Precipitation Hardened Matrix Drill Bit Segregation

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Solution Overview

Problem

Defects in composite materials used for matrix bit bodies in drill bits lead to reduced lifetime due to segregation of differently sized matrix particles during manufacturing, resulting in uneven erosion resistance and strength, which creates failure points.

Innovation Solution

The use of precipitation hardened composite material with matrix particles and precipitated intermetallic particles dispersed in a binder, where smaller-sized particles are formed in situ to enhance homogenous distribution and mitigate segregation issues, providing improved erosion resistance and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If differently sized matrix particles are used to provide both erosion resistance and strength, then the drill bit gains improved performance characteristics, but the particles segregate during manufacturing causing uneven distribution and failure points

Engineering Contradiction:

Improvedrill bit lifetimeVSAvoidparticle distribution uniformity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent changes the size parameter of matrix particles by forming smaller particles in situ within the binder material after infiltration, creating a bimodal distribution where larger particles provide strength and smaller particles enhance erosion resistance without segregation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining differently sized matrix particles (larger for strength, smaller for erosion resistance) with a binder material, where the smaller particles are formed in situ to ensure homogeneous distribution throughout the composite structure

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If smaller matrix particles are used to enhance erosion resistance, then the drill bit gains better erosion performance, but the particles may not provide sufficient strength compared to larger particles

Engineering Contradiction:

Improveerosion resistanceVSAvoidmatrix bit body strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent segments the matrix particle population into two distinct size groups with different functions: larger particles (50-200 micrometers) provide structural strength while smaller particles (1-30 micrometers) provide erosion resistance, with both dispersed in the binder material

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

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 solution results in a drill bit with enhanced erosion resistance and strength, reducing failure points and extending the drill bit's lifetime by ensuring uniform distribution of particles.

Implementation Method 1

a precipitation hardened composite material that includes matrix particles and precipitated intermetallic particles dispersed in a binder

Methodology Applied

Scientific EffectPrecipitation hardening: Precipitation Hardening

Data Source

PatentUS9752204B2Precipitation hardened matrix drill bit

Publication Date: 2017.09.05 HALLIBURTON ENERGY SERVICES INC

AI summary

A drill bit may include a matrix bit body and a plurality of cutting elements coupled to an exterior portion of the matrix bit body, wherein the matrix bit body includes matrix particles and precipitated intermetallic particles dispersed in a binder, at least some of the matrix particles having a diameter of 50 microns or greater, and at least some of the precipitated intermetallic particles having at least one dimension of 1 micron to 30 microns.