Abstract:
Earth-boring drill bits include a bit body, an element having an attachment feature bonded to the bit body, and a shank assembly. Methods for assembling an earth-boring rotary drill bit include bonding a threaded element to the bit body of a drill bit and engaging the shank assembly to the threaded element. In additional embodiments, a nozzle assembly for an earth-boring rotary drill bit may include a cylindrical sleeve having a threaded surface and a threaded nozzle disposed at least partially in the cylindrical sleeve and engaged therewith. Methods of forming an earth-boring drill bit include providing a nozzle assembly including a tubular sleeve and nozzle at least partially within a nozzle port of a bit body.
Abstract:
Geometric compensation techniques are used to improve the accuracy by which features may be located on drill bits formed using particle compaction and sintering processes. In some embodiments, a positional error to be exhibited by at least one feature in a less than fully sintered bit body upon fully sintering the bit body is predicted and the at least one feature is formed on the less than fully sintered bit body at a location at least partially determined by the predicted positional error. In other embodiments, bit bodies of earth-boring rotary drill bits are designed to include a design drilling profile and a less than fully sintered bit body is formed including a drilling profile having a shape differing from a shape of the design drilling profile. Less than fully sintered bit bodies of earth-boring rotary drill bits are formed using such methods.
Abstract:
Insertable devices include a body and at least one substantially circumferential groove in an outer surface of the body. An aperture in a receiving device comprises at least one annular recess extending radially into a sidewall thereof. At least one resilient split ring fits partially into both the at least one substantially circumferential groove of the insertable device and the at least one annular recess in the aperture. Methods of inserting the insertable device into a receiving device and of removing the insertable device from a receiving device are also disclosed.
Abstract:
Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC-SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC-SiC material, and the ABC-SiC material may be toughened to increase a fracture toughness exhibited by the ABC-SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.
Abstract:
Methods for welding a particle-matrix composite body (120) to another body (154) and repairing particle-matrix composite bodies (120) are disclosed. Additionally, earth-boring tools (110) having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body (120) of an earth-boring tool (100) may be repaired by removing a damaged portion, heating the particle-matrix composite bit body (120), and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body (120) may be welded to a metallic body (154) by forming a joint, heating the particle-matrix composite body (120), melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body (120), metallic filler material and metallic body (154) at a controlled rate.
Abstract:
Methods of forming cutting element pockets in earth-boring tools include machining at least one recess (52) to define at least one surface of a cutting element pocket using a cutter (56) oriented at an angle to a longitudinal axis of the cutting element pocket. Methods of forming earth-boring tools include forming a bit body (50) and forming at least one cutting element pocket therein using a rotating cutter oriented at an angle relative to a longitudinal axis (60) of the cutting element pocket being formed. Earth-boring tools have a bit body comprising a first surface defining a lateral sidewall (55) of a cutting element pocket, a second surface defining an end wall (66) of the cutting element pocket, and another surface defining a groove located between the first and second surfaces that extends into the body to enable a cutting element (18) to abut against an area of the lateral sidewall and end wall of the pocket.
Abstract:
Methods of forming earth-boring rotary drill bits by forming and joining two or less than fully sintered components, by forming and joining a first fully sintered component with a first shrink rate and forming a second less than fully sintered component with a second sinter-shrink rate greater that that of the first shrink rate of the first fully sintered component, by forming and joining a first less than fully sintered component with a first sinter-shrink rate and by forming and joining at least a second less than fully sintered component with a second sinter-shrink rate less than the first sinter- shrink rate. The methods include co-sintering a first less than fully sintered component and a second less than fully sintered component to a desired final density to form at least a portion of an earth-boring rotary drill bit which may either cause the first less than fully sintered component and the second less than fully sintered component to join or may cause one of the first less than fully sintered component and the second less than fully sintered component to shrink around and at least partially capture the other less than fully sintered component. Earth-boring rotary drill bits are formed using such methods.
Abstract:
Earth-boring rotary drill bits including a bit body attached to a shank assembly at a joint. In some embodiments, the joint may be configured to carry at least a portion of any tensile longitudinal and rotational load applied to the drill bit by mechanical interference at the joint. In additional embodiments, the joint may be configured to carry a selected portion of any tensile longitudinal load applied to the drill bit. Methods for attaching a shank assembly to a bit body of an earth-boring rotary drill bit include configuring a joint to carry at least a portion of any tensile longitudinal and rotational load applied to the drill bit by mechanical interference. Additional embodiments include configuring a joint to carry a selected portion of any tensile longitudinal load applied to the drill bit by mechanical interference.
Abstract:
Methods of forming cutting element pockets in earth-boring tools include machining at least one recess (52) to define at least one surface of a cutting element pocket using a cutter (56) oriented at an angle to a longitudinal axis of the cutting element pocket. Methods of forming earth-boring tools include forming a bit body (50) and forming at least one cutting element pocket therein using a rotating cutter oriented at an angle relative to a longitudinal axis (60) of the cutting element pocket being formed. Earth-boring tools have a bit body comprising a first surface defining a lateral sidewall (55) of a cutting element pocket, a second surface defining an end wall (66) of the cutting element pocket, and another surface defining a groove located between the first and second surfaces that extends into the body to enable a cutting element (18) to abut against an area of the lateral sidewall and end wall of the pocket.
Abstract:
Methods for forming bodies of earth-boring drill bits and other tools include milling a plurality of hard particles and a plurality of particles comprising a matrix material to form a mill product comprising powder particles, separating the particles into a plurality of particle size fractions. Some of the particles from the fractions may be combined to form a powder mixture, which may be pressed to form a green body. Additional methods include mixing a plurality of hard particles and a plurality of particles comprising a matrix material to form a powder mixture, and pressing the powder mixture with pressure having an oscillating magnitude to form a green body. In yet additional methods a powder mixture may be pressed within a deformable container to form a green body and drainage of liquid from the container is enabled as the powder mixture is pressed.