Replaceable Hardfacing Pads for Earth-Boring Tools
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Solution Overview
Problem
Earth-boring tools face challenges with abrasive, erosive, and corrosive wear, leading to reduced tool and component reusability and increased production and repair complexities due to the need for custom sizes and shapes.
Innovation Solution
The implementation of modular, replaceable gage pads secured to the earth-boring tool bodies using a braze material, allowing for efficient production and repair by securing and replacing these pads within recesses, facilitating the use of standard components for various tool sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom sizes and shapes are used for each tool component, then the tool can be optimized for specific applications, but the manufacturing complexity and repair difficulty increase significantly
Solution Approach 1:
The tool body is divided into modular segments including interchangeable gage pads, inserts, and cutting elements that can be independently manufactured and replaced. This segmentation allows standardization of base components while maintaining customization capability through different pad and insert configurations.
Solution Approach 2:
A universal base tool body design is created that can accommodate multiple types of gage pads, inserts, and cutting elements through standardized mounting interfaces. This universal base reduces manufacturing complexity while maintaining adaptability for various drilling applications through component interchangeability.
2Reliability
If abrasive-resistant coatings are applied to tool surfaces, then wear resistance is improved, but the application process becomes more complex and time-consuming
Solution Approach 1:
Instead of applying permanent abrasive-resistant coatings to the entire tool, the patent uses replaceable gage pads and inserts that can be economically manufactured with wear resistance features. When these components wear out, they are simply replaced rather than re-coated, reducing the complexity of wear protection application.
Solution Approach 2:
Abrasive-resistant properties are applied locally to specific high-wear areas through the use of hardened gage pads and inserts rather than coating the entire tool surface. This localized approach maintains wear resistance where needed while simplifying the overall manufacturing process.
3Productivity
If tools are designed for high reusability, then production costs decrease, but the initial manufacturing precision requirements increase
Solution Approach 1:
The tool is segmented into a durable base body and replaceable wear components. The base body is manufactured with high precision for long-term reuse, while the replaceable pads and inserts are manufactured with standard tolerances. This segmentation allows high reusability of the expensive base component without requiring high precision manufacturing for all tool components.
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 solution enhances tool reusability, reduces production and repair time, and minimizes material waste by enabling the use of standardized components for a range of tool sizes and shapes, improving efficiency and cost-effectiveness.
Implementation Method 1
The body, the braze material, and the at least one hardfacing pad may be exposed to an elevated temperature, at least partially flowing the braze material
Implementation Method 2
a braze material securing the at least one hardfacing pad to the body, the braze material extending around the at least one spacer and located between the plate and the body
Data Source
AI summary
Earth-boring tools may include a body having blades protruding therefrom and at least one hardfacing pad secured to at least one blade. The at least one hardfacing pad may be located at least partially within a recess extending at least into the at least one blade body around a circumference of a gage region of the body and may include a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that the plate is spaced from the body by at least a thickness of the at least one spacer. A braze material may secure the at least one hardfacing pad to the at least one blade, the braze material extending around the at least one spacer and located between the plate and the body.