Drilling tools having matrices with carbide-forming alloys, and methods of making and using same

Abstract

Drilling tools, such as drill bits, having a shank, a crown, and a plurality of abrasive cutting elements. In the case of impregnated drilling tools, the abrasive cutting elements are dispersed throughout at least a portion of the crown. In the case of surface-set drilling tools, the abrasive cutting media is secured to and projects from a cutting face of the crown. The matrix of the crown of the drilling tools includes a carbide-forming alloy that forms a direct carbide bond with at least one cutting element of the plurality of abrasive cutting elements.

What is claimed is: 
     
         1 . A drilling tool, comprising:
 a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;   a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank, wherein the hard particulate material is a powdered material that comprises one or more of carbide, tungsten, iron, cobalt, and/or molybdenum and carbides, borides, or alloys thereof, and wherein the carbide-forming alloy is provided as a powder; and   a plurality of abrasive cutting elements secured at least partially within the matrix of the crown, wherein the plurality of abrasive cutting elements comprise a plurality of uncoated diamond cutting elements,   wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, and wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond cutting element of the plurality of uncoated diamond cutting elements, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond cutting element and the carbide-forming alloy of the matrix,   wherein the carbide-forming alloy of the matrix is configured to convert portions of said at least one uncoated diamond cutting element to a carbide to form the direct carbide bond between the carbide-forming alloy and said at least one uncoated diamond cutting element.   
     
     
         2 . The drilling tool as recited in  claim 1 , wherein the carbide-forming alloy comprises chromium, titanium, aluminum, or vanadium. 
     
     
         3 . The drilling tool as recited in  claim 1 , wherein the plurality of abrasive cutting elements comprises a plurality of synthetic diamonds, a plurality of thermally stable polycrystalline diamonds, and/or natural diamond. 
     
     
         4 . The drilling tool as recited in  claim 1 , wherein the crown has an annular shape, a longitudinal axis, an inner surface, and an outer surface, wherein the inner surface of the crown defines an interior space about the longitudinal axis, and wherein the interior space is configured to receive a core sample. 
     
     
         5 . The drilling tool as recited in  claim 1 , wherein the drilling tool is infiltrated with the binder. 
     
     
         6 . The drilling tool as recited in  claim 1 , wherein the drilling tool is an all-cast drilling tool. 
     
     
         7 . The drilling tool as recited in  claim 6 , wherein the drilling tool is a reamer. 
     
     
         8 . The drilling tool as recited in  claim 1 , wherein the drilling tool is an impregnated drilling tool, and wherein the plurality of abrasive cutting elements are dispersed throughout at least a portion of the crown body, optionally wherein the impregnated drilling tool is an impregnated drill bit. 
     
     
         9 . The drilling tool as recited in  claim 8 , further comprising a plurality of fibers dispersed in an unorganized arrangement throughout at least a portion of the crown body, optionally wherein at least a portion of the plurality abrasive cutting elements are dispersed within the crown body proximate the cutting face. 
     
     
         10 . The drilling tool as recited in  claim 1 , wherein the drilling tool is a surface-set drilling tool, and wherein the plurality of abrasive cutting elements are secured to and project from the cutting face of the crown. 
     
     
         11 . The drilling tool as recited in  claim 1 , wherein the plurality of abrasive cutting elements comprises at least one abrasive cutting element that is not configured to form a carbide bond with the carbide-forming alloy. 
     
     
         12 . The drilling tool as recited in  claim 1 , wherein the binder does not comprise a carbide-forming material. 
     
     
         13 . A drilling system, comprising:
 a drill string configured for rotation; and   a drilling tool secured to the drill string, wherein the drilling tool comprises:   a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;   a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank, wherein the hard particulate material is a powdered material that comprises one or more of carbide, tungsten, iron, cobalt, and/or molybdenum and carbides, borides, or alloys thereof, and wherein the carbide-forming alloy is provided as a powder; and   a plurality of abrasive cutting elements secured at least partially within the matrix of the crown, wherein the plurality of abrasive cutting elements comprise a plurality of uncoated diamond cutting elements,   wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, and wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond cutting element of the plurality of uncoated diamond cutting elements, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond cutting element and the carbide-forming alloy of the matrix, and   wherein the carbide-forming alloy of the matrix is configured to convert portions of said at least one uncoated diamond cutting element to a carbide to form the direct carbide bond between the carbide-forming alloy and said at least one uncoated diamond cutting element.   
     
     
         14 . The drilling system as recited in  claim 13 , further comprising:
 a drill rig, wherein the drill string is adapted to be secured to and rotated by the drill rig;   or   a down-hole motor, wherein the drill string is adapted to be secured to and rotated by the down-hole motor.   
     
     
         15 . A method of forming a drilling tool, comprising:
 preparing a matrix comprising hard particulate material and a carbide-forming alloy, wherein the hard particulate material is a powdered material that comprises one or more of carbide, tungsten, iron, cobalt, and/or molybdenum and carbides, borides, or alloys thereof, and wherein the carbide-forming alloy is provided as a powder;   securing a plurality of abrasive cutting elements within at least a portion of the matrix, wherein the plurality of abrasive cutting elements comprise a plurality of uncoated diamond cutting elements;   infiltrating the matrix with a binder;   securing a shank to the matrix, the shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component; and   heating the shank and the matrix to consolidate a drilling tool,   wherein a crown of the drilling tool extends from the second end of the shank, the crown comprising the matrix, the binder, a cutting face, and a crown body between the cutting face and the shank,   wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, and wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond cutting element of the plurality of uncoated diamond cutting elements, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond cutting element and the carbide-forming alloy of the matrix, and   wherein the carbide-forming alloy of the matrix is configured to convert portions of said at least one uncoated diamond cutting element to a carbide to form the direct carbide bond between the carbide-forming alloy and said at least one uncoated diamond cutting element.   
     
     
         16 . The method as recited in  claim 15 , wherein the drilling tool is formed using a casting process. 
     
     
         17 . The method of  claim 16 , wherein the drilling tool is a drill bit. 
     
     
         18 . The method of  claim 16 , wherein the drilling tool is a reamer. 
     
     
         19 . The method as recited in  claim 15 , wherein the method does not comprise multiple heating operations.