Baker Hughes, a Ge Compnay, LLC

Baker Hughes Holdings LLC

Michael T Savage

Juan Miguel Bilen

James Andy Oxford

Stephen Duffy

Anthony Phillips

In some embodiments, the present disclosure includes a method of forming a body of an earth-boring downhole tool. A mold is formed that has at least one interior surface defining a mold cavity within the mold. The mold cavity has a shape corresponding to a shape of the body of the earth-boring downhole tool to be formed therein. At least one insert is formed that includes particles of hard-phase material and a binder material using an additive manufacturing process. The at least one insert is positioned within the mold cavity. Additional particles of hard-phase material are provided within the mold cavity, and the additional particles of hard-phase material are infiltrated with molten metal, thus sintering and/or infiltrating the at least one insert to form the body of the earth-boring downhole tool. The resulting body of the earth-boring downhole tool includes the sintered and/or infiltrated at least one insert.

Methods of forming earth-boring tools using inserts and molds

Earth-boring tools may include a body having blades protruding therefrom and at least one hardfacing pad secured to at least one blade. The at least one hardfacing pad may be located at least partially within a recess extending at least into the at least one blade body around a circumference of a gage region of the body and may include a plate, an abrasion-resistant material secured to the plate on a side of the plate opposite the body, and at least one spacer extending from the plate toward the body, such that the plate is spaced from the body by at least a thickness of the at least one spacer. A braze material may secure the at least one hardfacing pad to the at least one blade, the braze material extending around the at least one spacer and located between the plate and the body.

Earth-boring tools including replaceable hardfacing pads and related methods

An earth-boring tool includes a body, blades extending longitudinally and generally radially from the body, and cutting elements located on each blade. The earth-boring tool may also include a first group of at least two adjacent blades comprising the cutting elements proximate a front cutting edge of the blades and one or more shaped inserts located rotationally following the cutting elements, and a second group of one or more additional blades comprising the cutting elements proximate the front cutting edge of the blades while being entirely free of the one or more shaped inserts. Methods include drilling a subterranean formation including engaging a formation with the cutting elements and the shaped inserts of the earth-boring tool, the shaped inserts secured at selected locations on two or more adjacent blades of the first group of blades while the second group of blades is entirely free of the shaped inserts.

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Magnolia, TX, United States of America

Michael T Savage