IP Library Granted Patent US 8,978,734
Granted Patent B2
US 8,978,734 · App. 13/111,739 · Granted Mar 17, 2015

Methods of forming at least a portion of earth-boring tools, and articles formed by such methods

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Quick Facts
Patent No.
US 8,978,734
App. No.
13/111,739
Granted
Mar 17, 2015
Kind
B2
Abstract

Methods of forming at least a portion of an earth-boring tool include providing particulate matter including a hard material in a mold cavity, melting a metal and the hard material to form a molten composition comprising a eutectic or near-eutectic composition of the metal and the hard material, casting the molten composition to form the at least a portion of an earth-boring tool within the mold cavity, and providing an inoculant within the mold cavity. Methods of forming a roller cone of an earth-boring rotary drill bit include forming a molten composition, casting the molten composition within a mold cavity, solidifying the molten composition to form the roller cone, and controlling grain growth using an inoculant as the molten composition solidifies. Articles including components of earth-boring tools are fabricated using such methods.

Claims (26)

1. A method of forming at least a portion of an earth-boring tool, comprising:

providing particulate matter comprising a hard material in a mold cavity;

melting a metal and the hard material to form a molten composition comprising a eutectic or near-eutectic composition of the metal and the hard material;

casting the molten composition to form the at least a portion of an earth-boring tool within the mold cavity; and

providing an inoculant within the mold cavity.

2. The method of claim 1 , further comprising adjusting a stoichiometry of at least one hard material phase of the at least a portion of the earth-boring tool.

3. The method of claim 2 , wherein adjusting a stoichiometry of at least one hard material phase of the at least a portion of the earth-boring tool comprises converting at least one of an M 6 C phase and an M 12 C phase to at least one of an MC phase and an M 2 C phase, wherein M is at least one metal element and C is carbon.

4. The method of claim 3 , wherein converting at least one of an M 6 C phase and an M 12 C phase to at least one of an MC phase and an M 2 C phase comprises converting W x Co y C to WC, wherein x is from about 0.5 to about 6 and y is from about 0.5 to about 6.

5. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising from about 40% to about 90% cobalt or cobalt-based alloy by weight and from about 0.5% to about 3.8% carbon by weight, wherein a balance of the mixture is at least substantially comprised of tungsten.

6. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising from about 55% to about 85% cobalt or cobalt-based alloy by weight and from about 0.85% to about 3.0% carbon by weight, wherein a balance of the mixture is at least substantially comprised of tungsten.

7. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising from about 65% to about 78% cobalt or cobalt-based alloy by weight and from about 1.3% to about 2.35% carbon by weight, wherein a balance of the mixture is at least substantially comprised of tungsten.

8. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises melting a mixture comprising about 69% cobalt or cobalt-based alloy by weight, about 1.9% carbon by weight, and about 29.1% tungsten by weight.

9. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises melting about 75% cobalt or cobalt-based alloy by weight, about 1.53% carbon by weight, and about 23.47% tungsten by weight.

10. The method of claim 1 , wherein providing the inoculant comprises providing at least one of a transition metal aluminate, a transition metal metasilicate, and a transition metal oxide.

11. The method of claim 1 , wherein providing the inoculant comprises providing at least one of cobalt aluminate, cobalt metasilicate, and cobalt oxide.

12. The method of claim 1 , wherein melting a metal and a hard material to form a molten composition comprises forming a eutectic or near-eutectic composition of cobalt and tungsten carbide.

13. The method of claim 1 , wherein providing the inoculant comprises controlling grain growth as the molten composition solidifies.

14. A method of forming a roller cone of an earth-boring rotary drill bit, comprising:

forming a molten composition comprising a eutectic or near-eutectic composition of cobalt and tungsten carbide;

casting the molten composition within a mold cavity;

solidifying the molten composition within the mold cavity to form the roller cone; and

controlling grain growth using an inoculant as the molten composition solidifies within the mold cavity.

15. The method of claim 14 , further comprising converting at least one of a W 3 Co 3 C phase region and a W 6 Co 6 C phase region within the roller cone to at least one of WC and W 2 C.

16. The method of claim 14 , wherein forming a molten composition comprises forming a molten composition comprising about 69% cobalt or cobalt-based alloy by weight, about 1.9% carbon by weight, and about 29.1% tungsten by weight.

17. The method of claim 14 , wherein controlling grain growth comprises adding at least one of a transition metal aluminate, a transition metal metasilicate, and a transition metal oxide to the mold cavity.

18. The method of claim 14 , wherein controlling grain growth comprises adding at least one of cobalt aluminate, cobalt metasilicate, and cobalt oxide to the mold cavity.

Assignments (3)
CHANGE OF NAME Recorded Nov 30, 2022
From: BAKER HUGHES, A GE COMPANY, LLC
To: BAKER HUGHES HOLDINGS LLC
Reel/Frame 062020/0408 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 19, 2022
From: BAKER HUGHES INCORPORATED
To: BAKER HUGHES, A GE COMPANY, LLC.
Reel/Frame 061754/0380 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 19, 2011
From: STEVENS, JOHN H.
To: BAKER HUGHES INCORPORATED
Reel/Frame 026311/0712 →