UA93350C2 - DRILLING BIT$DRILLING BIT - Google Patents

Abstract

The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of (30) to (60) weight percent, boron up to (10) weight percent, silicon up to (20) weight percent, chromium up to (20) weight percent, and manganese up to (25) weight percent, wherein the weight percentages are based on the total weight of the binder. In addition, the hard particles may comprise at least one of (i) cast carbide (WC + WC) particles, (ii) transition metal carbide particles selected from the carbides of titanium, chromium, vanadium, zirconium, hafnium, tantalum, molybdenum, niobium, and tungsten, and (iii) sintered cemented carbide particles.

Description

The field of technology

This invention relates to the improvement of the drill bit and methods of its manufacture. In particular, it refers to the body of the bit, conical bits, insert conical bits, bits and bits for drilling and methods of their manufacture.

Prior art

A drill bit can have fixed or rotating cutting elements. A chisel with fixed cutting elements usually contains a body of the chisel made of steel by machining or obtained by impregnating a layer of solid particles, for example, cast carbide (M/SnL/с), tungsten carbide (M/S) and/or sintered cemented carbide. tough, such as, for example, a copper-based alloy. Several cutting inserts are attached to the body of the bit in predetermined positions to optimize cutting. The body of the bit can be mounted on a steel shank, which usually contains a connection based on a threaded nipple, by means of which the bit is attached to the drive shaft of the drilling motor or to the drill pipe from the far end of the drill string.

A chisel with a steel case is usually made by machining a round blank to the required shape with the required external surface and internal elements. Surfacing technologies can be used to apply wear-resistant materials to the front surface of the bit body and other important areas of the outer surface.

In the conventional method of manufacturing the body of the bit from solid particles and ties, the shape is milled or machined to define the elements of the outer surface of the body of the bit. Additional manual milling or clay work may also be necessary to create or improve the outer surface of the case.

After receiving the form, a pre-formed steel blank can be installed in its cavity, which is intended for internal strengthening of the bit body and is used as a matrix when creating a connection using a nipple after manufacturing. In addition, other inserts made of sand, graphite, transition or refractory metal can be installed in the cavity of the mold, which form internal channels for the fluid, nests for cutting elements, protrusions, platforms, narrowing nozzles, grooves for waste or other internal or topographical elements body of the bit.

Any inserts used must be precisely located to ensure proper positioning of cutting elements, bits, waste grooves, etc. in the finished bit.

Then the necessary solid particles can be poured into the form, which are compacted to the required density. After that, the solid particles are permeated by the molten bond, which solidifies to obtain a solid body of the bit, containing a dispersed phase of solid particles in the continuous phase of the bond.

After that, assembly of the housing and other components of the drill bit can be carried out. For example, a cutting shank may be welded or otherwise attached to the body, and cutting elements or inserts (typically cemented tungsten or diamond or polycrystalline synthetic diamond). Alternatively, the cutting inserts can be bonded to the face of the bit body during furnace heating or impregnation if thermally stable grades of polycrystalline synthetic diamond are used.

Rotary drill bits used in oil and gas exploration typically contain cemented carbide cutting inserts attached to bits that are part of an assembled taper bit or contain milled teeth machined into the cutting element.

In a typical case, milled teeth are subjected to deposition of tungsten carbide in a matrix of alloy steel. The body of the chisel with a conical shape is usually made of alloy steel.

Drill bits are usually attached to the end of the drill string, which is driven from the surface or by hydraulic hammer motors located directly above the bit on the drill string. The drilling fluid is pumped downwards through the hollow drill string and exits through the nozzles made in the bit body. Drilling fluid cools and lubricates the bit during its rotation, and also carries the material cut by this bit to the surface.

The housing and other elements of the drill bit are subject to many types of wear because they operate in an aggressive downhole environment. One of the most common types of wear is abrasive wear caused by contact with abrasive rocks. In addition, drilling mud containing pieces of rock causes erosive wear of the bit.

The service life of a drill bit is a function not only of the wear resistance of the inserts made of polycrystalline synthetic diamond or cemented carbide, but also of the wear resistance of the bit body (in the case of a bit with fixed cutting elements) or the balls (in the case of a bit with a conical ball). One way to increase the life of a drill bit is to use casings or shells made from materials with improved combinations of strength, impact toughness and resistance to abrasive wear/erosive wear.

Thus, there is a need for an improved drill bit housing that has increased wear resistance, strength, and impact toughness.

The essence of the invention

This invention belongs to the composition for the manufacture of the body of a drill bit. The bit body contains solid particles that include at least one of the following: carbides, nitrides, borides, silicides and oxides, as well as their solid solutions, and a bond that binds the solid particles together. The solid particles may contain at least one transition metal carbide selected from carbides of titanium, chromium, vanadium, zirconium, hafnium, tantalum, molybdenum, niobium and tungsten or their solid solutions. Solid particles may be present as individual or mixed carbides and/or as sintered cemented carbides.

Bond options may contain at least one metal selected from cobalt, nickel, iron, and their alloys. In another embodiment, the bond may further comprise at least one melting point lowering component selected from up to 60 weight percent of a transition metal carbide, up to 50 weight percent of one or more transition metals, up to 5 weight percent of carbon, boron with a content of up to 10 weight percent, silicon with a content of up to 20 weight percent, chromium with a content of up to 20 weight percent and manganese with a content of up to 25 weight percent of the total weight of the bond. In one variant, the bond contains from 40 to 50 weight percent of tungsten carbide and from 40 to 60 weight percent of at least one of the following: iron, cobalt, and nickel. According to the present invention, transition metals are elements belonging to groups IMV, MV and MIV of the periodic table.

Another version of the composition for the manufacture of the body contains solid particles and a bond having a melting point in the range of 10507C to 135070. The bond can also be an alloy that contains at least one of the following: iron, cobalt, and nickel, and at least one of the following: transition metal carbide, transition element, carbon, boron, silicon, chromium, manganese, silver, aluminum, copper, tin, and zinc. In a more preferred case, the bond can be an alloy that contains at least one of the following: iron, cobalt, and nickel, and at least one of the following: tungsten carbide, tungsten, carbon, boron, silicon, chromium, and manganese.

Another embodiment of the present invention is a housing composition that contains solid transition metal carbide particles and a bond that contains at least one of the following: nickel, iron, and cobalt, and has a melting point below 1350". The bond may additionally contain at least one of the following: transition metal carbide, tungsten carbide, tungsten, carbon, boron, silicon, chromium, manganese, silver, aluminum, copper, tin, and zinc.

In the manufacture of the drill bit body, solid particles and possibly inserts may be placed in the bit body mold. Inserts can be placed in the products according to this invention using any method. For example, the inserts can be installed in the mold before it is filled with powdered metal or solid particles, and any existing inserts can be permeated with a molten bond that solidifies to form a solid matrix that contains a dispersed phase of solid particles in the continuous phase of the bond. Variants of the implementation of this invention also include methods of manufacturing products, for example, housings of drill bits, conical layers and teeth of drilling bits with a conical layer. One of the options for implementing the method of manufacturing the product may include impregnation of a mass of solid particles that contain at least one carbide of a transition metal with a bond that contains at least one of the following: nickel, iron, and cobalt and has a melting point below 1350"C. Another option discloses a method that includes impregnating a mass of solid particles containing at least one transition metal carbide with a bond having a melting point in the range of 10507C to 135070. The bond may contain at least one of the following: iron, nickel, and cobalt, where the total the concentration of iron, nickel, and cobalt is from 40 to 99 weight percent, based on the weight of the bond.The bond may additionally contain at least one of the following: selected transition metal carbide, tungsten carbide, tungsten, carbon, boron, silicon, chromium, manganese, silver, aluminum, copper, tin and zinc in such a concentration that is able to lower the melting point of iron, nickel and/or cobalt.

The bond may be a eutectic or near-eutectic mixture. The reduced melting temperature of the bond contributes to the proper impregnation of the mass of solid particles.

Another object of this invention is a method of manufacturing a drill bit, which includes casting the bit from a molten mixture of at least one of the following: iron, nickel and cobalt with a transition metal carbide. The mixture can be eutectic or close to eutectic. In these variants, the drill bit can be cast directly without impregnation of the mass of solid particles.

Unless otherwise indicated, all numbers expressing amounts of ingredients, times, temperatures, etc., used in this description and the clauses of the appended Formulary of the Invention are to be understood as variables in all cases with the use of the term "about". Accordingly, unless otherwise specified, the numerical parameters specified in the following description and clauses of the attached Formula of the invention are approximate values that may vary depending on the required properties that must be obtained when using this invention. At least, and not as an attempt to limit the application of the principle of equivalents to the volume defined by the clauses of the applied Formula of the invention, each numerical parameter should be perceived at least from the point of view of the number of indicated significant figures and using the usual rounding methods.

Despite the fact that the numerical ranges and parameters that define the scope of the invention are approximate values, the numerical values indicated in the specific examples are given as accurately as possible. However, any numerical value may contain certain errors that inevitably arise from standard deviations that are present in measurements during the relevant tests.

The following details and advantages of this invention will become apparent to a person skilled in the art when considering the further detailed description of its implementation options. A person skilled in the art can also appreciate such additional details and advantages of this invention in practice and/or use of its variants.

Brief description of the drawings

The distinctive features and advantages of this invention can be better understood by referring to the accompanying drawings, which show the following:

Fig. 1 depicts a schematic cross-section of one of the variants of the drill bit body;

Fig. 2 - a graph of the results of differential thermal analysis (DTA) with two cycles during heating from 9007C to 1400C with a temperature increase rate of 10C/min. in an argon atmosphere for a sample containing about 4595 tungsten carbide and about 5595 cobalt;

Fig. C is a graph of two-cycle DTA results heated from 900°C to 13007°C at a rate of 10°C/min under an argon atmosphere for a sample containing approximately 4595 tungsten carbide, approximately 5390 cobalt, and approximately 295 boron; and

Fig. 4 is a graph of two-cycle DTA results when heated from 900°C to 14007°C at a rate of temperature increase of 10°C/min in an argon atmosphere for a sample containing approximately 4595 tungsten carbide, approximately 5395 nickel, and approximately 295 boron;

Fig. 5 is a graph of DTA results with two cycles when heated from 9007C to 12007 at a rate of temperature increase of 10"C/min in an argon atmosphere for a sample containing approximately 96.39o of nickel and approximately 3.790 of boron;

Fig. 6 is a graph of two-cycle DTA results when heated from 9007C to 13007 at a rate of temperature increase of 10"C/min in an argon atmosphere for a sample containing approximately 88.4905 nickel and approximately 11.695 silicon;

Fig. 7 is a graph of DTA results with two cycles when heated from 9007C to 12007 at a temperature increase rate of 10"C/min in an argon atmosphere for a sample containing approximately 9695 cobalt and approximately 4905 boron;

Fig. 8 is a graph of DTA results with two cycles when heated from 9007C to 13007 at a temperature increase rate of 10"C/min. in an argon atmosphere for a sample containing approximately 87.59o cobalt and approximately 12.595 silicon;

Fig. 9 - a photomicrograph of the material obtained by impregnating a mass of solid particles with a bond that actually consists of cobalt and boron;

Fig. 10 - a photomicrograph of the material obtained by impregnating a mass of solid particles with a bond that actually consists of cobalt and boron;

Fig. 11 - a photomicrograph of the material obtained by impregnating a mass of solid particles with a bond that actually consists of cobalt and boron;

Fig. 12 - a photomicrograph of the material obtained by impregnating a mass of solid particles with a bond that actually consists of cobalt and boron; and

Fig. 13 - a photomicrograph of the material obtained by impregnating a mass of cast carbide particles and a cemented carbide insert with a bond consisting actually of cobalt and boron;

Fig. 14 - the appearance of one of the variants of the body of the bit, according to this invention;

Fig. 15a, 156, and 15c are graphs of rotational flexural fatigue test data for compositions that may be used in embodiments of the present invention, including Ri-25 containing approximately 25 volume percent bond (FIG. 15a), RI/-30, containing approximately 30 volume percent of the bond (Fig. 156), and RI -35, containing approximately 35 volume percent of the bond (Fig. 15c);

Fig. 16 - the appearance of one of the variants of the conical shell according to the present invention.

Description of the invention

Variants of the implementation of this invention relate to the composition for the manufacture of drill bits housings, conical shells, insert conical shells, shells and teeth of drill bits with a conical shell, as well as methods of manufacturing such products. In addition, the method can be used for the manufacture of other products. Some versions of the body of the bit, in accordance with this invention, contain at least one dispersed solid phase and a continuous phase of the bond that binds the solid phase. Variants of the compositions and methods offered by the present invention provide an increased service life for the body of the bit, conical balls, insert conical balls, teeth and balls obtained with their use and, thus, increase the service life of the drill bit or other tool. The material of the body of the bit, the conical ball, the insertable conical ball ensures the invariance of the properties in any part of the product. In fig. 1 shows a typical housing 10 of a drill bit with fixed cutting elements. In the general case, the body 10 includes means 11 for fastening to the shank 12 and a blank part 12A included in the body 10. The shank 12, the blank part 12A and the nipple can be independently made of alloy steel or at least one dispersed solid phase and solid phase bond, and the attachment means 11, the shank 12 and the blank 12A can be attached to the body of the bit by any method, for example, soldering, threaded connections, pins, keys, hot fitting, adhesives, diffusion welding, tension fitting or any other mechanical or chemical connection. However, in embodiments of the present invention, the shank 12 containing the fastener can be made of alloy steel, or the same or a different composition of solid particles in the bond compared to other parts of the bit body. In fact, the body 10 of the bit can structurally have different parts, and each part can be characterized by a different concentration, composition and size of crystals of solid particles or connections. This allows you to adjust the properties of specific parts of the product as required in a specific application. In fact, the product can be made in such a way that the properties or composition when moving from part to part can change abruptly or gradually.

An exemplary bit body 10 shown in Fig. 1, has three parts. For example, the upper part 13 may contain a dispersed solid phase of tungsten and/or tungsten carbide, the middle part 14 may contain a dispersed solid phase of coarse-grained cast tungsten carbide (M/2C, MC), tungsten carbide and/or sintered particles of cemented carbide, and the lower part 15, if any, may contain a dispersed solid phase of fine-grained cast carbide, tungsten carbide and/or sintered cemented carbide particles. The body 10 also contains sockets 16, which are located in the lower part of this body, and in which cutting inserts can be installed. These sockets can be made in the housing directly during the manufacture of the mold, in the machining of the raw or semi-finished workpiece, as inserts, for example, which are installed during the manufacture of the housing, or as inserts that are attached after the construction of the housing by means of soldering or other fastening method, as described above. The housing 10 may also include internal fluid channels, protrusions, pads, nozzles, waste grooves, and any other conventional housing surface features. Alternatively, these elements can be defined by pre-formed inserts, for example, inserts 17, which are located in the corresponding places of the mold for the body. Variants of the implementation of this invention include the casings of drill bits, which contain inserts made of cemented carbide. In a conventional case, the solid phase particles are embedded in a matrix of a copper-based alloy such as brass or bronze. Casing variants of the present invention may contain or be manufactured using new types of bonding to give the casing increased wear resistance, strength, and impact resistance.

The process of obtaining solid particles placed in a bond, in a typical case, involves the compaction of metallurgical powder (in a typical case, ceramics in the form of macroparticles and metal-bond) with the creation of a raw blank. Powder consolidation processes using conventional technologies such as mechanical or hydraulic pressing in rigid molds, wet mass isostatic pressing or semi-dry isostatic pressing may be used. After that, the raw workpiece can undergo preliminary or full sintering for further consolidation and compaction of the powder. Preliminary sintering leads only to partial consolidation and compaction of the part.

The raw billet may be pre-sintered at a lower temperature than that achieved during the final sintering operation to produce a pre-sintered billet ("semi-finished billet"). The semi-finished billet has relatively low hardness and strength compared to the finished, fully sintered product, which are significantly higher compared to the raw billet. During manufacture, the product may be machined as a raw blank, a semi-finished blank, or as a fully sintered product. In a typical case, the machinability of a raw or semi-finished workpiece is significantly better than the machinability of a fully sintered product. Machining a green or semi-finished billet may be advantageous if the fully sintered part is difficult to machine or requires grinding to meet final dimensional tolerances. Other methods of improving the machinability of the part can also be used, for example, the addition of substances that contribute to mechanical processing to eliminate the porosity of the workpiece, a typical such substance is a polymer. And, finally, sintering can be performed at the temperature of existence of the liquid phase in conventional vacuum furnaces or at high pressure in a ZipiegNir furnace.

The billet can be sintered under excessive pressure of 3000-2000 psi. inch, and a temperature of 13507"0-15007C. Pre-sintering and sintering of the workpiece leads to the removal of lubricants, reduction of oxides, compaction and improvement of the microstructure. As stated above, after sintering, the bit body, conical ball, insert conical ball or ball can be additionally suitable mechanically machined or polished to obtain the final configuration.

The present invention also proposes a method of manufacturing a drill bit body, a conical ball, an insert conical ball or a ball with parts, the composition of which has different properties. One of the variants of the method includes placing the first metallurgical powder in the first part of the mold cavity and the second metallurgical powder in the second part of the mold cavity. In some embodiments, the mold can be divided into two or more parts, for example, by placing a physical partition, such as paper or polymeric material, in the mold cavity to separate said parts. Metallurgical powders can be selected in such a way as to ensure, after consolidation and sintering, the production of cemented carbides having the necessary properties described above. In another variant, a part of at least the first metallurgical powder and the second metallurgical powder is placed inside the mold in contact, without partitions. To create separate parts without the use of physical partitions, together with metallurgical powders, wax or another bond can be used.

A product with a gradual change in properties or composition can also be obtained, for example, by placing the first metallurgical powder in the first part of the mold. The second part of the mold can then be filled with metallurgical powder containing a mixture of the mentioned first metallurgical powder and the second metallurgical powder. This mixture will result in a product, at least one of whose properties is intermediate between the similar properties in the product made using the first and second metallurgical powders independently. This process can be repeated until the required gradient of composition or compositional structure is obtained in the form, and in a typical case it will end with the filling of part of the form with the second metallurgical powder. Variations of this process may also be performed with or without physical barriers. Additional parts can be filled with different materials, for example, a third metallurgical powder or even a product that was previously impregnated with a copper alloy. Isostatic compression can then be applied to the mold to consolidate the metallurgical powders into a blank. This blank is further sintered for its further compaction and creation of internal connections between the mentioned parts.

As described earlier, any alloy can be used, such as nickel, cobalt, iron and alloys of nickel, cobalt and iron. In addition, in certain embodiments of the present invention, the bond used to produce the body of the bit can have a melting point of 10507C to 135070C.

Here it is meant that the melting point or melting point represents the solidus of a particular composition. In other variants of the implementation of this invention, the bond contains an alloy of at least one of the following: cobalt, iron and nickel, which has a melting point below 1350"C. In other variants of the composition, according to this invention, it contains at least one of the following: cobalt, nickel and iron as well as a melting point lowering component Pure cobalt, nickel and iron have high melting points (about 15007) and therefore the impregnation of solid particle layers with pure molten cobalt, iron or nickel is difficult to achieve adequately without obtaining excessive porosity or undesirable phases. However, an alloy of: at least one of the following: cobalt, iron, and nickel may be used if it contains a sufficient amount of at least one component that lowers the melting point. This component may be at least one of the following: a transition metal carbide , transition element, tungsten, carbon, boron, silicon, chromium, manganese, sri aluminum, copper, tin, and zinc, and other elements, which alone or in combination may be added in amounts sufficient to lower the melting point of the bond so that the bond can be used effectively to form the body of the bit in the chosen way. A bond can be effectively used to form a bit body if its properties, such as melting point, melt viscosity, and soak interval, are such that the bit body can be cast without excessive porosity. In a preferred embodiment, the melting point lowering component is at least one of the following: transition metal carbide, transition metal, tungsten, carbon, boron, silicon, chromium, and manganese. It may be advantageous to combine two or more of the melting point lowering components mentioned above to produce a bond capable of effectively impregnating a mass of solids. For example, tungsten and carbon may be added together to obtain a greater reduction in melting point than that obtained by adding tungsten alone, in which case the tungsten and carbon may be added as tungsten carbide. Similarly, other components that lower the melting point can be added.

One or more components that lower the melting point can be added alone or in combination with other components of the bond, in any amount that provides a bond composition effective for making the body of the bit. In addition, one or more components can be added that lower the melting point so that the bond is eutectic or close to eutectic composition.

Providing a bond with a eutectic or near-eutectic concentration of ingredients ensures that the bond will have a lower melting point, which can facilitate casting and percolation of the solids layer. In certain variants of the implementation of this invention, it is preferable that one or more components that lower the melting point are present in the bond in the following percentage content of the total weight of the bond: tungsten - up to 5595, carbon - up to 495, boron - up to 1095 , silicon - up to 2095, chromium - up to 2095, and manganese - up to 2595. In some other embodiments of the present invention, it may be preferred that one or more melting point lowering components be present in the bond in the following percent of the total bond weights: tungsten - from 3095 to 5595, carbon - from 1.595 to 495, boron - from 195 to 1090, silicon - from 295 to 2095, chromium - from 295 to 2095 and manganese - from 1095 to 2595. In some others in variants of the composition, according to this invention, the component that lowers the melting point can be tungsten carbide, present in an amount from 30 to 60 percent by weight.

Under certain casting conditions and bond concentration, all or part of the tungsten carbide will separate from the bond during hardening and form a solid phase. This separated solid phase can be added to any solid phase that is in particulate form. However, if no solid particles are placed in the mold or part of it, then all solid phase particles in the body of the bit or its section may be obtained as tungsten carbide released during casting.

Embodiments of the articles of the present invention may contain 50 or more volume percent solids or solids, in some embodiments it may be preferred that the solids or solids comprise 50 to 80 volume percent of the article, and more preferably for such options, so that the solid phase was from 60 to 80 volume percent of the product. In fact, in some embodiments, the bonding phase may be less than 50% by volume of the product or, preferably, 20 to 50% by volume of the product.

In some embodiments, the bond may comprise 20 to 40 volume percent of the product.

Embodiments of the present invention also include drill bit casings and other products containing transition metal carbides, in which the volume fraction of tungsten carbide exceeds 7595. Now it has become possible to manufacture bit casings with such a volume fraction, for example, of tungsten carbide, thanks to the method , offered by this invention, the variants of which are described below. One of the variants of the method includes impregnation of a layer of solid particles of tungsten carbide with a bond that is eutectic or close to eutectic composition of at least one of the following: cobalt, iron and nickel with tungsten carbide. It is contemplated that dolite bodies with a concentration of tungsten carbide in the dispersed phase of up to 95 volume percent can be obtained using the methods offered by the present invention if the tungsten layer is impregnated with a molten eutectic or near-eutectic composition of tungsten carbide and at least one of the following: cobalt, iron and nickel. In contrast, conventional impregnation methods for the manufacture of dolot housings can only be used for the manufacture of housings containing a maximum of approximately 72 volume percent tungsten carbide. Applicants have found that the volume concentration of tungsten carbide in the cast body of a drill bit and other products can be from 7595 to 959565, if a eutectic or near-eutectic composition of tungsten carbide and at least one of the following: cobalt, iron and nickel is used as impregnation. At this time, there are limitations in the volume content of the solid phase that can be formed in the body of the drill bit due to limitations in the density of filling the mold with solid particles and difficulties in percolation of a densely packed mass of solid particles. However, the separation of carbide from a seepage bond containing a eutectic or near-eutectic composition avoids these complications. During solidification of the bond in the form for the body of the bit, an additional solid phase is formed due to separation from the molten impregnating substance during cooling. Thus, a higher concentration of the solid phase occurs in the body of the bit than that which can be achieved using a molten bond with insufficient dissolved tungsten carbide. The use of compositions of molten binder/absorbent substance with a eutectic or near-eutectic composition makes it possible to have a higher volume content of the solid phase in the housings of dolits and other products in comparison with what could be obtained before.

The volume content of tungsten carbide in the body of the bit can be further increased by inserting cemented carbide inserts into the body. Cemented Carbide Inserts can be used to create internal fluid channels, cutting element slots, projections, landings, tapers, waste grooves, or other topographic features of the bit body, or simply to provide structural support, stiffness, impact toughness, strength or wear resistance in selected areas of the housing or holder. Conventional cemented carbide inserts may contain from 70 to 99 volume percent tungsten carbide when manufactured using conventional cemented carbide production techniques. Any known cemented carbide can be used for inserts in the bit body, for example, composites of carbides of at least one of the following: titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, and tungsten in combination with at least one of the following: cobalt , iron and nickel, but not limited to the listed. Cemented carbides may contain additional alloying elements known in the art.

Variations of the compositions for making the body of the bit also include at least one type of solid particles. As indicated above, the body of the bit may also contain parts containing different types and/or concentrations of solid particles. For example, the body 10 of the bit in Fig. 1 may contain a lower part 15 of a harder wear-resistant material of a dispersed solid phase with a small particle size and a middle part 14 of a more viscous material of a dispersed solid phase with a relatively large particle size.

The solid phase or solid particles in any part may contain at least one of the following: carbide, nitride, boride, oxide, lithium carbide, cemented carbide, mixtures thereof, and solid solutions thereof. In some embodiments of the present invention, the solid phase may contain at least one cemented carbide containing at least one of the following: titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, and tungsten.

Cemented carbides can have any suitable particle size or shape, such as irregular, spherical, oblate and elongated. Cobalt cemented carbide grades have a commercially attractive combination of strength, crack resistance and wear resistance.

"Strength" is the stress at which a material cracks or breaks. "Impact toughness" is the ability of a material to absorb energy and deform plastically before breaking. Impact toughness is proportional to the area under the stress-strain curve from the origin to the point of rupture. See

Meagham-No! Oisiopagu oi Zsiepiis apa Tesppisa! Tegptv (5th edition, 1994). "Wear resistance" - the ability of the material to resist surface damage. Wear usually involves the gradual loss of material due to relative movement between the material and the contacting surface or substance. See MeiaI5 Naparook

Oezk Eiyop (2nd Eiyop, 1998). "Crack resistance" is the critical stress at the tip of a crack, necessary for its propagation, and is usually characterized by the "Critical stress intensity factor" (Ks).

The strength, impact toughness, and wear resistance of cemented carbide are related to the average grain size of the dispersed solid phase and the volume (or weight) fraction of the bond phase present in conventional cemented carbide. In general, an increase in the average grain size of tungsten carbide and/or an increase in the volumetric particle size of the cobalt bond will lead to an increase in crack resistance.

However, this increase in viscosity is generally accompanied by a decrease in wear resistance. Thus, a specialist in cemented carbide metallurgy is required to create carbides with both high wear resistance and high impact toughness when developing grades for demanding applications.

The body 140 of the drill bit, shown in fig. 14, may contain sections that contain different concentrations or compositions of components to provide different properties in certain places of the housing, for example, wear resistance, impact strength or corrosion resistance. For example, the areas 141 of nests for inserts in the area around the cutting inserts 142 of the drill bit, the platform 143 for measuring devices or the area 144 of the discharge opening of the nozzle, the area of the cutting edge of the conical ball, or the outer surface of the spear-shaped tip 145 may contain more wear-resistant materials. In addition to this, variants of the body of the bit according to the present invention may have regions with high impact toughness, for example, the inner region of the cutting edge 146, the inner region of the conical ball, at least the inner region of the shank or neck, or the region near the shank. The properties of various areas of the drill bit body, taper, insert taper, or taper can also be adjusted to provide ease of machinability or corrosion resistance.

Drill bit housing, taper, plug-in taper or taper housing options can have unique properties that cannot be achieved in conventional drill bits, taper, plug-in taper housings. For testing, samples having a composition suitable for use in this invention were made. Nominal compositions of test samples are given in

Tables 1.

Table 1 weight weight weight

As can be seen from Table 2, embodiments of this invention include materials having a transverse bending strength greater than 300x103 lb/sq. inch. Conventional drill bit casings containing materials made of steel or hard particles impregnated with brass or bronze do not have as high transverse bending strength as the embodiments of this invention.

Fig. 15a, 156, and 15c show graphs of data for rotational bending fatigue tests for test specimens with a composition suitable for use in the embodiments of the present invention listed in Table 1. As can be seen, the test specimens are characterized by fully alternating bending stress, which exceeds 100x103 lb/sq. inch at 107 cycles.

Certain properties of casing materials in certain areas of downhole tools contribute to increased tool life. These properties include, but are not limited to, strength, stiffness, wear or abrasion resistance, and fatigue strength. A drill bit body, taper, insert taper, or taper may contain multiple regions, each containing different materials. Strength is typically measured as transverse bending strength or tensile strength. Stiffness can be measured as the modulus of elasticity. Properties of embodiments of the present invention and prior art copper-based matrices are shown in Table 2. As can be seen, embodiments of the present invention have transverse flexural strength values in excess of 250 lb/sq. inch, in some versions the transverse bending strength can exceed 300x103 lb/sq. inch or even 400x103 lb/sq. inch. The modulus of elasticity of the implementation options of this invention exceeds 55x106 lb/sq. inch and preferably for some applications requiring higher rigidity, embodiments of the present invention may have a modulus of elasticity greater than 75x109 lb/sq. inch or even 90x109 lb/sq. inch. In addition to the corresponding values of transverse bending strength and modulus of elasticity, the implementation options of this invention are characterized by increased hardness. Embodiments of this invention can be selected to have a hardness greater than 65 on the A scale.

Rockwell or, for example, by reducing the concentration of the bond, the hardness in specific versions can be achieved above 75 or even above 85 on the scale of A. Rockwell in certain versions.

Abrasion resistance, measured in accordance with the standard Wb611 of the American Society for Testing Materials for material variants of the present invention, may exceed 1.0 or even 1.4. In some applications or downhole tool parts, material variants of the present invention may have abrasive wear resistances in the range of 2 to 14.

Embodiments of the present invention include materials that also contain combinations of properties used for drill bit casings, tapers, plug-in tapers, and tapers.

For example, embodiments of the present invention may include a material having a transverse flexural strength greater than 200x103 lb/sq. inch or even 250x103 lb/sq. inch, together with a modulus of elasticity exceeding 40x109 lb/sq. inch. Other embodiments of the present invention may include material having a fatigue strength greater than 30x103 lb/sq. inch, in combination with a modulus of elasticity exceeding 30x109 lb/sq. inch. Such combinations of properties ensure obtaining tools for drilling, which in certain areas of application will have a longer service life compared to conventional products.

Table 2

Comparison of material properties

Known level Method of testing technique

Property | Carbide, b-1695 So |Carbide (RI30)| Matrix (overall| -:/ (KN) RK; SS niyishzhjiayalyapyapy VV I I PO 91777771 bends, x103 psi

Limit of proportionality, x1 03

Futkadyut 00001606

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In addition to this, certain variants of the composition according to this invention may contain from up to 95 volume percent of the solid phase and from 5 to 70 volume percent of the bond phase. Isolated areas of the body of the drill bit can be characterized by a wider range of concentration of the solid phase, for example, from 30 to 99 volume percent. This can be achieved, for example, by placing solid particles with different fill densities at certain locations in the mold or by placing cemented carbide inserts in the mold prior to casting the body of a drill bit or other product. In addition to this, the body can be made by molding using more than one bond.

Difficulties in making a body or holder containing a bond that includes at least one of the following: cobalt, iron, and nickel by impregnation are due to the relatively high melting points of cobalt, iron, and nickel. The melting point of each of these metals at atmospheric pressure is approximately 1500°C. In addition, because cobalt, iron, and nickel have high solubility in the liquid state for tungsten carbide, it is difficult to prevent premature solidification of, for example, a molten tungsten carbide-cobalt alloy or tungsten carbide - nickel, during the impregnation of a layer of tungsten carbide particles in the process of casting the body of a drill bit for subsurface drilling. This phenomenon can lead to the formation of microholes in the casting even when using high temperatures, for example, above 1400 "С, in the process of impregnation.

When using variants of the method according to this invention, it is possible to overcome the difficulties associated with cast composites impregnated with cobalt, iron and nickel by using a pre-alloyed eutectic or near-eutectic composition of cobalt and tungsten carbide (30-60 weight percent carbide tungsten and 40-70 percent by weight of cobalt). For example, a cobalt alloy having a concentration of about 43 percent by weight tungsten carbide has a melting point of about 1300°C (see Fig. 2). The lower melting point of a eutectic or near-eutectic alloy relative to cobalt, iron, and nickel, along with a small solidification of a eutectic or near-eutectic composition can greatly facilitate the production of tungsten-cobalt carbide-based drill bits and cemented carbide taper drill bits. For example, it can be expected that eutectic or near-eutectic cobalt-carbide alloys tungsten, nickel-tungsten carbide, cobalt-nickel-tungsten carbide and iron-tungsten carbide will exhibit significantly higher levels of strength and impact toughness compared to brass and bronze-based composites with equivalent levels of abrasion/erosion wear resistance. You can also expect that these alloys will be well ob be made using ordinary cutting tools.

Certain embodiments of the method according to the present invention include impregnating the mass of solid particles with a bond that is eutectic or near-eutectic composition containing at least one of the following: cobalt, iron, and nickel, as well as tungsten carbide, and where the bond has a melting point lower than 1350"C. It is meant here that the term "close to eutectic concentration" means that the concentration of the main components of the composition does not differ by more than 10 weight percent from the eutectic concentrations of these components. The eutectic concentration of tungsten carbide in cobalt is approximately 43 weight percent. Eutectic compositions are well known or can be readily determined by one skilled in the art. Casting of a eutectic or near-eutectic composition may be performed with or without solids in the mold. However, it may be preferable for the composition to form a solid phase upon crystallization , which was released, from tungsten carbide and phase connections The bond may additionally contain alloying elements such as at least one of the following: boron, silicon, chromium, manganese, silver, aluminum, copper, tin and zinc.

Variants of the implementation of this invention can include as one of the distinguishing features the manufacture of housings and shells from eutectic or close to eutectic compositions using several different methods. Variants of these methods include the following. 1. Impregnation of a layer or mass of solid particles containing a mixture of transition metal carbide particles and at least one of the following: cobalt, iron, and nickel (i.e., cemented carbide) with a molten impregnant that is a eutectic or near-eutectic composition of carbide and at least one from the following: cobalt, iron and nickel. 2. Impregnation of a layer or mass of transition metal carbide particles with a molten impregnating substance, which is a eutectic or near-eutectic composition of carbide and at least one of the following: cobalt, iron, and nickel. 3. Casting a molten eutectic or near-eutectic composition of carbide, for example, tungsten carbide, and at least one of the following: cobalt, iron, and nickel, to obtain a given or close to a given profile of the body of the bit, conical ball or ball. 4. Mixing the powder bond and solid particles, placing the mixture in a mold, heating the powders to a temperature that exceeds the melting point of the bond, and cooling to produce a body of a drill bit, a conical ball or a ball in the casting process. This so-called "cast-in-place" method can allow the use of binders with a relatively low mass of solids percolation, since the binder is mixed with the solids prior to melting, and thus shorter percolation intervals are required to produce the product.

In certain methods, in accordance with this invention, percolation of solid particles may include loading a spigot with a binder, melting the binder, and molding the binder into a mold with solid particles and possibly inserts. As discussed above, the bond may be a eutectic or near-eutectic composition, or may contain at least one of the following: cobalt, iron, and nickel, as well as at least one component that lowers the melting point.

Another method, according to this invention, includes preparing a mold and casting a eutectic or near-eutectic mixture of at least one of the following: cobalt, iron, and nickel, as well as a solid phase component. As the eutectic mixture cools, the mentioned component can separate from it with the formation of a solid phase. This method can be useful in the production of conical layers and teeth in three-layer drill bits.

Another embodiment of the present invention includes the above-mentioned cast-in-place. One example of this option includes preparing a mold, adding a mixture of solid particles and binder to it, and heating the mold to a temperature above the melting point of the binder. This method allows you to cast the body of the drill bit, the conical bit and the teeth for three-bit drill bits on the spot. This method may prove to be preferable if the estimated interval of percolation of the bond is insufficient for satisfactory percolation of solid particles in the usual way.

The solid particles or solid phase may contain one or more of the following materials: carbides, oxides, borides, and nitrides, and the bonding phase may consist of one or more metals of the MI group of the periodic table, namely, Co, Mi, and/or Ge. By morphology, the solid phase can be particles of irregular, equiaxed or spherical shape, fibers, filamentous crystals, plates, prisms, or can be of any other suitable shape. In some embodiments, the cobalt, iron, and nickel alloys useful in the present invention may contain additional elements such as boron, chromium, silicon, aluminum, copper, manganese, or ruthenium in a total amount of up to 20 percent by weight of the plastic solid phase.

Fig. 2 - Fig. 8 are graphs of results of differential thermal analysis (DTA) for connection variants according to this invention. Fig. 2 - graph of DTA results with two cycles when heated from 9007C to 1400" with a temperature increase rate of 10"C/min. in an argon atmosphere for a sample containing about 4595 tungsten carbide and about 5595 cobalt (relative contents are given in weight percent throughout unless otherwise indicated). The graph shows that the melting point of the alloy is approximately 133920.

Fig. C is a graph of two-cycle DTA results when heated from 900°C to 13007°C at a rate of 10°C/min in an argon atmosphere for a sample containing about 4595 tungsten carbide, about 5395 cobalt, and about 295 boron. The graph shows that the melting point of the alloy is approximately 1151"C. In comparison with the DTA for the alloy in fig. 2, replacing approximately 295% of the cobalt with boron lowers the melting point of the alloy in FIG. From almost 200 "s.

Fig. 4 - graph of DTA results with two cycles when heated from 9007C to 1400C with a temperature increase rate of 10C/min. in an argon atmosphere for a sample containing about 4595 tungsten carbide, about 5395 nickel and about 295 boron. The graph shows that the melting point of the alloy is approximately 1089°C. Compared to the DTA for the alloy in Fig. C, replacing cobalt with nickel lowers the melting point of the alloy in Fig. 4 by almost 60°C.

Fig. 5 is a graph of the results of DTA with two cycles when heated from 9007C to 12007 at a temperature increase rate of 10"C/min in an argon atmosphere for a sample containing approximately 96.39o of nickel and approximately 3.796 of boron. The graph shows that the melting point of the alloy is approximately 110026.

Fig. 6 - a graph of DTA results with two cycles when heated from 9007C to 1300" with a temperature increase rate of 10"C/min. in an argon atmosphere for a sample containing about 88.495 nickel and about 11.695 silicon. The graph shows that the melting point of the alloy is approximately 115026.

Fig. 7 - a graph of DTA results with two cycles when heated from 9007C to 1200" with a temperature increase rate of 10"C/min. in an argon atmosphere for a sample containing about 9695 cobalt and about 495 boron. The graph shows that the melting point of the alloy is approximately 11002С.

Fig. 8 is a graph of DTA results with two cycles when heated from 9007C to 13007 at a temperature increase rate of 10"C/min in an argon atmosphere for a sample containing approximately 87.59o cobalt and approximately 12.595 silicon. The graph shows that the melting temperature of the alloy is approximately

In Fig. 9-Fig. 11 shows photomicrographs of materials produced using variants of methods according to this invention. Fig. 9 is a scanning electron microscope micrograph of a bond-cast material consisting essentially of a eutectic mixture of cobalt and boron, wherein boron is present in an amount of approximately 4 percent by weight of the total bond weight. The lighter phase 92 is SozB, and the darker phase 91 is actually cobalt. A mixture of cobalt and boron was melted by heating to approximately 1200C, followed by cooling in air to room temperature and crystallization.

Fig. 10-Fig. 12 - photomicrographs obtained using a scanning electron microscope of different locations and different features of the microstructure for the same material. The material was made by impregnating solid particles with a binder. The solid particles were a filler made of cast carbide (MU2C,

MUS), which is approximately 60-65 volume percent of the total volume of material. The filler was impregnated with a bond containing approximately 96 weight percent cobalt and 4 weight percent boron.

The seepage temperature was approximately 12857C.

Fig. 13 is a photomicrograph of the material produced by impregnating a mass of cast carbide particles 130 and an insert 131 of cemented carbide with a bond consisting actually of cobalt and boron. To produce the material shown in Fig. 13, a 3/4" diameter, 1.5" high cemented carbide insert 131 was placed in the mold to impregnate the mass of cast carbide solids 130 with a bond containing cobalt and boron. As can be seen in fig. 13, the impregnation bond and cemented carbide bond are mixed to form a single continuous matrix 132 that bonds both cast carbides and cemented carbides.

In addition, in variants of the implementation of this invention, surfacing with a hard alloy can be added.

Surfacing can be added in the manufacture of end caps, conical shells, insert conical shells and shells, if increased wear resistance is required. For example, the conical ball 160 shown in Fig. 16, may have surfacing on the teeth 161 and in the zone 162 of the apex. The body of the conical shell can also have a surfacing, for example, in the area around the nozzles. If you refer to fig. 14, the body of the bit may have a surfacing, for example, in the areas of nozzles 144, platforms 143 for measuring devices and sockets 141 for inserts. A typical surfacing material contains tungsten carbide in an alloy steel matrix.

It is to be understood that this description illustrates those aspects of the invention which are relevant for a clear understanding thereof.

Certain aspects of the present invention, which may be obvious to those skilled in the art and therefore do not facilitate understanding, are not presented in order to simplify this description. Although embodiments of the present invention are described herein, one skilled in the art after reading the above description will understand that many modifications and changes to the present invention can be made. It is assumed that all such modifications and changes are covered by the above description and clauses of the attached Formula of the invention.

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Claims (50)

1. The body of a drill bit with fixed cutting elements, made of sintered material from metallurgical powder, which includes solid particles that contain at least one of the following materials: carbide, nitride, boride, silicide, oxide 1 their solid solutions and a bond that is up to 35 90 by mass of metallurgical powder and which contains at least one metal selected from cobalt, nickel, iron and their alloys. 2. The body according to item 1I, in which the bond has a melting point in the range from 1050 "C to 1350 "C. 3. The body according to claim 1, in which the bond additionally contains at least one component that lowers the melting point, selected from at least one of the following materials: a transition metal carbide, a boride or a silicide with a content of up to 60 mass percent, a transition metal with a content of up to 50 mass percent, boron with a content of up to 10 mass percent, silicon with a content of up to 20 mass percent, chromium with a content of up to 20 mass percent and manganese with a content of up to 25 mass percent of the total mass of the bond. 4. The body according to item I, in which the solid particles are at least one of the following: individual single crystals, polycrystalline particles, solid solutions, polycrystalline particles that contain two or more phases, sintered granules containing a bond, and sintered granules without connection. 5. The body according to item I, in which the solid particles contain at least one transition metal carbide selected from titanium carbide, chromium carbide, vanadium carbide, zirconium carbide, hafnium carbide, tantalum carbide, molybdenum carbide, niobium carbide and tungsten carbide. 6. The body according to claim 3, in which the component that lowers the melting point is at least one of the following materials: tungsten carbide, boride 1 silicide with a content in the range from 30 to 60 mass percent of the total mass of the bond. 7. The housing according to claim 1, in which the carbide is at least one transition metal carbide selected from titanium carbide, chromium carbide, vanadium carbide, zirconium carbide, hafnium carbide, tantalum carbide, molybdenum carbide, niobium carbide, and tungsten carbide. 8. The housing according to claim 7, in which the transition metal carbide contained in the solid particles is tungsten carbide. 9. The housing according to claim 8, in which the bond additionally contains at least one transition metal carbide selected from titanium carbide, tantalum carbide, niobium carbide, chromium carbide, molybdenum carbide, boron carbide, carbon carbide, silicon carbide and ruthenium carbide. 10. The housing according to claim 7, in which the concentration of transition metal carbide in the metallurgical powder is in the range of 30 to 99 percent by volume. 11. The body according to item I, which additionally contains at least one cemented carbide insert attached to the sintered material. 12. The housing of claim 11, wherein the cemented carbide insert includes at least one socket for the cutting element. 13. The body according to point I, in which the bond is more than 20 percent by volume of metallurgical powder. 14. Bit body according to claim 13, in which the bond is from 20 to 60 volume percent of metallurgical powder. 15. Bit body according to claim 13, in which the bond is from 20 to 50 volume percent of metallurgical powder. 16. The bit body according to claim 13, in which the bond is from 25 to 40 volume percent of the metallurgical powder. 17. The body according to item 1I, in which the solid particles contain crystals containing tungsten carbides, and the bond contains cobalt. 18. The body according to claim 1, which additionally includes a shank of alloy steel attached to the sintered material. 19. The body of claim I, wherein the sintered material has a transverse tear strength greater than 300 lb/sq. inch. 20. The body of claim 1, wherein the sintered material has a transverse tear strength greater than 280 lb/sq. inch, 1 Young's modulus exceeding 55,000,000 lb/sq. inch. 21. The method of manufacturing a bit body with fixed cutting elements, which includes the following stages: compaction of metallurgical powder to form a raw, unsintered billet, and the metallurgical powder contains a set of solid particles selected from the group consisting of carbides, nitrides, borides, silicides, oxides and their solid solutions, and a bond that is up to 35 90 of masses of metallurgical powder 1 containing a metal selected from the group consisting of cobalt, nickel, iron and their alloys; formation of the body of the chisel with fixed cutting elements, which essentially consists of the composite material of the unsintered workpiece. 22. The method according to claim 21, which further includes placing the cutting element in a socket formed in the formed body of the bit. 23. The method according to claim 21, in which forming the body of the bit further includes pre-sintering the unsintered blank to form the pre-sintered blank and sintering the pre-sintered blank. 24. The method according to claim 23, which additionally includes machining the pre-sintered preform before sintering the pre-sintered preform. 25. The method according to claim 23, which additionally includes mechanical processing of the unsintered blank before preliminary sintering of the unsintered blank. 26. The method according to claim 25, which additionally includes machining at least one socket for the cutting element in the unsintered workpiece. 27. The method according to claim 21, in which compacting the metallurgical powder includes pressing the metallurgical powder. 28. The method according to claim 27, in which pressing of metallurgical powder includes isostatic pressing of metallurgical powder. 29. The method according to claim 21, in which the plurality of solid particles contains a transition metal carbide selected from the group consisting of titanium carbide, chromium carbide, vanadium carbide, zirconium carbide, hafnium carbide, tantalum carbide, molybdenum carbide, niobium carbide and tungsten carbide . 30. The method according to claim 23, in which the sintering of the pre-sintered billet is carried out under a pressure of 300-2000 lb/sq. inch and at a temperature of 1350 2C-1500 2C. 31. The method according to claim 21, in which the metallurgical powder contains a first region having a first composition and a second region having a second composition. 32. The method according to claim 21, which additionally includes placing the first composition of the metallurgical powder in the first region of the cavity of the mold for the unsintered blank 1 and placing the second composition of the metallurgical powder in the second region of the cavity, performed before compaction of the metallurgical powder. 33. The method according to claim 21, which additionally includes attaching the shank to the bit body. 34. The method according to claim 24, in which the machining includes machining at least one socket for the cutting element in the pre-sintered workpiece. 35. The method of claim 21, wherein the formed bit body has a transverse tear resistance greater than 300 lb/sq. inch. 36. The method of claim 35, wherein the Young's modulus of the formed bit body exceeds 55,000,000 lb/sq. inch. 37. The method of manufacturing a body of a drill bit with fixed cutting elements, which includes the following stages: compaction of metallurgical powder to form a compacted powder, and the metallurgical powder contains a set of solid particles selected from the group consisting of carbides, nitrides, borides, silicides, oxides 1 their solid solutions and the bond, which is up to 35 90 from the mass of metallurgical powder 1 containing a metal selected from the group consisting of cobalt, nickel, iron 1 and their alloys; forming a bit body with fixed cutting elements, which essentially consists of compacted powder, which includes at least one stage of compacted powder sintering. 38. The method according to claim 37, which further includes placing the cutting element in a socket formed in the formed body of the bit. 39. The method according to claim 37, in which the formation of the bit body includes pre-sintering of compacted powder to form the pre-sintered blank 1 sintering of the pre-sintered blank. 40. The method according to claim 39, which additionally includes machining the pre-sintered preform before sintering the pre-sintered preform. 41. The method according to claim 37, in which compacting the metallurgical powder includes pressing the metallurgical powder. 42. The method according to claim 41, in which pressing of metallurgical powder includes isostatic pressing of metallurgical powder. 43. The method according to claim 37, in which the plurality of solid particles contains a transition metal carbide selected from the group consisting of titanium carbide, chromium carbide, vanadium carbide, zirconium carbide, hafnium carbide, tantalum carbide, molybdenum carbide, niobium carbide and tungsten carbide . 44. The method according to claim 39, in which the sintering of the pre-sintered billet is carried out under a pressure of 300-2000 lb/sq. inch and at a temperature of 1350 2C-1500 2C. 45. The method according to claim 37, in which the metallurgical powder contains a first section having a first composition and a second section having a second composition. 46. The method according to claim 37, which additionally includes the placement of the first composition of the metallurgical powder in the first region of the mold cavity and the placement of the second composition of the metallurgical powder in the second region of the cavity, performed before compaction of the metallurgical powder. 47. The method according to claim 37, which additionally includes attaching the shank to the bit body. 48. The method according to claim 40, in which the machining includes machining at least one socket for the cutting element in the pre-sintered workpiece. 49. The method of claim 37, wherein the formed bit body has a transverse tear resistance greater than 300 lb/sq. inch. 50. The method of claim 37, wherein the Young's modulus of the formed bit body exceeds 000,000 lb/sq. inch.