Downhole tool parts and compositions thereof
View Patent ↗Methods, systems, and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to the external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.
1. A downhole tool part for drilling subterranean material, the downhole tool part having a composition comprising:
a continuous composite matrix material comprising a eutectic or near eutectic composition, the eutectic or near eutectic composition comprising a carbide and at least one of cobalt, iron, and nickel; and
a particulate material dispersed within the continuous composite matrix material, the particulate material comprising at least one constituent selected from the group consisting of: polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), and polycrystalline cubic boron nitride (PCBN).
2. The downhole tool part of claim 1 , wherein the particulate material is evenly distributed throughout the continuous composite matrix material.
3. The downhole tool part of claim 1 , wherein the continuous composite matrix material comprises a eutectic or near eutectic composition of cobalt and monotungsten carbide (WC).
4. The downhole tool part of claim 3 , wherein the eutectic or near eutectic composition comprises about 75 atomic percent cobalt and about 25 atomic percent monotungsten carbide (WC).
5. The downhole tool part of claim 4 , wherein the eutectic or near eutectic composition has a eutectic temperature of about 1357° C.
6. The downhole tool part of claim 1 , wherein the eutectic or near eutectic composition does not include any melting point depressing additives.
7. A downhole tool part for drilling subterranean material, the downhole tool part having a composition comprising:
a continuous composite matrix material comprising a eutectic or near eutectic composition;
a particulate material dispersed within the continuous composite matrix material, the particulate material comprising at least one constituent selected from the group consisting of: polycrystalline diamond compact (PDC) thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), and polycrystalline cubic boron nitride (PCBN); and
a sub-stoiciometric phase having the formula M x C, where M is cobalt or tungsten, C is carbide, and x is a number between 1 and 6.
8. A downhole tool part for drilling subterranean material, the downhole tool part having a composition comprising:
a continuous composite matrix material comprising a eutectic or near eutectic composition, the eutectic or near eutectic composition comprising a carbide and at least one metal; and
a particulate material dispersed within the continuous composite matrix material, the particulate material comprising at least one constituent selected from the group consisting of: polycrystalline diamond compact (PDC), thermally stable polycrystalline diamond (TSP), cubic boron nitride (CBN), and polycrystalline cubic boron nitride (PCBN);
wherein the downhole tool part is a bit body or a roller cone.