Nanoparticle-Reinforced Drill Bit Composite Materials

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Solution Overview

Problem

Existing rotary drill bits face challenges in achieving enhanced physical properties such as strength, toughness, and wear resistance, particularly in rigorous subterranean drilling conditions.

Innovation Solution

Development of composite materials incorporating hard particles and nanoparticles dispersed within a matrix material, where the nanoparticles are made of a different material than the hard particles, to form a particle-matrix composite for use in earth-boring tool bit bodies, enhancing properties like hardness and abrasion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional particle-matrix composite materials with hard tungsten carbide particles dispersed in copper-based alloy matrix are used, then erosion and wear resistance is improved, but strength and toughness deteriorate

Engineering Contradiction:

Improveerosion and wear resistanceVSAvoidstrength and toughness

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent employs a multi-phase composite material system consisting of hard particles (tungsten carbide), nanoparticles (copper-based alloy), and a binder matrix. This composite structure allows the hard particles to provide wear resistance while the nanoparticle-reinforced binder maintains strength and toughness, resolving the contradiction between hardness and mechanical properties

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different regions and phases within the composite. The hard tungsten carbide particles provide localized wear resistance at the cutting interface, while the copper-based alloy binder with nanoparticle reinforcement provides the necessary structural strength and toughness in the matrix regions

Inventive Principle:

Principle #3Local quality

2Force

If hard metal inserts or coated teeth are used on roller cones, then cutting ability is improved, but the overall bit strength and toughness are reduced

Engineering Contradiction:

Improvecutting abilityVSAvoidbit strength and toughness

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The patent merges the cutting function and structural support function into a single integrated bit body material. Instead of separate hard metal inserts or coated teeth on roller cones, the entire bit body is formed from the particle-matrix composite material that simultaneously provides cutting ability through hard particles and structural strength through the reinforced binder matrix

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11045870B2Composite materials including nanoparticles, earth-boring tools and components including such composite materials, polycrystalline materials including nanoparticles, and related methods

Publication Date: 2021.06.29 BAKER HUGHES CO

AI summary

A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.