Downhole cutting tool and method

Abstract

A downhole cutting tool includes a base including a first consolidated powder; and at least one cutting feature affixed to the base, the at least one cutting feature including a cutting material suspended in a second consolidated powder, wherein the base and the at least one cutting feature are both consolidated and bonded together simultaneously. Also included is a method of manufacturing a cutting tool.

1 . A downhole cutting tool comprising:
 a base including a first consolidated powder; and   at least one cutting feature affixed to the base, the at least one cutting feature including a cutting material suspended in a second consolidated powder, wherein the base and the at least one cutting feature are both consolidated and bonded together simultaneously.   
     
     
         2 . The cutting tool of  claim 1 , wherein the first consolidated powder comprises steel. 
     
     
         3 . The cutting tool of  claim 1 , wherein the second consolidated powder comprises nickel, copper, iron, cobalt, or combinations including at least one of the foregoing. 
     
     
         4 . The cutting tool of  claim 1 , wherein the cutting material comprises tungsten carbide, cubic boron nitride, diamond, silicon carbide, or combinations including at least one of the foregoing. 
     
     
         5 . The cutting tool of  claim 1 , further including at least one watercourse proximate the at least one cutting feature. 
     
     
         6 . A method of manufacturing a cutting tool comprising:
 layering a first powder and a second powder in a die, the second powder comprising cutting material suspended therein; and   simultaneously consolidating the first and second powders to form a base and at least one cutting feature, respectively, the simultaneous consolidating also bonding the base to the at least one cutting feature.   
     
     
         7 . The method of  claim 6 , wherein the first powder comprises steel. 
     
     
         8 . The method of  claim 6 , wherein the second powder comprises nickel, copper, iron, cobalt, or combinations including at least one of the foregoing. 
     
     
         9 . The method of  claim 6 , wherein the cutting material comprises tungsten carbide, cubic boron nitride, diamond, silicon carbide, or combinations including at least one of the foregoing. 
     
     
         10 . A tool manufactured by the process of  claim 6 .