US2015240566A1PendingUtilityA1

Manufacture of low cost bits by infiltration of metal powders

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Assignee: AMUNDSEN MARVIN WINDSORPriority: Feb 21, 2014Filed: Feb 13, 2015Published: Aug 27, 2015
Est. expiryFeb 21, 2034(~7.6 yrs left)· nominal 20-yr term from priority
Inventors:Marvin Windsor AmundsenFederico BellinGary M. ThigpenCharles Daniel Johnson
B22F 1/12B22F 1/09C22C 1/1036C22C 32/0052B22F 7/08B22F 3/26E21B 10/46B22F 7/008B22F 1/0003C22C 33/0292E21B 10/00
39
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Claims

Abstract

An apparatus and method for manufacturing a downhole tool. The cemented matrix material is formed from a metal powder, a shoulder powder, and a binder material, wherein the metal powder and/or the shoulder powder includes at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or powders of other suitable metals or alloys, or a combination of such mentioned powders.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A downhole tool, comprising:
 a metal component comprising a top portion, a bottom portion, and a channel extending from the top portion to the bottom portion; and   an infiltrated metal powder bonded to an exterior surface and an interior surface of the metal component, the infiltrated metal powder formed from infiltration of a binder material with a metal powder, the infiltrated metal powder coupled to at least the bottom portion of the metal component;   an infiltrated shoulder powder bonded to an exterior surface and an interior surface of the metal component, the infiltrated shoulder powder formed from infiltration of the binder material with a shoulder powder, the infiltrated shoulder powder coupled to at least the top portion of the metal component, the infiltrated shoulder powder being positioned above the infiltrated metal powder,   wherein at least one of the metal powder or shoulder powder used for fabricating the downhole tool comprises:
 at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders; and 
 a concentration of less than 25% of a tungsten carbide powder or a tungsten powder, respectively. 
   
     
     
         2 . The downhole tool of  claim 1 , wherein the metal powder comprises at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten carbide powder. 
     
     
         3 . The downhole tool of  claim 1 , wherein the shoulder powder comprises at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten powder. 
     
     
         4 . The downhole tool of  claim 1 , wherein the metal powder and the shoulder powder comprise at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten carbide powder and the tungsten powder, respectively. 
     
     
         5 . The downhole tool of  claim 1 , wherein the metal powder is the same composition as the shoulder powder. 
     
     
         6 . The downhole tool of  claim 1 , wherein the metal powder is a different composition than the shoulder powder. 
     
     
         7 . The downhole tool of  claim 6 , wherein the metal powder and the shoulder powder comprise the same powders. 
     
     
         8 . The downhole tool of  claim 1 , wherein the metal powder is formed of at least more than 25% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         9 . The downhole tool of  claim 1 , wherein the metal powder is formed of at least more than 30% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         10 . The downhole tool of  claim 1 , wherein the metal powder is formed of at least more than 40% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         11 . The downhole tool of  claim 1 , wherein the shoulder powder is formed of at least more than 25% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         12 . The downhole tool of  claim 1 , wherein the shoulder powder is formed of at least more than 30% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         13 . The downhole tool of  claim 1 , wherein the shoulder powder is formed of at least more than 40% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         14 . The downhole tool of  claim 1 , wherein at least one of the metal powder or the shoulder powder comprise a concentration of less than 20% of a tungsten carbide powder or a tungsten powder, respectively. 
     
     
         15 . The downhole tool of  claim 1 , wherein at least one of the metal powder or the shoulder powder comprise a concentration of less than 15% of a tungsten carbide powder or a tungsten powder, respectively. 
     
     
         16 . A method for manufacturing a downhole tool, comprising:
 placing a blank within a downhole tool casting assembly, the blank comprising a top portion, a bottom portion, and a channel extending from the top portion to the bottom portion;   placing a mixture around at least a portion of the surface of the blank within the downhole tool casting assembly, the mixture comprising a metal powder and a shoulder powder, the metal powder positioned adjacent at least the bottom portion of the blank and the shoulder powder being positioned adjacent to at least the top portion of the blank, the shoulder powder being positioned above the metal powder;   melting a binder material into the mixture;   forming an infiltrated metal powder and an infiltrated shoulder powder from the mixture and the binder material; and   bonding the infiltrated metal powder and the infiltrated shoulder powder to the blank,   wherein at least one of the metal powder or shoulder powder used for fabricating the downhole tool comprises:
 at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders; and 
 a concentration of less than 25% of a tungsten carbide powder or a tungsten powder, respectively. 
   
     
     
         17 . The method of  claim 16 , wherein the metal powder comprises at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten carbide powder. 
     
     
         18 . The method of  claim 16 , wherein the shoulder powder comprises at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten powder. 
     
     
         19 . The method of  claim 16 , wherein the metal powder and the shoulder powder comprise at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders and a concentration of less than 25% of the tungsten carbide powder and the tungsten powder, respectively. 
     
     
         20 . The method of  claim 16 , wherein the metal powder is the same composition as the shoulder powder. 
     
     
         21 . The method of  claim 16 , wherein the metal powder is a different composition than the shoulder powder. 
     
     
         22 . The method of  claim 21 , wherein the metal powder and the shoulder powder comprise the same powders. 
     
     
         23 . The method of  claim 16 , wherein the metal powder is formed of at least more than 25% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         24 . The method of  claim 16 , wherein the metal powder is formed of at least more than 30% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         25 . The method of  claim 16 , wherein the metal powder is formed of at least more than 40% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         26 . The method of  claim 16 , wherein the shoulder powder is formed of at least more than 25% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         27 . The method of  claim 16 , wherein the shoulder powder is formed of at least more than 30% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         28 . The method of  claim 16 , wherein the shoulder powder is formed of at least more than 40% of at least one of stainless steel powder, nickel powder, cobalt powder, iron powder, or a combination of two or more of these powders. 
     
     
         29 . The method of  claim 16 , wherein at least one of the metal powder or the shoulder powder comprise a concentration of less than 20% of a tungsten carbide powder or a tungsten powder, respectively. 
     
     
         30 . The method of  claim 16 , wherein at least one of the metal powder or the shoulder powder comprise a concentration of less than 15% of a tungsten carbide powder or a tungsten powder, respectively. 
     
     
         31 . The method of  claim 16 , further comprising applying a hardfacing material onto at least a portion of the downhole tool.

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