are used in MMC tools, then erosion resistance is improved, but brittleness increases leading to stress cracks

Engineering Contradiction:

Improveerosion resistanceVSAvoidbrittleness and stress crack susceptibility

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies composite materials by creating a reinforcement material blend consisting of multiple components (e.g., WC, Co, Ni, Cu) with specific particle size distributions. This composite blend is then infiltrated with a binder material to form the MMC tool, combining the erosion resistance of ceramic particles with the ductility and toughness of metallic phases, thereby reducing brittleness and stress crack susceptibility while maintaining erosion resistance.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If larger particle sizes are used in reinforcement material, then manufacturing ease is improved, but mechanical properties including strength and ductility deteriorate

Engineering Contradiction:

Improvemanufacturing easeVSAvoidtransverse rupture strength and ductility

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies segmentation by dividing the reinforcement material into multiple particle size fractions (e.g., fine particles <45 microns, intermediate particles 45-75 microns, and coarse particles >75 microns). This segmented approach allows smaller particles to pack into interstices between larger particles, improving density and mechanical properties while maintaining manufacturability through controlled distribution of different size segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by creating regions with different particle size concentrations and distributions within the reinforcement material blend. Specific areas may have higher concentrations of fine particles to improve strength and ductility, while other areas maintain larger particles for erosion resistance, optimizing local properties to resolve the contradiction between manufacturing ease and mechanical properties.

Inventive Principle:

Principle #3Local quality

3Device complexity

If reinforcement particles are not evenly dispersed, then manufacturing simplicity is maintained, but mechanical properties and erosion resistance deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical properties and erosion resistance

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent applies preliminary action by pre-mixing and pre-distributing the reinforcement material components in specific ratios and particle size distributions before infiltration. This preliminary blending ensures even dispersion is achieved before the infiltration process, improving mechanical properties and erosion resistance without significantly increasing manufacturing complexity, as the dispersion is prepared in advance rather than during infiltration.

Inventive Principle:

Principle #10Preliminary action

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 enhances the mechanical properties of MMC tools by ensuring even dispersion of reinforcing particles, reducing porosity, and increasing transverse rupture strength and erosion resistance, as demonstrated by test data showing improved performance with smaller particle sizes and optimal weight percentages of the metallic component.

Implementation Method 1

the mold may be placed within a furnace to liquefy the binder material and thereby allow the binder material to infiltrate the reinforcing particles

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

allow the binder material to infiltrate the reinforcing particles of the matrix reinforcement material

Methodology Applied

Scientific EffectInfiltration: Permeation

Data Source

PatentUS10774402B2Reinforcement material blends with a small particle metallic component for metal-matrix composites

Publication Date: 2020.09.15 HALLIBURTON ENERGY SERVICES INC

AI summary

A metal-matrix composite includes a reinforced composite material including reinforcement material dispersed in a binder material. The reinforcement material includes a metallic component dispersed with reinforcing particles and at least 25 percent of the metallic component has a particle size of 50 microns or less.