Use of tungsten carbide tube rod to hard-face pdc matrix

Abstract

A hardfaced infiltrated matrix downhole tool and a method for hardfacing such items is provided. The hardfaced infiltrated matrix downhole tool includes a body, an intermediate base coat coupled to at least a portion of the surface of the body, and a hardfacing material coupled to at least a portion of the intermediate base coat. The body is composed of at least a carbide material and an infiltrating binder material. The intermediate base coat bonds to the surface of the body and to the hardfacing material. The method includes obtaining an infiltrated matrix downhole tool, applying and bonding the intermediate base coat to at least a portion of the surface of the infiltrated matrix downhole tool, and applying and bonding the hardfacing material to at least a portion of the intermediate base coat.

We claim: 
     
         1 . A method for hardfacing an infiltrated matrix downhole tool, comprising:
 obtaining an infiltrated matrix downhole tool fabricated using at least a carbide material and an infiltrating binder material;   applying an intermediate base coat onto at least a portion of a surface of the infiltrated matrix downhole tool;   bonding the intermediate base coat onto at least a portion of the surface of the infiltrated matrix downhole tool;   applying a hardfacing material onto at least a portion of the intermediate base coat; and   bonding the hardfacing material onto at least a portion of the intermediate base coat.   
     
     
         2 . The method of  claim 1 , wherein applying an intermediate base coat comprises:
 heating at least a portion of the infiltrated matrix downhole tool to a first temperature and forming a heated infiltrated matrix downhole tool;   applying the intermediate base coat onto at least a portion of the heated infiltrated matrix downhole tool; and   allowing the heated infiltrated matrix downhole tool to cool to a second temperature.   
     
     
         3 . The method of  claim 2 , wherein the first temperature ranges between about 900 degrees Fahrenheit to about 1250 degrees Fahrenheit. 
     
     
         4 . The method of  claim 2 , wherein the second temperature ranges between about 400 degrees Fahrenheit to about 600 degrees Fahrenheit. 
     
     
         5 . The method of  claim 1 , wherein the hardfacing material comprises a first phase and a second phase, the second phase being a metal matrix material. 
     
     
         6 . The method of  claim 5 , wherein applying the hardfacing material comprises:
 heating the hardfacing material to an operating temperature, the operating temperature being equal to or greater than the melting temperature of the second phase;   applying the hardfacing material onto at least a portion of the intermediate base coat previously bonded to the infiltrated matrix downhole tool; and   allowing the hardfacing material on the intermediate base coat to cool.   
     
     
         7 . The method of  claim 1 , wherein the hardfacing material is applied onto the infiltrated matrix downhole tool using a tube rod, the tube rod comprising a first phase and a second phase, the second phase substantially surrounding the first phase and disposed at one end of the tube rod. 
     
     
         8 . The method of  claim 7 , wherein the first phase comprises at least one of tungsten carbide, titanium carbide, tantalum carbide, titanium diboride, chromium carbide, titanium nitride, aluminum nitride, aluminum oxide, and silicon carbide. 
     
     
         9 . The method of  claim 7 , wherein the second phase comprises at least one of cobalt, iron, nickel, aluminum, copper, magnesium, titanium, and one or more alloys thereof. 
     
     
         10 . The method of  claim 1 , wherein the carbide material is formed using one or more metals selected from a group consisting of titanium, zirconium, halfnium, rutherfordium, vanadium, niobium, tantalum, dubnium, chromium, molybdenum, tungsten, and seaborgium. 
     
     
         11 . The method of  claim 1 , wherein the infiltrating binder material includes at least one of copper, nickel, iron, cobalt, and alloys thereof.