WO2016099459A1 - Downhole tools with hard, fracture-resistant tungsten carbide elements - Google Patents
Downhole tools with hard, fracture-resistant tungsten carbide elements Download PDFInfo
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- WO2016099459A1 WO2016099459A1 PCT/US2014/070603 US2014070603W WO2016099459A1 WO 2016099459 A1 WO2016099459 A1 WO 2016099459A1 US 2014070603 W US2014070603 W US 2014070603W WO 2016099459 A1 WO2016099459 A1 WO 2016099459A1
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- tungsten carbide
- cemented tungsten
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- downhole tool
- cemented
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- 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
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
Definitions
- the present disclosure relates to cemented tungsten carbide-based downhole elements
- Downhole tools such as earth-boring drill bits, often contain elements formed from tungsten carbide. Although such elements are suitable for many applications, they typically exhibit a trade-off between hardness and fracture toughness in the tungsten carbide. This trade-off occurs both in elements made largely of cemented tungsten carbide and elements that contain pellets, particles, or inserts of tungsten carbide.
- FIGURE 1A is a micrograph of cemented tungsten carbide with angular particles
- FIGURE IB is a micrograph of cemented tungsten carbide with rounded particles
- FIGURE 2 is a graph of the typical trade-off between hardness and fracture toughness in cemented tungsten carbide (line), and the area in which cemented tungsten carbide with rounded particles lies (rectangle);
- FIGURE 3 is one embodiment of a roller cone drill bit with a tungsten-carbide insert with rounded particles
- FIGURE 4 is a cross-section of a polycrystalline diamond cutting element with a cemented tungsten carbide insert with rounded particles.
- the present disclosure relates to cemented tungsten carbide-based downhole elements containing rounded tungsten carbide particles. These particles impart improvements to the typical trade-off between hardness and fracture toughness in cemented tungsten carbide.
- Rounded tungsten carbide particles are defined with reference to ASTM International Standard ASTM D 2488, as applied to tungsten carbide particles instead of soil.
- angular particles such as those shown in FIGURE 1A
- Subangular particles-particles are similar to angular particles, but have rounded edges.
- Subrounded particles have nearly plane sides but have well-rounded corners and edges.
- Rounded particles such as those shown in FIGURE IB, are particles that have smoothly curved sides and no edges.
- Cemented tungsten carbide according to the present disclosure may contain rounded tungsten carbide particles, such as may be seen in the right micrograph of FIGURE 1. These particles may be contained in a cementing material, such as a binder.
- the cemented tungsten carbide may contain substantially no, less than 0.1%, less than 0.5%, less than 1%, or less then 5% angular tungsten carbide particles, such as those depicted in the left micrograph of FIGURE 1, which are used conventionally.
- Rounded tungsten carbide particles may have a measurable angle at a junction of two surfaces on 1% or less, 0.5%> or less, or 0.1 % or less of their total surface area.
- Rounded tungsten carbide particles may be substantially spherical or ovoid in shape.
- Rounded tungsten carbide particles may be produced through mechanical processes, such as milling or grinding processes, or they may be chemically processed to produce a rounded shape.
- Cemented tungsten carbide conventionally contains a particular grade of carbide and a cementing material. However, even with a variety of combinations, there is typically a fairly linear trade-off between hardness and fracture toughness in conventional cemented tungsten carbide as shown by the line in FIGURE 2.
- the use of rounded tungsten carbide produces an improved combination of hardness and fracture toughness in the region of the box in FIGURE 2. This improvement may be with respect to an otherwise identical cemented tungsten carbide containing angular tungsten carbide particles, or it may be with respect to any cemented tungsten carbide containing angular tungsten carbide particles. This improvement may result because rounded tungsten carbide particles prevent or slow the initiation and propagation of any cracks that form in the cemented tungsten carbide.
- the rounded tungsten carbide particles may be micron sized or nano sized. For example, they may be small nano (less than 200 nm), medium nano (200 nm to ⁇ ), or micron (1 ⁇ to 10 ⁇ ) in size. They may have the same general dimensions as conventional angular tungsten carbide particles.
- the rounded tungsten carbide particles may be substantially all within a particular size range or grade or they may be at least two different size ranges or grades. The use of two different size ranges or grades may allow the tungsten carbide particles to be packed more tightly.
- the rounded tungsten carbide particles may also be present in any appropriate proportion of the cemented tungsten carbide.
- the cemented tungsten carbide may contain between 10% and 96% rounded tungsten carbide particles by volume.
- the rounded tungsten carbide particles may be present in the same general proportions as conventional angular tungsten carbide particles.
- the cementing material may include any conventional cementing material, such as a binder. Binders commonly include Group VIII metals or Group VIII metal alloys, such a cobalt (Co), iron (Fe) or nickel (Ni). The proportions of any metal, such as Co, Fe or Ni, present in the cementing material may be similar to conventional amounts. In addition, because the cementing material, particularly metal-based components, usually detract from the hardness of the cemented tungsten carbide, cementing material proportions and compositions may be adjusted outside of conventional parameters and still used with rounded tungsten carbide particles to obtain a suitable cemented tungsten carbide material.
- the rounded tungsten carbide particles may be formed from any type of tungsten carbide, including WC and W 2 C.
- the cemented tungsten carbide may have a hardness in the range of 88-92 HRA (Rockwell Standard A). They may have a fractures toughness range of 16-20
- Cemented tungsten carbide containing rounded tungsten carbide particles may be formed using any method otherwise able to form cemented tungsten carbide. For instance, it may be formed using a sintering process, such as sinter-hipping or rapid omnidirectional compaction, and microwave sintering. Special molds or adjustments to the processes may be used, if applicable, but typically are not needed.
- a sintering process such as sinter-hipping or rapid omnidirectional compaction, and microwave sintering. Special molds or adjustments to the processes may be used, if applicable, but typically are not needed.
- Cemented tungsten carbides of the present disclosure may be used in the place of any conventional cemented tungsten carbide in a downhole tool used in connection with the formation, use, or maintenance of a wellbore in a formation.
- cemented tungsten carbides of the present disclosure may also sometimes be used in place of other hard or superhard materials, such as polycrystalline diamond (PCD) in downhole tools.
- PCD polycrystalline diamond
- FIGURE 3 is an elevation view of roller cone drill bit 10.
- Drill bit 10 as shown in FIGURE 3 may be referred to as a "roller cone drill bit,” “rotary cone drill bit,” “rotary rock bit,” or “rock bit.”
- Drill bit 10 may include various types of such bits.
- Roller cone drill bits may have at least one support arm with a respective cone assembly rotatably disposed thereon.
- a drill string 64 may be attached to and rotate drill bit 10 relative to bit rotational axis 12.
- Drill bit 10 may rotate as indicated by arrow 13.
- Cutting action associated with forming a wellbore in a downhole formation may occur as cone assemblies, indicated generally at 40, engage and roll around the bottom or downhole end of a borehole or wellbore (not shown) in response to rotation of drill bit 10.
- Cone assembly 40 may be referred to as a "roller cone,” “rotary cone cutter,”
- Each of cone assemblies 40 may include a plurality of cutting elements or inserts 42 which penetrate and scrape against adjacent portions of a downhole formation in response to rotation of drill bit 10.
- Cone assemblies 40 may also include a plurality of compacts 44 disposed on respective gauge surface 46 of each cone assembly 40. These compacts may include or be formed substantially from a cemented tungsten carbide according to the present disclosure.
- Cutting elements 42 may include various types of compacts, inserts, milled teeth and welded compacts satisfactory for use with roller cone drill bits. In particular, cutting elements 42 may include or be formed substantially form a cemented tungsten carbide according to this disclosure.
- Cone assembly 40 may also include generally circular base portion 45.
- Drill bit 10 may include bit body 16 having three support arms 18 extending therefrom. Only two support arms 18 may be seen in FIGURE 3, but the teachings of the present disclosure may be used in drill bits with various numbers of support arms 18. Support arms 18 may also include a plurality of compacts 50 on the exterior portion 24. These compacts may include or be formed substantially from a cemented tungsten carbide according to the present disclosure. Uphole portion or pin end 20 of drill bit 10 may include generally tapered, external threads 22. Threads 22 may be used to releasably engage drill bit 10 with the downhole end of an associated drill string or bottomhole assembly (not expressly shown).
- Formation materials and other downhole debris created during impact between cutting elements or inserts 42 and adjacent portions of a downhole formation may be carried from the bottom or end of an associated wellbore by drilling fluid flowing from nozzles 30.
- drilling fluid may be supplied to drill bit 10 by a drill string 64 attached to threads 22.
- Drilling fluid with formation cuttings and other downhole debris may flow upwardly around exterior portions of drill bit 10 and through an annulus (not expressly shown) formed between exterior portions of drill bit 10 and exterior portions of an attached drill string and inside diameter or side wall of the wellbore to an associated well surface (not expressly shown).
- Nozzles 30 or other components of drill bit 10 designed to direct drilling fluid or prevent or slow erosion may include or be formed substantially from cemented tungsten carbide according to the present disclosure.
- Each support arm 18 may include a respective lubricant system 60.
- Lubricant may refer to any fluid, grease, composite grease, or mixture of fluids and solids satisfactory for lubricating journal bearings, thrust bearings, bearing surfaces, bearing assemblies and/or other supporting structures associated with rotatably mounting one or more cone assemblies on a roller cone drill bit.
- Lubricant system 60 may include external end or opening 62 adjacent to exterior portion 24 of associated support arm 18.
- One or more components of lubricant system 60, such as internal bearings (not shown) may include or be formed substantially from a cemented tungsten carbide according to the present disclosure.
- Cemented tungsten carbide according to the present disclosure may be used in a similar capacity in other earth-boring drill bits, such as fixed cutter drill bits or diamond-impregnated bits.
- it may be included in or used to substantially form motion control elements such as backup arrestors, impact arrestors, and gage surfaces, fluid flow directing components, and erosion-resistant surfaces.
- cemented tungsten carbide may also be used as a substrate 120 for a PCD layer 110 in a PCD element 100, such as the pictured cutter for a fixed cutter drill bit.
- the cemented tungsten carbide may be particularly useful in forming PCD elements with an unusual geometry, particularly at the interface of substrate 120 and PCD layer 110.
- the PCD may benefit from reduced metal as well.
- downhole tools that may include components formed from cemented tungsten carbide according to the present disclosure include downhole motors.
- Injection-molded components or other components that are difficult to form from superhard materials, such as PCD, may be particularly well-suited to being formed from cemented tungsten carbides of the present disclosure.
- the present disclosure also relates to a method of making a cemented tungsten carbide in which rounded tungsten carbide particles are mixed with cementing material then subjected to a high temperature process. Because they are already rounded, the tungsten carbide particles undergo little to no additional rounding during the high temperature process.
- the disclosure provides a downhole tool including a cemented tungsten carbide, the cemented tungsten carbide including a plurality of rounded tungsten carbide particles and a cementing material.
- the disclosure provides a roller cone drill bit including a spindle or journal, a cone assembly disposed on the spindle or journal and comprising at least one cutter, and a cemented tungsten carbide, wherein the cemented tungsten carbide includes a plurality of rounded tungsten carbide particles, and a cementing material.
- the disclosure provides a fixed cutter drill bit including a bit body, at least one superhard cutter, and a cemented tungsten carbide, wherein the cemented tungsten carbide includes a plurality of rounded tungsten carbide particles, and a cementing material.
- the cemented tungsten carbide may have a
- the rounded tungsten carbide particles may be substantially spherical; 3) the rounded tungsten carbide particles may be on average less then 200 nm in size; 4) the rounded tungsten carbide particles may be on average between 200 nm and 1 ⁇ in size; 5) the rounded tungsten carbide particles may be on average between 1 ⁇ and 10 ⁇ in size; 6) the rounded tungsten carbide particles may be of at least two different average sizes or grades; 7) the cemented tungsten carbide may less of a trade-off between hardness and fracture toughness than an otherwise identical cemented tungsten carbide including a plurality of angular tungsten carbide particles; 8) the tool may include a cutter including the cemented tungsten carbide; 9) the cutter may be a superhard cutter; 10) the cutter may further include PCD; 11) the tool may include a motion control element including the
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Abstract
The present disclosure relates to downhole tools containing cemented tungsten carbide including rounded tungsten carbide particles. The cemented tungsten carbide may not exhibit convention trade-offs between hardness and fracture-resistance.
Description
DOWNHOLE TOOLS WITH HARD, FRACTURE-RESISTANT TUNGSTEN
CARBIDE ELEMENTS
TECHNICAL FIELD
The present disclosure relates to cemented tungsten carbide-based downhole elements
BACKGROUND
Downhole tools, such as earth-boring drill bits, often contain elements formed from tungsten carbide. Although such elements are suitable for many applications, they typically exhibit a trade-off between hardness and fracture toughness in the tungsten carbide. This trade-off occurs both in elements made largely of cemented tungsten carbide and elements that contain pellets, particles, or inserts of tungsten carbide. BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings in which:
FIGURE 1A is a micrograph of cemented tungsten carbide with angular particles;
FIGURE IB is a micrograph of cemented tungsten carbide with rounded particles;
FIGURE 2 is a graph of the typical trade-off between hardness and fracture toughness in cemented tungsten carbide (line), and the area in which cemented tungsten carbide with rounded particles lies (rectangle);
FIGURE 3 is one embodiment of a roller cone drill bit with a tungsten-carbide insert with rounded particles;
FIGURE 4 is a cross-section of a polycrystalline diamond cutting element with a cemented tungsten carbide insert with rounded particles.
DETAILED DESCRIPTION
The present disclosure relates to cemented tungsten carbide-based downhole
elements containing rounded tungsten carbide particles. These particles impart improvements to the typical trade-off between hardness and fracture toughness in cemented tungsten carbide.
Rounded tungsten carbide particles are defined with reference to ASTM International Standard ASTM D 2488, as applied to tungsten carbide particles instead of soil. According to this standard, angular particles, such as those shown in FIGURE 1A, are particles that have sharp edges and relatively plane sides with unpolished surfaces. Subangular particles-particles are similar to angular particles, but have rounded edges. Subrounded particles have nearly plane sides but have well-rounded corners and edges. Rounded particles, such as those shown in FIGURE IB, are particles that have smoothly curved sides and no edges.
Cemented tungsten carbide according to the present disclosure may contain rounded tungsten carbide particles, such as may be seen in the right micrograph of FIGURE 1. These particles may be contained in a cementing material, such as a binder. The cemented tungsten carbide may contain substantially no, less than 0.1%, less than 0.5%, less than 1%, or less then 5% angular tungsten carbide particles, such as those depicted in the left micrograph of FIGURE 1, which are used conventionally.
Rounded tungsten carbide particles may have a measurable angle at a junction of two surfaces on 1% or less, 0.5%> or less, or 0.1 % or less of their total surface area. Rounded tungsten carbide particles may be substantially spherical or ovoid in shape. Rounded tungsten carbide particles may be produced through mechanical processes, such as milling or grinding processes, or they may be chemically processed to produce a rounded shape.
Cemented tungsten carbide conventionally contains a particular grade of carbide and a cementing material. However, even with a variety of combinations, there is typically a fairly linear trade-off between hardness and fracture toughness in conventional cemented tungsten carbide as shown by the line in FIGURE 2. The use of rounded tungsten carbide produces an improved combination of hardness and fracture toughness in the region of the box in FIGURE 2. This improvement may be with respect to an otherwise identical cemented tungsten carbide containing angular tungsten carbide particles, or it may be with respect to any cemented tungsten carbide containing angular tungsten carbide particles. This improvement may result because
rounded tungsten carbide particles prevent or slow the initiation and propagation of any cracks that form in the cemented tungsten carbide.
The rounded tungsten carbide particles may be micron sized or nano sized. For example, they may be small nano (less than 200 nm), medium nano (200 nm to Ιμιη), or micron (1 μιη to 10 μιη) in size. They may have the same general dimensions as conventional angular tungsten carbide particles. The rounded tungsten carbide particles may be substantially all within a particular size range or grade or they may be at least two different size ranges or grades. The use of two different size ranges or grades may allow the tungsten carbide particles to be packed more tightly.
The rounded tungsten carbide particles may also be present in any appropriate proportion of the cemented tungsten carbide. For example, the cemented tungsten carbide may contain between 10% and 96% rounded tungsten carbide particles by volume. The rounded tungsten carbide particles may be present in the same general proportions as conventional angular tungsten carbide particles.
The cementing material may include any conventional cementing material, such as a binder. Binders commonly include Group VIII metals or Group VIII metal alloys, such a cobalt (Co), iron (Fe) or nickel (Ni). The proportions of any metal, such as Co, Fe or Ni, present in the cementing material may be similar to conventional amounts. In addition, because the cementing material, particularly metal-based components, usually detract from the hardness of the cemented tungsten carbide, cementing material proportions and compositions may be adjusted outside of conventional parameters and still used with rounded tungsten carbide particles to obtain a suitable cemented tungsten carbide material.
The rounded tungsten carbide particles may be formed from any type of tungsten carbide, including WC and W2C.
The cemented tungsten carbide may have a hardness in the range of 88-92 HRA (Rockwell Standard A). They may have a fractures toughness range of 16-20
1/2
kilo pound force per square inch (ksi).in .
Cemented tungsten carbide containing rounded tungsten carbide particles may be formed using any method otherwise able to form cemented tungsten carbide. For instance, it may be formed using a sintering process, such as sinter-hipping or rapid omnidirectional compaction, and microwave sintering. Special molds or adjustments
to the processes may be used, if applicable, but typically are not needed.
Cemented tungsten carbides of the present disclosure may be used in the place of any conventional cemented tungsten carbide in a downhole tool used in connection with the formation, use, or maintenance of a wellbore in a formation. In addition, due to the improved trade-off between hardness and fracture toughness, cemented tungsten carbides of the present disclosure may also sometimes be used in place of other hard or superhard materials, such as polycrystalline diamond (PCD) in downhole tools.
One such downhole tool may be an earth-boring drill bit or other components of an oil or mining drilling operation. FIGURE 3 is an elevation view of roller cone drill bit 10. Drill bit 10 as shown in FIGURE 3 may be referred to as a "roller cone drill bit," "rotary cone drill bit," "rotary rock bit," or "rock bit." Drill bit 10 may include various types of such bits. Roller cone drill bits may have at least one support arm with a respective cone assembly rotatably disposed thereon.
A drill string 64 may be attached to and rotate drill bit 10 relative to bit rotational axis 12. Drill bit 10 may rotate as indicated by arrow 13. Cutting action associated with forming a wellbore in a downhole formation may occur as cone assemblies, indicated generally at 40, engage and roll around the bottom or downhole end of a borehole or wellbore (not shown) in response to rotation of drill bit 10.
Cone assembly 40 may be referred to as a "roller cone," "rotary cone cutter,"
"roller cone cutter," "rotary cutter assembly" and "cutter cone assembly." Each of cone assemblies 40 may include a plurality of cutting elements or inserts 42 which penetrate and scrape against adjacent portions of a downhole formation in response to rotation of drill bit 10. Cone assemblies 40 may also include a plurality of compacts 44 disposed on respective gauge surface 46 of each cone assembly 40. These compacts may include or be formed substantially from a cemented tungsten carbide according to the present disclosure. Cutting elements 42 may include various types of compacts, inserts, milled teeth and welded compacts satisfactory for use with roller cone drill bits. In particular, cutting elements 42 may include or be formed substantially form a cemented tungsten carbide according to this disclosure. Cone assembly 40 may also include generally circular base portion 45.
Drill bit 10 may include bit body 16 having three support arms 18 extending therefrom. Only two support arms 18 may be seen in FIGURE 3, but the teachings of the present disclosure may be used in drill bits with various numbers of support arms 18. Support arms 18 may also include a plurality of compacts 50 on the exterior portion 24. These compacts may include or be formed substantially from a cemented tungsten carbide according to the present disclosure. Uphole portion or pin end 20 of drill bit 10 may include generally tapered, external threads 22. Threads 22 may be used to releasably engage drill bit 10 with the downhole end of an associated drill string or bottomhole assembly (not expressly shown).
Formation materials and other downhole debris created during impact between cutting elements or inserts 42 and adjacent portions of a downhole formation may be carried from the bottom or end of an associated wellbore by drilling fluid flowing from nozzles 30. Such drilling fluid may be supplied to drill bit 10 by a drill string 64 attached to threads 22. Drilling fluid with formation cuttings and other downhole debris may flow upwardly around exterior portions of drill bit 10 and through an annulus (not expressly shown) formed between exterior portions of drill bit 10 and exterior portions of an attached drill string and inside diameter or side wall of the wellbore to an associated well surface (not expressly shown). Nozzles 30 or other components of drill bit 10 designed to direct drilling fluid or prevent or slow erosion, may include or be formed substantially from cemented tungsten carbide according to the present disclosure.
Each support arm 18 may include a respective lubricant system 60. Lubricant may refer to any fluid, grease, composite grease, or mixture of fluids and solids satisfactory for lubricating journal bearings, thrust bearings, bearing surfaces, bearing assemblies and/or other supporting structures associated with rotatably mounting one or more cone assemblies on a roller cone drill bit. Lubricant system 60 may include external end or opening 62 adjacent to exterior portion 24 of associated support arm 18. One or more components of lubricant system 60, such as internal bearings (not shown) may include or be formed substantially from a cemented tungsten carbide according to the present disclosure.
Cemented tungsten carbide according to the present disclosure may be used in a similar capacity in other earth-boring drill bits, such as fixed cutter drill bits or
diamond-impregnated bits. For example, it may be included in or used to substantially form motion control elements such as backup arrestors, impact arrestors, and gage surfaces, fluid flow directing components, and erosion-resistant surfaces.
As shown in FIGURE 4, cemented tungsten carbide according to the present disclosure may also be used as a substrate 120 for a PCD layer 110 in a PCD element 100, such as the pictured cutter for a fixed cutter drill bit. The cemented tungsten carbide may be particularly useful in forming PCD elements with an unusual geometry, particularly at the interface of substrate 120 and PCD layer 110. In embodiments where less Co or other metal may be included in the cementing material as compared to conventional cemented tungsten carbide, the PCD may benefit from reduced metal as well.
Other downhole tools that may include components formed from cemented tungsten carbide according to the present disclosure include downhole motors. Injection-molded components or other components that are difficult to form from superhard materials, such as PCD, may be particularly well-suited to being formed from cemented tungsten carbides of the present disclosure.
The present disclosure also relates to a method of making a cemented tungsten carbide in which rounded tungsten carbide particles are mixed with cementing material then subjected to a high temperature process. Because they are already rounded, the tungsten carbide particles undergo little to no additional rounding during the high temperature process.
In an embodiment A, the disclosure provides a downhole tool including a cemented tungsten carbide, the cemented tungsten carbide including a plurality of rounded tungsten carbide particles and a cementing material.
In an embodiment B, the disclosure provides a roller cone drill bit including a spindle or journal, a cone assembly disposed on the spindle or journal and comprising at least one cutter, and a cemented tungsten carbide, wherein the cemented tungsten carbide includes a plurality of rounded tungsten carbide particles, and a cementing material.
In an embodiment C, the disclosure provides a fixed cutter drill bit including a bit body, at least one superhard cutter, and a cemented tungsten carbide, wherein the
cemented tungsten carbide includes a plurality of rounded tungsten carbide particles, and a cementing material.
In addition, the following elements may be combined with each other and any of embodiments A, B and C above: 1) the cemented tungsten carbide may have a
1/2 hardness of between 88-92 HRA and a fracture toughness of between 16-20 Ksi.in ; 2) wherein the rounded tungsten carbide particles may be substantially spherical; 3) the rounded tungsten carbide particles may be on average less then 200 nm in size; 4) the rounded tungsten carbide particles may be on average between 200 nm and 1 μιη in size; 5) the rounded tungsten carbide particles may be on average between 1 μιη and 10 μιη in size; 6) the rounded tungsten carbide particles may be of at least two different average sizes or grades; 7) the cemented tungsten carbide may less of a trade-off between hardness and fracture toughness than an otherwise identical cemented tungsten carbide including a plurality of angular tungsten carbide particles; 8) the tool may include a cutter including the cemented tungsten carbide; 9) the cutter may be a superhard cutter; 10) the cutter may further include PCD; 11) the tool may include a motion control element including the cemented tungsten carbide; 12) the tool may include a fluid flow directing component including the cemented tungsten carbide; 13) the tool may include an erosion-resistant surface including the cemented tungsten carbide; 14) the tool may include a bearing including the cemented tungsten carbide.
Although only exemplary embodiments of the invention are specifically described above, it will be appreciated that modifications and variations of these embodiments are possible without departing from the spirit and intended scope of the invention. For example, the principles may be applied to other carbides used in downhole tools. Measurements given here are "about" or "approximately" the recited number.
Claims
1. A downhole tool comprising a cemented tungsten carbide, the cemented tungsten carbide comprising:
a plurality of rounded tungsten carbide particles; and
a cementing material.
2. The downhole tool of Claim 1, wherein the cemented tungsten carbide has a hardness of between 88-92 HRA and a fracture toughness of between 16-20 Ksi.in172.
3. The downhole tool of Claim 1, wherein the rounded tungsten carbide particles are substantially spherical.
4. The downhole tool of Claim 1, wherein the rounded tungsten carbide particles are on average less then 200 nm in size.
5. The downhole tool of Claim 1, wherein the rounded tungsten carbide particles are on average between 200 nm and 1 μιη in size. 6. The downhole tool of Claim 1, wherein the rounded tungsten carbide particles are on average between 1 μιη and 10 μιη in size.
7. The downhole tool of Claim 1, wherein the rounded tungsten carbide particles are of at least two different average sizes or grades.
8. The downhole tool of Claim 1, wherein the cemented tungsten carbide exhibits less of a trade-off between hardness and fracture toughness than an otherwise identical cemented tungsten carbide comprising a plurality of angular tungsten carbide particles.
9. The downhole tool of Claim 1, wherein the tool comprises a cutter comprising the cemented tungsten carbide.
10. The downhole tool of Claim 1, wherein the tool comprises a motion control element comprising the cemented tungsten carbide.
11. The downhole tool of Claim 1 , wherein the tool comprises a fluid flow directing component comprising the cemented tungsten carbide.
13. The downhole tool of Claim 1, wherein the tool comprises an erosion- resistant surfaces comprising the cemented tungsten carbide. 14. The downhole tool of Claim 1, wherein the tool comprises a bearing comprising the cemented tungsten carbide.
15. The downhole tool of Claim 1, wherein the tool comprises an element comprising both the cemented tungsten carbide and poly crystalline diamond (PCD).
16. A roller cone drill bit comprising:
a spindle or journal;
a cone assembly disposed on the spindle or journal and comprising at least one cutter; and
a cemented tungsten carbide, wherein the cemented tungsten carbide comprises:
a plurality of rounded tungsten carbide particles; and
a cementing material. 17. The roller cone drill bit of Claim 16, wherein the at least one cutter comprises the cemented tungsten carbide.
18. The roller cone drill bit of Claim 16, further comprising a fluid flow direction component or an erosion-resistant surface formed from the cemented tungsten carbide.
19. The roller cone drill bit of Claim 16, further comprising a motion control element formed from the cemented tungsten carbide.
20. A fixed cutter drill bit comprising:
a bit body;
at least one superhard cutter; and
a cemented tungsten carbide, wherein the cemented tungsten carbide comprises:
a plurality of rounded tungsten carbide particles; and
a cementing material.
21. The fixed cutter drill bit of Claim 20, wherein the superhard cutter comprises the cemented tungsten carbide and poly crystalline diamond (PCD). 23. The fixed cutter drill bit of Claim 20, further comprising a fluid flow direction component or an erosion-resistant surface formed from the cemented tungsten carbide.
23. The fixed cutter drill bit of Claim 20, further comprising a motion control element formed from the cemented tungsten carbide.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US2014/070603 WO2016099459A1 (en) | 2014-12-16 | 2014-12-16 | Downhole tools with hard, fracture-resistant tungsten carbide elements |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US2014/070603 WO2016099459A1 (en) | 2014-12-16 | 2014-12-16 | Downhole tools with hard, fracture-resistant tungsten carbide elements |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2016099459A1 true WO2016099459A1 (en) | 2016-06-23 |
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|---|---|---|---|
| PCT/US2014/070603 Ceased WO2016099459A1 (en) | 2014-12-16 | 2014-12-16 | Downhole tools with hard, fracture-resistant tungsten carbide elements |
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040140133A1 (en) * | 2001-12-14 | 2004-07-22 | Dah-Ben Liang | Fracture and wear resistant compounds and down hole cutting tools |
| US20090263646A1 (en) * | 2003-11-21 | 2009-10-22 | H. C. Starck Gmbh | Dual-phase hard material, method for the production thereof and its use |
| US20090260482A1 (en) * | 2005-10-11 | 2009-10-22 | Baker Hughes Incorporated | Materials for enhancing the durability of earth-boring bits, and methods of forming such materials |
| EP2610426A2 (en) * | 2011-12-30 | 2013-07-03 | Smith International, Inc. | Diamond Enhanced Drilling Insert with High Impact Resistance |
| US20130183887A1 (en) * | 2008-03-31 | 2013-07-18 | Jimmy Carlsson | Drill Bit For A Rock Drilling Tool With Increased Toughness And Method For Increasing The Toughness Of Such Drill Bits |
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- 2014-12-16 WO PCT/US2014/070603 patent/WO2016099459A1/en not_active Ceased
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040140133A1 (en) * | 2001-12-14 | 2004-07-22 | Dah-Ben Liang | Fracture and wear resistant compounds and down hole cutting tools |
| US20090263646A1 (en) * | 2003-11-21 | 2009-10-22 | H. C. Starck Gmbh | Dual-phase hard material, method for the production thereof and its use |
| US20090260482A1 (en) * | 2005-10-11 | 2009-10-22 | Baker Hughes Incorporated | Materials for enhancing the durability of earth-boring bits, and methods of forming such materials |
| US20130183887A1 (en) * | 2008-03-31 | 2013-07-18 | Jimmy Carlsson | Drill Bit For A Rock Drilling Tool With Increased Toughness And Method For Increasing The Toughness Of Such Drill Bits |
| EP2610426A2 (en) * | 2011-12-30 | 2013-07-03 | Smith International, Inc. | Diamond Enhanced Drilling Insert with High Impact Resistance |
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