US2008164070A1PendingUtilityA1

Reinforcing overlay for matrix bit bodies

39
Assignee: SMITH INTERNATIONALPriority: Jan 8, 2007Filed: Jan 8, 2007Published: Jul 10, 2008
Est. expiryJan 8, 2027(~0.5 yrs left)· nominal 20-yr term from priority
Inventors:Madapusi K. KeshavanKumar T. KembaiyanAlysia C. WhiteAnthony Griffo
E21B 10/54E21B 10/55
39
PatentIndex Score
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Claims

Abstract

A drill bit that includes a matrix bit body having a reinforcing overlay thereon and having at least one blade thereon; at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; and a braze material disposed between the at least one cutter and the at least one cutter pocket, wherein the reinforcing overlay comprises carbide particles and at least one binder and has a melting point greater than a melting point of the braze material is disclosed.

Claims

exact text as granted — not AI-modified
1 . A drill bit, comprising:
 a matrix bit body having a reinforcing overlay thereon and having at least one blade thereon;   at least one cutter pocket disposed on the at least one blade;   at least one cutter disposed in the at least one cutter pocket; and   a braze material disposed between the at least one cutter and the at least one cutter pocket,   wherein the reinforcing overlay comprises carbide particles and at least one binder and has a melting point greater than a melting point of the braze material.   
   
   
       2 . The drill bit of  claim 1 , wherein the at least one binder comprises at least one of nickel, cobalt, iron, and alloys thereof. 
   
   
       3 . The drill bit of  claim 1 , wherein the reinforcing overlay has a hardness greater than about 50 HRc. 
   
   
       4 . (canceled) 
   
   
       5 . The drill bit of  claim 1 , wherein the reinforcing overlay has a thickness ranging from about 0.010 to 0.125 inches. 
   
   
       6 . The drill bit of  claim 1 , wherein the matrix bit body comprises a matrix of tungsten carbide particles and a second binder. 
   
   
       7 . The drill bit of  claim 6 , wherein the second binder comprises at least one of nickel, cobalt, iron, and copper. 
   
   
       8 . The drill bit of  claim 6 , wherein the second binder comprises about 30 to 40 volume percent of the matrix bit body. 
   
   
       9 . The drill bit of  claim 1 , wherein the reinforcing overlay comprises a plurality of layers. 
   
   
       10 . (canceled) 
   
   
       11 . The drill bit of  claim 1 , wherein the reinforcing overlay has a melting point greater than 1000° C. 
   
   
       12 . A drill bit, comprising:
 a matrix bit body having a reinforcing overlay thereon and having at least one blade thereon;   at least one cutter pocket disposed on the at least one blade;   at least one cutter disposed in the at least one cutter pocket; and   a braze material disposed between the at least one cutter and the at least one cutter pocket,   wherein the reinforcing overlay comprises carbide particles and at least one binder and has a hardness greater than about 50 KRc.   
   
   
       13 . (canceled) 
   
   
       14 . The drill bit of  claim 12 , wherein the reinforcing overlay has a hardness ranging from about 50 to 75 HRc. 
   
   
       15 . The drill bit of  claim 12 , wherein the matrix bit body has a hardness ranging from about 38 to 45 HRc. 
   
   
       16 . The drill bit of  claim 12 , wherein the reinforcing overlay has a thickness ranging from about 0.010 to 0.125 inches. 
   
   
       17 . The drill bit of  claim 12 , wherein the matrix bit body comprises a matrix of tungsten carbide particles and a second binder. 
   
   
       18 . The drill bit of  claim 17 , wherein the second binder comprises at least one of nickel, cobalt, iron, and copper. 
   
   
       19 . The drill bit of  claim 17 , wherein the second binder comprises about 30 to 40 volume percent of the matrix bit body. 
   
   
       20 . A method of forming a drill bit, comprising:
 forming a matrix bit body having at least one blade thereon, wherein the at least one blade has at least one cutter pocket disposed thereon;   applying a reinforcing overlay to the formed matrix bit body; and brazing at least one cutter in the at least one cutter pocket with a braze material.   
   
   
       21 . The method of  claim 20 , wherein forming the matrix bit body comprises infiltrating a mold filled with carbide particles with a first binder. 
   
   
       22 . The method of  claim 20 , wherein forming the matrix bit body comprises hot-pressing carbide particles with a first binder. 
   
   
       23 . The method of  claim 20 , wherein applying the reinforcing overlay comprises using at least one of a spray-and-fuse, d-gun, HVOF, and high velocity cold spray. 
   
   
       24 . The method of  claim 20 , wherein the reinforcing overlay comprises carbide particLes and a second binder selected from at least one of nickel and cobalt. 
   
   
       25 . The method of  claim 20 , wherein the reinforcing overlay has a melting point greater than a melting point of the braze material. 
   
   
       26 . The method of  claim 20 , wherein the forming the matrix bit body and applying the reinforcing overlay occur simultaneously. 
   
   
       27 . The method of  claim 20 , wherein the applying the reinforcing overlay occurs prior to the brazing the at least one cutter. 
   
   
       28 . The method of  claim 20 , wherein the applying the reinforcing overlay occurs after the brazing at least one cutter.

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