Earth-boring tools with stiff insert support regions and related methods

Abstract

Earth-boring tools comprising bodies with one or more stiff insert support regions and one or more inserts secured to the one or more stiff insert support regions are disclosed. The inserts may each comprise an insert body, which may be secured to the one or more insert support regions of the body. In some embodiments, one or more insert support regions of the body may have an elastic modulus similar the elastic modulus of the insert body of the one or more inserts. In additional embodiments, one or more insert support regions of the body may have an elastic modulus that is greater than the elastic modulus of the insert body of the one or more inserts. In further embodiments, methods of forming earth-boring tools comprising bodies with one or more stiff insert support regions are disclosed.

1 . An earth-boring tool, comprising:
 a body comprising at least one insert support region; and   at least one insert comprising an insert body secured to the at least one insert support region; and
 wherein the at least one insert support region of the body has an elastic modulus within a range of about 65% to about 135% of the elastic modulus of the insert body of the at least one insert. 
   
   
   
       2 . The earth-boring tool of  claim 1 , wherein the at least one insert support region of the body has an elastic modulus within a range of about 73% to about 127% of the elastic modulus of the insert body of the at least one insert. 
   
   
       3 . The earth-boring tool of  claim 1 , wherein the at least one insert support region of the body has an elastic modulus within a range of about 78% to about 123% of the elastic modulus of the insert body of the at least one insert. 
   
   
       4 . The earth-boring tool of  claim 3 , wherein the at least one insert support region of the body has an elastic modulus within a range of about 85% to about 115% of the elastic modulus of the insert body of the at least one insert. 
   
   
       5 . The earth-boring tool of  claim 4 , wherein the at least one insert support region of the body has an elastic modulus within a range of about 95% to about 105% of the elastic modulus of the insert body of the at least one insert. 
   
   
       6 . The earth-boring tool of  claim 5 , wherein the at least one insert support region of the body has an elastic modulus that is substantially the same as the elastic modulus of the insert body of the at least one insert. 
   
   
       7 . The earth-boring tool of  claim 1 , wherein the at least one insert support region of the body has an elastic modulus greater than the elastic modulus of a majority of the body. 
   
   
       8 . The earth-boring tool of  claim 1 , wherein the at least one insert support region of the body has the same material composition as a majority of the body. 
   
   
       9 . The earth-boring tool of  claim 1 , wherein the at least one insert support region of the body is formed of a different material composition than a majority of the body. 
   
   
       10 . The earth-boring tool of  claim 1 , wherein the at least one insert comprises a cutter. 
   
   
       11 . The earth-boring tool of  claim 1 , wherein the at least one insert support region has an elastic modulus greater than about 50,000,000 psi. 
   
   
       12 . The earth-boring tool of  claim 1 , wherein the at least one insert support region has an elastic modulus greater than about 60,000,000 psi. 
   
   
       13 . The earth-boring tool of  claim 1 , wherein the at least one insert support region has an elastic modulus greater than about 70,000,000 psi. 
   
   
       14 . The earth-boring tool of  claim 1 , wherein the at least one insert support region has an elastic modulus greater than about 80,000,000 psi. 
   
   
       15 . An earth-boring tool, comprising:
 at least one insert comprising a particle-matrix composite insert body having an elastic modulus greater than about 70,000,000 psi, and   a body having at least one particle-matrix composite insert support region formed therein, the at least one particle-matrix composite insert support region having an elastic modulus within a range of about 65% to about 135% of the elastic modulus of the insert body of the at least one insert; and   wherein the insert body of the at least one insert is secured to the at least one particle-matrix composite insert support region.   
   
   
       16 . The earth-boring tool of  claim 15 , wherein the at least one particle-matrix composite insert support region has an elastic modulus within a range of about 78% to about 123% of the elastic modulus of the insert body of the at least one insert. 
   
   
       17 . The earth-boring tool of  claim 16 , wherein the insert body of the at least one insert has an elastic modulus greater than about 80,000,000 psi. 
   
   
       18 . The earth-boring tool of  claim 17 , wherein the at least one particle-matrix composite insert support region of the body has an elastic modulus within a range of about 85% to about 115% of the elastic modulus of the insert body of the at least one insert. 
   
   
       19 . The earth-boring tool of  claim 18 , wherein the at least one particle-matrix composite insert support region of the body has an elastic modulus within a range of about 95% to about 105% of the elastic modulus of the insert body. 
   
   
       20 . The earth-boring tool of  claim 19 , wherein the at least one particle-matrix composite insert support region of the body has an elastic modulus that is substantially the same as the elastic modulus of the insert body. 
   
   
       21 . The earth-boring tool of  claim 15 , wherein the at least one particle-matrix composite insert support region of the body has an elastic modulus greater than an elastic modulus of a majority of the body. 
   
   
       22 . A method of forming an earth-boring tool, the method comprising:
 forming a body having at least one insert support region with an elastic modulus within a range of about 65% to about 135% of the elastic modulus of an insert body of at least one insert by sintering a powder mixture;   securing the insert body of the at least one insert to the at least one insert support region of the body.   
   
   
       23 . The method of  claim 22 , wherein forming a body having at least one insert support region with an elastic modulus within a range of about 65% to about 135% of the elastic modulus of an insert body of at least one insert by sintering a powder mixture comprises forming a body having at least one insert support region with an elastic modulus within a range of about 78% to about 123% of the elastic modulus of an insert body of at least one insert by sintering a powder mixture. 
   
   
       24 . The method of  claim 22 , wherein securing the at least one insert body to the at least one insert support region of the body comprises brazing the insert body to the at least one insert support region. 
   
   
       25 . The method of  claim 22 , wherein securing the insert body to the at least one insert support region of a body comprises integrally forming the insert body to the at least one insert support region of the body by sintering the body while the at least one insert is positioned within at least one pocket formed in the at least one insert support region of the body. 
   
   
       26 . An earth-boring tool, comprising:
 a body comprising at least one insert support region; and   at least one insert comprising an insert body secured to the at least one insert support region; and   wherein the at least one insert support region of the body has an elastic modulus that is greater than the elastic modulus of the insert body of the at least one insert.   
   
   
       27 . An earth-boring tool, comprising a body having at least one insert support region having an elastic modulus greater than an elastic modulus of a majority of the body.