Matrix powder for matrix body fixed cutter bits

Abstract

A drill bit is disclosed that has a bit body with a plurality of blades extending radially therefrom and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades. At least a portion of the plurality of blades has a first matrix region made of a plurality of first carbide particles separated by a first binder phase, wherein the plurality of first carbide particles have a mean free path of at least 40 microns.

1 .- 10 . (canceled) 
     
     
         11 . A drill bit, comprising:
 a bit body having a plurality of blades extending radially therefrom, at least a portion of the plurality of blades comprises a first matrix region comprising a plurality of first carbide particles separated by a first binder phase, wherein the plurality of first carbide particles have a mean free path of at least 40 microns; and   at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.   
     
     
         12 . The drill bit of  claim 11 , wherein the plurality of first carbide particles have a mean free path of at least 50 microns. 
     
     
         13 . The drill bit of  claim 12 , wherein the plurality of first carbide particles have a mean free path of at least 60 microns. 
     
     
         14 . The drill bit of  claim 11 , wherein the first binder phase comprises from about 35 to 55 percent by volume of the first matrix region. 
     
     
         15 . The drill bit of  claim 14 , wherein the first binder phase comprises from about 40 to 50 percent by volume of the first matrix region. 
     
     
         16 . The drill bit of  claim 12 , wherein the first matrix region is formed from a first matrix powder and an infiltrant binder, the matrix powder consisting essentially of:
 a plurality of first carbide particles having a particle size distribution of ±20% of a median particle size; and   a plurality of first binder particles.   
     
     
         17 . The drill bit of  claim 11 , wherein at least a portion of the plurality of blades comprises a second matrix region comprising a plurality of second carbide particles separated by a second binder phase, wherein the plurality of second carbide particles have a particle size distribution of greater than ±20% of a median particle size. 
     
     
         18 . The drill bit of  claim 17 , wherein the plurality of second carbide particles comprise at least one of cemented tungsten carbide, cast tungsten carbide, macrocrystalline tungsten carbide, carburized tungsten carbide, and combinations thereof. 
     
     
         19 . The drill bit of  claim 17 , wherein the plurality of second carbide particles comprise at least two types of carbide particles each having a particle size distribution of greater than ±20% of a median particle size for each type of carbide particle. 
     
     
         20 . The drill bit of  claim 17 , wherein the first matrix region forms a cutting portion of the plurality of blades, and the second matrix region forms a base portion of the plurality of blades. 
     
     
         21 . A drill bit, comprising:
 a bit body having a plurality of blades extending radially therefrom, at least a portion of the plurality of blades comprises a first matrix region comprising a plurality of first carbide particles separated by a first binder phase;
 wherein the plurality of first carbide particles have a particle size distribution of ±20% of a median particle size; 
 wherein the median particle size greater than 50 microns; and 
   at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.   
     
     
         22 . The drill bit of  claim 21 , wherein the first binder phase comprises from about 35 to 55 percent by volume of the first matrix region. 
     
     
         23 . The drill bit of  claim 21 , wherein at least a portion of the plurality of blades comprises a second matrix region comprising a plurality of second carbide particles separated by a second binder phase. 
     
     
         24 . The drill bit of  claim 21 , wherein the plurality of first carbide particles comprise at least one of cast tungsten carbide, cemented tungsten carbide, and macrocrystalline tungsten carbide. 
     
     
         25 . A drill bit, comprising:
 a bit body having a plurality of blades extending radially therefrom, at least a portion of the plurality of blades comprises a first region comprising a plurality of first particles separated by a first binder phase;
 wherein the plurality of first particles have a particle size distribution of ±20% of a median particle size; and 
   at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.   
     
     
         26 . The drill bit of  claim 25 , wherein the first binder phase comprises from about 35 to 55 percent by volume of the first matrix region. 
     
     
         27 . The drill bit of  claim 25 , wherein the plurality of first particles comprises tungsten carbide. 
     
     
         28 . The drill bit of  claim 25 , wherein at least a portion of the plurality of blades comprises a second region comprising a plurality of carbide particles. 
     
     
         29 . The drill bit of  claim 28 , wherein the plurality of carbide particles are separated by a second binder phase. 
     
     
         30 . The drill bit of  claim 28 , wherein the plurality of carbide particles are separated by the first binder phase.