Baker Hughes Corporation

Kenneth E Gilmore

James Leslie Overstreet

Alan J Massey

David Keith Luce

Keith L Nehring

Travis E Puzz

Timothy P Uno

John H Stevens

Robert J Buske

Jeremy K Morgan

Michael L Doster

Bruce Stauffer

Mark E Morris

Robert M Welch

Danielle V Roberts

James C Green

Methods of repairing earth-boring tools may involve providing wear-resistant material over a temporary displacement member to repair a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools may include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature may be configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools may include a depth-of-cut control feature extending over a temporary displacement member.

Methods of repairing cutting element pockets in earth-boring tools with depth-of-cut control features

Methods of depositing hardfacing material portions of earth-boring tools may involve supporting at least a portion of an earth-boring tool in a holder of a workpiece positioner, the holder being movable in at least a third plane. A location of a surface of the at least a portion of the earth-boring tool may be determined utilizing at least one sensor. The workpiece positioner, the sensor, and a torch positioner comprising a hardfacing torch movable in at least a first plane perpendicular to the third plane and a second plane parallel to the third plane may be controlled utilizing a programmable control system to cause the torch positioner to oscillate the hardfacing torch in the second plane while selectively causing the workpiece positioner to move the holder in the third plane and causing the torch to deposit hardfacing material on the surface.

Methods for automated deposition of hardfacing material on earth-boring tools and related systems

Methods for depositing hardfacing material on portions of drill bits comprise providing a vertically oriented plasma transfer arc torch secured to a positioner having controllable movement in a substantially vertical plane. A rolling cutter is secured to a chuck mounted on an articulated arm of a robot. A surface of a tooth of the rolling cutter is positioned in a substantially perpendicular relationship beneath the torch. The torch is oscillated along a substantially horizontal axis. The rolling cutter is moved with the articulated arm of the robot in a plane beneath the oscillating torch. A hardfacing material is deposited on the tooth of the rolling cutter.

Methods for automated application of hardfacing material to drill bits

Methods of forming and repairing earth-boring tools include providing wear-resistant material over a temporary displacement member to form a cutting element pocket in a body and a depth-of-cut control feature using the wear-resistant material. In some embodiments, the wear-resistant material may comprise a particle-matrix composite material. For example, a hardfacing material may be built up over a temporary displacement member to form or repair a cutting element pocket and provide a depth-of-cut control feature. Earth-boring tools include a depth-of-cut control feature comprising a wear-resistant material. The depth-of-cut control feature is configured to limit a depth-of-cut of a cutting element secured within a cutting element pocket partially defined by at least one surface of the depth-of-cut control feature. Intermediate structures formed during fabrication of earth-boring tools include a depth-of-cut control feature extending over a temporary displacement member.

Methods of forming and repairing cutting element pockets in earth-boring tools with depth-of-cut control features, and tools and structures formed by such methods

Hardfacing is applied on gage surfaces of bit blades, the leading and trailing edges of bit blades, and on carbide inserts. The gage surfaces contains natural diamonds, synthetic diamonds, thermally stable polycrystalline (TSP) diamonds and carbide inserts, and the hardfacing is applied over at least a portion of them. As primary cutters on the bit blades are worn down during drilling, the gage surfaces of the bit blades are also worn down. A hardfacing is applied to the worn gage surfaces of the bit blades, thereby allowing the drill bit to drill deeper and longer without requiring replacement.

Method of repairing diamond rock bit

The present invention relates to a system and method for automated or 'robotic' application of hardfacing to the surface of a steel-toothed cutter of a rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program selection, and welding program correction. The control system, aided by data from the sensors, manipulates the robotically held cutter while controlling the operation and oscillation of the torch.

Method and apparatus for the automated application of hardfacing material to rolling cutters of earth-boring drill bits

The present invention relates to a system and method for automated or 'robotic' application of hardfacing to the surface of a steel-toothed cutter of a standard earth-boring rock bit or a hybrid-type rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter, particularly a hybrid rock bit cutter, beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program selection, and welding program correction. The control system, aided by data from the sensors, manipulates the robotically held cutter while controlling the operation and oscillation of the torch. These systems and methods can be applied to hardfacing steel teeth of the rolling cutters of both standard tri-cone or di-cone type rolling cone bits, as well as to hybrid-type earth boring drill bits.

Method and apparatus for automated application of hardfacing material to rolling cutters of hybrid-type earth boring drill bits, hybrid drill bits comprising such hardfaced steel-toothed cutting elements, and methods of use thereof

A system and method for the automated or 'robotic' application of hardfacing to a surface of a drill bit.

Apparatus for automated application of hardfacing material to drill bits

Earth-boring tools include wear-resistant materials disposed in at least one recess formed in an exterior surface of a body thereof. Exposed surfaces of the wear-resistant material are substantially level with exterior surfaces of the body adjacent the wear-resistant material. In some embodiments, recesses may be formed in formation-engaging surfaces of blades of earth-boring rotary tools, adjacent one or more inserts secured to bodies of earth-boring tools, or adjacent one or more cutting elements secured to bodies of earth-boring tools. Methods of forming earth-boring tools include filling one or more recesses formed in an exterior surface of a body with wear-resistant material and causing exposed surfaces of the wear-resistant material to be substantially level with the exterior surface of the body.

Methods for applying wear-resistant material to exterior surfaces of earth-boring tools and resulting structures

Earth-boring tools include at least one up-drill feature disposed on a transition surface so as to be passive during down drilling and active during up drilling and/or back reaming operations. Systems for down drilling and up drilling with drill bits comprising one or more up-drill features are also disclosed. Furthermore, methods for forming a borehole with an earth-boring tool including such up-drill features and for forming an earth-boring tool comprising such up-drill features are also disclosed.

Passive and active up-drill features on fixed cutter earth-boring tools and related systems and methods

A rotary drill bit includes a bit body substantially formed of a particle-matrix composite material having an exterior surface and an abrasive wear-resistant material disposed on at least a portion of the exterior surface of the bit body. Methods for applying an abrasive wear-resistant material to a surface of a drill bit are also provided.

Particle-matrix composite drill bits with hardfacing

A drill bit having steel teeth is provided with a combination of hardfacing materials on the teeth. The bases of the teeth are hardfaced with nickel-based materials to significantly reduce any potential cracking therein. Portions of the supporting cones adjacent the teeth also may be fabricated with the nickel-based hardfacing. All other portions of the teeth are hardfaced with iron-based materials.

Growing community of inventors

Cleveland, TX, United States of America

Kenneth E Gilmore