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EP2118329A1 - A hardfacing material for hardfacing earth boring bits used in abrasive wear environments and a method of manufacturing the same - Google Patents

A hardfacing material for hardfacing earth boring bits used in abrasive wear environments and a method of manufacturing the same

Info

Publication number
EP2118329A1
EP2118329A1 EP07853447A EP07853447A EP2118329A1 EP 2118329 A1 EP2118329 A1 EP 2118329A1 EP 07853447 A EP07853447 A EP 07853447A EP 07853447 A EP07853447 A EP 07853447A EP 2118329 A1 EP2118329 A1 EP 2118329A1
Authority
EP
European Patent Office
Prior art keywords
hard component
hardfacing
tungsten carbide
matrix
downhole tool
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP07853447A
Other languages
German (de)
French (fr)
Inventor
James L. Overstreet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Baker Hughes Holdings LLC
Original Assignee
Baker Hughes Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Baker Hughes Inc filed Critical Baker Hughes Inc
Publication of EP2118329A1 publication Critical patent/EP2118329A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
    • C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/50—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of roller type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware

Definitions

  • the present invention relates in general to hardfacing and, in particular, to an improved highly abrasive wear metal matrix composite hardfacing materials, such as for downhole tools.
  • earth-boring bits 15 It is a long-standing practice in the design and manufacture of earth-boring bits 15 to apply wear-resistant hardfacing materials to the surfaces of such bits that are subjected to abrasive wear during drilling operations, hi earth-boring bits of the rolling cutter variety, these surfaces include the teeth of bits of the milled or steel tooth variety, the gage surfaces of the rolling cutters and the shirttails of the bit legs comprising the bit body.
  • these hardfacing compositions generally comprise carbides of the elements of Groups IVB, VB and VIB in a matrix metal of iron, cobalt or nickel and alloys and mixtures thereof.
  • the hardfacing is applied by melting the matrix and a portion of the surface to which the hardfacing is applied with an oxyacetylene or atomic hydrogen torch.
  • the carbide particles give the hardfacing material hardness and wear 25 resistance, while the matrix metal lends the hardfacing fracture toughness.
  • a hardfacing composition must strike an adequate balance between wear resistance (hardness) and fracture toughness.
  • a hardfacing composition that is extremely hard and wear-resistant may lack fracture toughness, causing the hardfacing to crack and flake prematurely. Conversely, a hardfacing with adequate fracture toughness, but inadequate hardness 30 and wear resistance, is eroded prematurely and fails to serve its purpose.
  • U.S. Pat. No. 4,836,307 to Keshavan, discloses a hardfacing composition employing particles of cemented or sintered tungsten carbide and relatively small particles of single crystal monotungsten carbide, sometimes referred to as "macrocrystalline" tungsten carbide, in a mild steel matrix.
  • This composition purports to possess the advantages of sintered tungsten carbide, as disclosed in U.S. Pat. No. 3,800,891, with the advantages of single crystal monotungsten carbide, which is harder than the cemented or sintered tungsten carbide, yet is less brittle than the alternative cast carbide.
  • U.S. Pat. No. 5,089,182 discloses a method of manufacturing cast carbide pellets that are generally spherical in shape and have improved mechanical and metallurgical properties over prior-art carbide pellets. These cast pellets are not truly spherical, but are sufficiently symmetrical that residual stresses in the pellets are minimized. Also, the generally spherical shape of these pellets eliminates corners, sharp edges and angular projections, which are present in conventional crushed particles, that increase residual stresses in the particles and tend to melt as the hardfacing composition is applied to the surface.
  • U.S. Pat. No. 5,663,512 discloses a hardfacing composition which includes a quantity of spherical sintered tungsten carbide granules and a quantity of cast spherical cast tungsten carbide granules in a eutectic form of WC/W2C. During application, some melting of the sintered spherical carbide granules occurs, which precipitates into the metal matrix and coats the spherical WC/W2C granules.
  • Embodiments of a system, method, and apparatus for a highly abrasive wear metal matrix composite hardfacing material for downhole tools are disclosed.
  • the hardfacing material may comprise a matrix of relatively softer material with high hardness, such as amorphous nanocomposite steel alloys, and one or more hard component materials.
  • the hard component materials may comprise sintered tungsten carbide (e.g., WC/Co), monocrystalline WC, multicrystalline or polycrystalline WC, and the additional component of spherical cast tungsten carbide (e.g., a eutectic of
  • WC/W2C WC/W2C
  • a matrix of softer material, hard component materials and crushed cast tungsten carbide may be used.
  • FIG. 1 is an isometric view of one embodiment of a bit constructed in accordance with the present invention
  • FIG. 2 is a micrograph illustration of one embodiment of hardfacing material constructed in accordance with the invention
  • FIG. 3 is a micrograph illustration of another embodiment of hardfacing material constructed in accordance with the invention.
  • Hardfacing materials formed from amorphous nanocomposite steel alloys such as NANOSTEEL®, such as those now commercially available for plasma transferred arc (PTA) welding applications. Some recent materials are reported to have high hardness while retaining their toughness, which is desirable for impact loading.
  • sintered tungsten carbide or cast tungsten carbide e.g., spherical or crushed, monocrystalline or polycrystalline WC, or other carbide formers may be used as the hard component materials in the softer amorphous nanocomposite steel alloys to achieve even better wear resistance without losing toughness or compromising the end deposit.
  • these hard component materials especially spherical sintered tungsten carbide pellets and/or spherical cast tungsten carbide, superior wear resistant compositions are achieved.
  • FIG. 1 one embodiment of a highly abrasive wear metal matrix composite hardfacing material 21 is shown.
  • the hardfacing material may comprise a matrix 11 of a softer material with high hardness (e.g., a minimum of 60 Rc, and in some embodiments, 65+ Rc, e.g., 72 Rc) such as amorphous nanocomposite steel alloys (e.g., NANOSTEEL®) and one or more hard component materials.
  • a softer material with high hardness e.g., a minimum of 60 Rc, and in some embodiments, 65+ Rc, e.g., 72 Rc
  • amorphous nanocomposite steel alloys e.g., NANOSTEEL®
  • the hard component materials may be selected from, for example, sintered tungsten carbide (e.g., WC/Co) (spherical 13 or crushed 15), monocrystalline WC, macrocrystalline WC, multicrystal or polycrystalline WC and, in some embodiments, the additional component of spherical cast tungsten carbide (e.g., a eutectic of WC/W2C) 17, each of which may be crushed in form.
  • a matrix 31 of relatively softer material e.g., amorphous nanocomposite steel alloy
  • hard component materials such as monocrystalline WC 33 and crushed cast tungsten carbide 35.
  • the invention may comprise numerous different size ratios between the various components.
  • the particle size for each component may range from, for example, mesh -16 to +325.
  • the distribution between the components also may be formulated in weight percentages as, for example, 30wt% soft component and 70wt% hard component.
  • the range for other embodiments comprises a soft component low end of about 20wt% to a soft component high end of 90%, with complementary hard component low and high ends at 10wt% and 80wt%.
  • the hard component may comprise up to 100% sintered tungsten carbide (e.g., crushed or spherical), or less than 100% spherical cast tungsten carbide (e.g., crushed), or mono- , macro- or polycrystalline WC, or any combination thereof.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Powder Metallurgy (AREA)
  • Earth Drilling (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Drilling Tools (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

A highly abrasive wear metal matrix composite hardfacing material for downhole tools is disclosed. The hardfacing material may comprise a matrix of a softer material with high hardness, such as amorphous nanocomposite steel alloys, and one or more hard component materials. The hard component materials may comprise sintered tungsten carbide, monocrystalline WC, polycrystalline WC, and the additional component of spherical cast tungsten carbide. Alternatively, a matrix of softer material, hard component materials and crushed cast tungsten carbide may be used.

Description

A HARDFACING MATERIAL FOR HARDFACING EARTH BORING BITS USED IN ABRASIVE WEAR
ENVIRONMENTS AND A METHOD OF MANUFACTURING THE SAME.
5 PRIORITY CLAIM
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/871,270, filed December 21, 2006, and U.S. Utility Patent Application Serial No. 11/954,909, filed December 12, 2007.
TECHNICAL FIELD
10 The present invention relates in general to hardfacing and, in particular, to an improved highly abrasive wear metal matrix composite hardfacing materials, such as for downhole tools.
BACKGROUND
It is a long-standing practice in the design and manufacture of earth-boring bits 15 to apply wear-resistant hardfacing materials to the surfaces of such bits that are subjected to abrasive wear during drilling operations, hi earth-boring bits of the rolling cutter variety, these surfaces include the teeth of bits of the milled or steel tooth variety, the gage surfaces of the rolling cutters and the shirttails of the bit legs comprising the bit body.
20 In the past, these hardfacing compositions generally comprise carbides of the elements of Groups IVB, VB and VIB in a matrix metal of iron, cobalt or nickel and alloys and mixtures thereof. The hardfacing is applied by melting the matrix and a portion of the surface to which the hardfacing is applied with an oxyacetylene or atomic hydrogen torch. The carbide particles give the hardfacing material hardness and wear 25 resistance, while the matrix metal lends the hardfacing fracture toughness. A hardfacing composition must strike an adequate balance between wear resistance (hardness) and fracture toughness. A hardfacing composition that is extremely hard and wear-resistant may lack fracture toughness, causing the hardfacing to crack and flake prematurely. Conversely, a hardfacing with adequate fracture toughness, but inadequate hardness 30 and wear resistance, is eroded prematurely and fails to serve its purpose.
Many factors affect the suitability of a hardfacing composition for a particular application. These factors include the chemical composition and physical structure of the carbides employed in the composition, the chemical composition and microstructure of the matrix metal or alloy, and the relative proportions of the carbide materials to one another and to the matrix metal or alloy.
One early advance in hardfacing compositions for use in earth-boring bits is disclosed in commonly assigned U.S. Pat. No. 3,800,891, to White. This patent discloses a hardfacing composition comprising sintered tungsten carbide in an alloy steel matrix. Sintered tungsten carbide comprises grains or particles of tungsten carbide sintered with and held together by a binder of non-carbide material, such as cobalt. The sintered tungsten carbide possesses greater fracture toughness than the more conventional cast tungsten carbide, such that the resulting hardfacing composition possess good fracture toughness without sacrificing hardness and wear resistance.
U.S. Pat. No. 4,836,307, to Keshavan, discloses a hardfacing composition employing particles of cemented or sintered tungsten carbide and relatively small particles of single crystal monotungsten carbide, sometimes referred to as "macrocrystalline" tungsten carbide, in a mild steel matrix. This composition purports to possess the advantages of sintered tungsten carbide, as disclosed in U.S. Pat. No. 3,800,891, with the advantages of single crystal monotungsten carbide, which is harder than the cemented or sintered tungsten carbide, yet is less brittle than the alternative cast carbide.
U.S. Pat. No. 5,089,182, to Findeisen, discloses a method of manufacturing cast carbide pellets that are generally spherical in shape and have improved mechanical and metallurgical properties over prior-art carbide pellets. These cast pellets are not truly spherical, but are sufficiently symmetrical that residual stresses in the pellets are minimized. Also, the generally spherical shape of these pellets eliminates corners, sharp edges and angular projections, which are present in conventional crushed particles, that increase residual stresses in the particles and tend to melt as the hardfacing composition is applied to the surface.
U.S. Pat. No. 5,663,512, to Schader, discloses a hardfacing composition which includes a quantity of spherical sintered tungsten carbide granules and a quantity of cast spherical cast tungsten carbide granules in a eutectic form of WC/W2C. During application, some melting of the sintered spherical carbide granules occurs, which precipitates into the metal matrix and coats the spherical WC/W2C granules. Although this composition provides a good balance between hardness and fractures toughness, a drill bit having the toughness, ductility, and impact strength of steel and the hardness and wear resistance of tungsten carbide or other hard metal on the exterior surface, but without the problems of prior art steel body or steel tooth bits would be desirable.
DISCLOSURE OF THE INVENTION
Embodiments of a system, method, and apparatus for a highly abrasive wear metal matrix composite hardfacing material for downhole tools are disclosed. The hardfacing material may comprise a matrix of relatively softer material with high hardness, such as amorphous nanocomposite steel alloys, and one or more hard component materials. The hard component materials may comprise sintered tungsten carbide (e.g., WC/Co), monocrystalline WC, multicrystalline or polycrystalline WC, and the additional component of spherical cast tungsten carbide (e.g., a eutectic of
WC/W2C). Alternatively, a matrix of softer material, hard component materials and crushed cast tungsten carbide may be used.
The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features and advantages of the present invention, which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings which form a part of this specification. It is to be noted, however, that the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is an isometric view of one embodiment of a bit constructed in accordance with the present invention;
FIG. 2 is a micrograph illustration of one embodiment of hardfacing material constructed in accordance with the invention; and FIG. 3 is a micrograph illustration of another embodiment of hardfacing material constructed in accordance with the invention. MODE(S) FOR CARRYING OUT THE INVENTION
Hardfacing materials formed from amorphous nanocomposite steel alloys, such as NANOSTEEL®, such as those now commercially available for plasma transferred arc (PTA) welding applications. Some recent materials are reported to have high hardness while retaining their toughness, which is desirable for impact loading.
One of the problems associated with conventional PTA nickel-based or iron- based hardfacing materials is that their retention of the hard component particles is compromised as the hardness of the softer material is increased. This may produce an embrittled deposit and compromise the hardfacing. However, as a result of improved application techniques, more exotic materials such as amorphous nanocomposite steel alloys may be utilized as a relatively softer material in conjunction with hard component materials on downhole tools.
For example, sintered tungsten carbide or cast tungsten carbide, e.g., spherical or crushed, monocrystalline or polycrystalline WC, or other carbide formers may be used as the hard component materials in the softer amorphous nanocomposite steel alloys to achieve even better wear resistance without losing toughness or compromising the end deposit. By varying the physical sizes and combinations of these hard component materials, especially spherical sintered tungsten carbide pellets and/or spherical cast tungsten carbide, superior wear resistant compositions are achieved. Referring now to FIG. 1, one embodiment of a highly abrasive wear metal matrix composite hardfacing material 21 is shown. The invention is particularly well suited for use at many different locations on downhole tools, such as on the roller cone legs of a drill bit 23 or other types of downhole tools (e.g., steel tooth bits, TCI bits, steel body PDC bits, RWD tools, etc.) but it is not limited to these applications. As shown in FIG. 2, the hardfacing material may comprise a matrix 11 of a softer material with high hardness (e.g., a minimum of 60 Rc, and in some embodiments, 65+ Rc, e.g., 72 Rc) such as amorphous nanocomposite steel alloys (e.g., NANOSTEEL®) and one or more hard component materials. The hard component materials may be selected from, for example, sintered tungsten carbide (e.g., WC/Co) (spherical 13 or crushed 15), monocrystalline WC, macrocrystalline WC, multicrystal or polycrystalline WC and, in some embodiments, the additional component of spherical cast tungsten carbide (e.g., a eutectic of WC/W2C) 17, each of which may be crushed in form. Another example is shown in FIG. 3, having a matrix 31 of relatively softer material (e.g., amorphous nanocomposite steel alloy) and hard component materials such as monocrystalline WC 33 and crushed cast tungsten carbide 35.
The invention may comprise numerous different size ratios between the various components. For example, the particle size for each component may range from, for example, mesh -16 to +325. In addition, the distribution between the components also may be formulated in weight percentages as, for example, 30wt% soft component and 70wt% hard component. The range for other embodiments comprises a soft component low end of about 20wt% to a soft component high end of 90%, with complementary hard component low and high ends at 10wt% and 80wt%. Moreover, the hard component may comprise up to 100% sintered tungsten carbide (e.g., crushed or spherical), or less than 100% spherical cast tungsten carbide (e.g., crushed), or mono- , macro- or polycrystalline WC, or any combination thereof.
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. For example, although the invention is described with PTA welding, other welding techniques known to those skilled in the art, such as MIG, TIG (any of preceding may be continuous or pulsed arc applications), Flamespray, oxy-acetylene, etc., also may be used.

Claims

CLAIMSWhat is claimed is:
1. A hardfacing material formed from a metal matrix composite for highly abrasive wear applications, comprising: a matrix formed from a softer amorphous nanocomposite steel alloy and having a hardness of at least 60 Rc; and a hard component in the matrix of softer amorphous nanocomposite steel alloy, the hard component having a higher hardness than the matrix.
2. A hardfacing material according to Claim 1, wherein the matrix comprises a range of about 20 to 90wt% of the metal matrix composite, and the hard component comprises a range of about 10 to 80wt% of the metal matrix composite.
3. A hardfacing material according to Claim 1, wherein the matrix comprises about 30wt% of the metal matrix composite, and the hard component comprises about 70wt% of the metal matrix composite.
4. A hardfacing material according to Claim 1, wherein the matrix comprises about 40wt% of the metal matrix composite, and the hard component comprises about 60wt% of the metal matrix composite.
5. A hardfacing material according to Claim 1, wherein the hard component comprises spherical sintered tungsten carbide pellets.
6. A hardfacing material according to Claim 1, wherein the hard component is formed from at least one of sintered tungsten carbide and cast tungsten carbide.
7. A hardfacing material according to Claim 1, wherein the hard component is formed from at least one of spherical and crushed tungsten carbide.
8. A hardfacing material according to Claim 1, wherein the hard component is formed from at least one of monocrystalline WC, macrocrystalline WC and polycrystalline WC.
9. A hardfacing material according to Claim 1, wherein the hard component further comprises spherical cast tungsten carbide.
10. A hardfacing material according to Claim 1, wherein the hard component has a particle size in a mesh range of -16 to +325, and the matrix has a hardness of at least 65 Rc.
11. A downhole tool, comprising: a downhole tool body; a hardfacing on the downhole tool body, the hardfacing being formed from a metal matrix composite for highly abrasive wear applications; the hardfacing comprising: a matrix formed from a softer amorphous nanocomposite steel alloy and having a hardness of at least 60 Rc; and a hard component in the matrix of softer amorphous nanocomposite steel alloy, the hard component having a higher hardness than the matrix.
12. A downhole tool according to Claim 11, wherein the matrix comprises a range of about 20 to 90wt% of the metal matrix composite, and the hard component comprises a range of about 10 to 80wt% of the metal matrix composite.
13. A downhole tool according to Claim 11, wherein the downhole tool body comprises a drill bit body having gage areas, legs, and roller cones rotatably mounted to the legs, and each of the roller cones having steel teeth extending therefrom, and wherein the hardfacing is located on at least one of the gage areas, legs, and steel teeth.
14. A downhole tool according to Claim 11, wherein the matrix comprises about 40wt% of the metal matrix composite, and the hard component comprises about 60wt% of the metal matrix composite.
15. A downhole tool according to Claim 11, wherein the hard component comprises spherical sintered tungsten carbide pellets.
16. A downhole tool according to Claim 11, wherein the hard component is formed from at least one of sintered tungsten carbide and cast tungsten carbide.
17. A downhole tool according to Claim 16, wherein the hard component further comprises at least one of spherical and crushed tungsten carbide.
18. A downhole tool according to Claim 16, wherein the hard component further comprises at least one of monocrystalline WC, macrocrystalline WC and polycrystalline WC.
19. A downhole tool according to Claim 11, wherein the hard component further comprises spherical cast tungsten carbide.
20. A downhole tool according to Claim 11, wherein the hard component has a particle size in a mesh range of -16 to +325, and the matrix has a hardness of at least 65 Rc.
21. A method of forming a drill bit, comprising:
(a) providing roller cones with steel teeth extending therefrom;
(b) applying a hardfacing on the steel teeth, the hardfacing being formed from a metal matrix composite for highly abrasive wear applications; the hardfacing comprising a matrix formed from a softer amorphous nanocomposite steel alloy and having a hardness of at least 60 Rc, and a hard component in the matrix of softer amorphous nanocomposite steel alloy, the hard component having a higher hardness than the matrix; and
(c) rotatably mounting the roller cones to a drill bit body.
22. A method according to Claim 21, wherein step (b) comprises applying the hardfacing to the steel teeth with a welding technique selected from the group consisting of PTA pulsed arc, PTA continuous arc, MIG pulsed arc, MIG continuous arc, TIG pulsed arc, TIG continuous arc, and oxy-acetylene.
23. A method according to Claim 21, wherein the matrix comprises a range of about 20 to 90wt% of the metal matrix composite, and the hard component comprises a range of about 10 to 80wt% of the metal matrix composite.
24. A method according to Claim 21, wherein the hard component is selected from the group consisting of sintered tungsten carbide, cast tungsten carbide, spherical sintered tungsten carbide pellets, spherical tungsten carbide, crushed tungsten carbide, monocrystalline WC, macrocrystalline WC and polycrystalline WC.
25. A method according to Claim 21, wherein the hard component further comprises spherical cast tungsten carbide, and the hard component has a particle size in a mesh range of -16 to +325, and the matrix has a hardness of at least 65 Rc.
EP07853447A 2006-12-21 2007-12-20 A hardfacing material for hardfacing earth boring bits used in abrasive wear environments and a method of manufacturing the same Withdrawn EP2118329A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US87127006P 2006-12-21 2006-12-21
US11/954,909 US20080149397A1 (en) 2006-12-21 2007-12-12 System, method and apparatus for hardfacing composition for earth boring bits in highly abrasive wear conditions using metal matrix materials
PCT/US2007/026050 WO2008079285A1 (en) 2006-12-21 2007-12-20 A hardfacing material for hardfacing earth boring bits used in abrasive wear environments and a method of manufacturing the same

Publications (1)

Publication Number Publication Date
EP2118329A1 true EP2118329A1 (en) 2009-11-18

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EP07853447A Withdrawn EP2118329A1 (en) 2006-12-21 2007-12-20 A hardfacing material for hardfacing earth boring bits used in abrasive wear environments and a method of manufacturing the same

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US (1) US20080149397A1 (en)
EP (1) EP2118329A1 (en)
MX (1) MX2009006658A (en)
RU (1) RU2009127643A (en)
WO (1) WO2008079285A1 (en)

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US8617289B2 (en) * 2008-08-12 2013-12-31 Smith International, Inc. Hardfacing compositions for earth boring tools
US9353578B2 (en) * 2009-03-20 2016-05-31 Smith International, Inc. Hardfacing compositions, methods of applying the hardfacing compositions, and tools using such hardfacing compositions
US8945720B2 (en) * 2009-08-06 2015-02-03 National Oilwell Varco, L.P. Hard composite with deformable constituent and method of applying to earth-engaging tool
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US20110064963A1 (en) * 2009-09-17 2011-03-17 Justin Lee Cheney Thermal spray processes and alloys for use in same
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