Tools having a structural metal-matrix composite portion

Abstract

Structural metal-matrix composites (MMC) comprising a foam matrix material infiltrated with a binder material, where the binder material binds the foam matrix material to a structural element of a tool, thereby enhancing three-dimensional reinforcement of the tool. In some instances, the structural element is a portion of a wellbore tool or a bit body, such that portions of such tools or bit bodies are composed of the structural MMC. The foam matrix material may be composed of a metallic foam, a ceramic foam, and any combination thereof.

What is claimed is: 
     
         1 . A structural metal-matrix composite (MMC) comprising:
 a foam matrix material having a cellular structure, the foam matrix material selected from the group consisting of a metallic foam, a ceramic foam, and any combination thereof;   a structural element of a tool; and   a binder material infiltrated through the cellular structure of the foam matrix material to bind the foam matrix material and the structural element of the tool.   
     
     
         2 . The structural MMC of  claim 1 , wherein the cellular structure of the foam matrix material is an open-cell foam structure or a closed-cell foam structure. 
     
     
         3 . The structural MMC of  claim 1 , wherein the foam matrix material comprises the metallic foam composed of a metallic material selected from the group consisting of a metal, a metal alloy, a metal carbide, a superalloy, and any combination thereof. 
     
     
         4 . The structural MMC of  claim 1 , wherein the foam matrix material comprises the ceramic foam composed of a ceramic material selected from the group consisting of an oxide ceramic, a boride ceramic, a nitride ceramic, a silicate ceramic, a carbide ceramic, diamond, and any combination thereof. 
     
     
         5 . The structural MMC of  claim 1 , wherein the structural MMC further comprises reinforcement particulates. 
     
     
         6 . The structural MMC of  claim 1 , wherein the binder material is at least partially selected from the group consisting of copper, nickel, manganese, zinc, and any combination thereof. 
     
     
         7 . The structural MMC of  claim 1 , wherein the structural element of the tool corresponds to a portion of a wellbore tool. 
     
     
         8 . The structural MMC of  claim 1 , wherein the structural element of the tool corresponds to a bit body of a drill bit. 
     
     
         9 . A method comprising:
 placing a foam matrix material in a region of a mold, the foam matrix material having a cellular structure and selected from the group consisting of a metallic foam, a ceramic foam, and any combination thereof;   placing a binder material in the mold;   placing a structural element of a tool in the mold;   heating the mold, the foam matrix material, the binder material, and the structural element of the tool to a temperature above the melting point of the binder material;   infiltrating the cellular structure of the foam matrix material with the binder material; and   cooling the mold, the foam matrix material, the binder material, and the structural element of the tool, wherein the infiltrated binder material binds the foam matrix material and the structural element of the tool.   
     
     
         10 . The method of  claim 9 , wherein the cellular structure of the foam matrix material is an open-cell foam structure or a closed-cell foam structure. 
     
     
         11 . The method of  claim 9 , wherein the structural MMC further comprises reinforcement particulates. 
     
     
         12 . The method of  claim 9 , wherein the foam matrix material melts into, dissolves into, diffuses into, or reacts with the binder material during infiltration of the foam matrix material with the binder material, thereby forming a networked ductile phase. 
     
     
         13 . The method of  claim 9 , wherein the foam matrix material reacts with the binder material during infiltration of the foam matrix material with the binder material, thereby forming an intermetallic phase. 
     
     
         14 . The method of  claim 9 , wherein the mold corresponds to all or a portion of a wellbore tool mold. 
     
     
         15 . The method of  claim 9 , wherein the mold corresponds to all or a portion of a drill bit. 
     
     
         16 . The method of  claim 9 , wherein the mold corresponds to a bit body of a drill bit. 
     
     
         17 . A drilling assembly comprising:
 a drill string extendable from a drilling platform and into a wellbore;   a drill bit attached to an end of the drill string and including a bit body and a plurality of cutting elements coupled to an exterior portion of the bit body, the bit body composed of a structural metal-matrix composite (MMC) comprising:
 a foam matrix material having a cellular structure, the foam matrix material selected from the group consisting of a metallic foam, a ceramic foam, and any combination thereof; 
 the bit body; and 
 a binder material infiltrated through the cellular structure of the foam matrix material to bind the foam matrix material and the bit body; and 
   a pump fluidly connected to the drill string and configured to circulate a drilling fluid to the drill bit through the wellbore.   
     
     
         18 . The drilling assembly of  claim 17 , wherein the cellular structure of the foam matrix material is an open-cell foam structure or a closed-cell foam structure. 
     
     
         19 . The drilling assembly of  claim 17 , wherein the foam matrix material comprises the metallic foam composed of a metallic material selected from the group consisting of a metal, a metal alloy, a metal carbide, a superalloy, and any combination thereof. 
     
     
         20 . The drilling assembly of  claim 17 , wherein the foam matrix material comprises the ceramic foam composed of a ceramic material selected from the group consisting of an oxide ceramic, a boride ceramic, a nitride ceramic, a silicate ceramic, a carbide ceramic, diamond, and any combination thereof.