Fabrication Method Using Foam Elements, and Structures Fabricated Using The Method
A method of fabricating a structure having an open cell foam element includes providing an open cell foam element of metallic, diamond, ceramic and/or refractory material form, and/or having one or more metallic, diamond, ceramic and/or refractory material coatings, the foam element defining a plurality of interconnected cells. The method further includes locating a material within the cells, and treating the material, in situ, by sintering and/or infiltration, to form a continuous mesh or lattice structure that extends within and through the cells of the open cell foam element. Structures fabricated using the method are also described.
1 . A method of fabrication of a structure, the method comprising:
providing an open cell foam element of metallic, diamond, ceramic and/or refractory material form, and/or having one or more metallic, diamond, ceramic and/or refractory material coatings, the foam element defining a plurality of interconnected cells;
locating a material within the cells; and
treating the material, in situ, by sintering and/or infiltration, to form a continuous mesh or lattice structure extending within and through the cells of the open cell foam element.
2 . A method according to claim 1 wherein the foam element is of metallic form and the method further comprises a step of leaching the metallic material of the foam element.
3 . A method according to claim 1 , wherein the cells of the foam element are irregularly arranged, and the mesh or lattice structure is an irregular mesh or lattice.
4 . A method according to claim 1 , wherein the cells of the foam element are regularly arranged, and the mesh or lattice structure is of regular form.
5 . A method according to claim 1 , wherein the foam element is of pyrolysed organic material form, provided with a metallic, diamond, ceramic and/or refractory material coating.
6 . A method according to claim 5 , wherein the coating is applied using a CVD technique.
7 . A method according to claim 1 , wherein the foam element is of 3D printed construction.
8 . A method according to claim 1 , wherein the foam element has an average pore dimension falling within the range of 0.35 to 2 mm.
9 . A method according to claim 1 , wherein the foam element has a surface area falling within the range of 1600 to 6900 m 2 per m 3 .
10 . A method according to claim 1 , wherein the foam element is of substantially uniform density.
11 . A method according to claim 1 , wherein the foam element is of graded density.
12 . A structure comprising:
an open cell foam element of metallic, diamond, ceramic and/or refractory material form, and/or provided with one or more metallic, diamond, ceramic and/or refractory material coatings, the element defining a plurality of interconnected cells; and
a material located within the cells, the material having been treated, in situ, by sintering and/or infiltration, to form a continuous mesh or lattice structure extending within and through the cells of the open cell foam element.
13 . A structure according to claim 12 and forming part of a downhole tool.
14 . A structure according to claim 13 , wherein the downhole tool comprises a drill bit.
15 . A structure according to claim 14 , and forming a part of a bit body of the drill bit.
16 . A structure according to claim 14 , and forming a part of a cutting element of the drill bit.
17 . A structure comprising:
an open cell foam element defining a plurality of interconnected cells;
tungsten carbide material located within the cells; and
an alloy infiltrated into the tungsten carbide material in the cells such that the infiltrated tungsten carbide material forms a continuous lattice structure extending within and through the cells of the open cell foam element.
18 . A structure according to claim 17 and forming part of a bit body of a downhole tool.
19 . A manufacturing method for use in the manufacture of the structure of claim 17 , the method comprising:
providing an open cell foam material element defining a plurality of interconnected cells;
locating a tungsten carbide material within the cells; and
infiltrating an alloy into the tungsten carbide material in the cells such that the infiltrated tungsten carbide material forms a continuous lattice structure extending within and through the cells of the open cell foam element.
20 . A method according to claim 19 , wherein the foam material element is placed within a mould for a bit body prior to the introduction of tungsten carbide powder material into the mould.
21 . A structure comprising a metallic or refractory material open cell foam element defining a plurality of interconnected cells and diamond material located within the cells, the diamond material having been sintered, in situ, to form a lattice structure extending within the cells of the open cell foam element.
22 . A structure according to claim 21 and forming a cutting element of a downhole drill bit.
23 . A manufacturing method for use in the manufacture of the structure of claim 21 , the method comprising:
providing a metallic or refractory material open cell foam element defining a plurality of interconnected cells;
locating a diamond material within the cells; and
sintering the diamond material, in situ, to form a lattice structure extending within the cells of the open cell foam element.
24 . A structure comprising an open cell foam diamond material element defining a plurality of interconnected cells, and a second diamond material located within the cells, the second diamond material having been sintered, in situ, to form a continuous lattice structure extending within the cells of the open cell foam element.
25 . A method of manufacture of the structure of claim 24 , the method comprising:
providing a structure comprising an open cell foam diamond material element defining a plurality of interconnected cells;
locating a second diamond material within the cells; and
sintering the second diamond material, in situ, to form a lattice structure extending within the cells of the open cell foam element.
26 . A structure comprising a diamond material open cell foam element defining a plurality of interconnected cells, and a material infiltrated into the cells such that the infiltrated material forms a continuous lattice structure extending within and through the cells of the open cell foam element.
27 . A structure according to claim 26 and adapted for use as an abrasive material.
28 . A method of manufacture of the structure of claim 26 , the method comprising: providing a diamond material open cell foam element defining a plurality of interconnected cells, and infiltrating a material into the cells such that the infiltrated material forms a continuous lattice structure extending within and through the cells of the open cell foam element.