Baker Hughes Corporation

Wesley Dean Fuller

Dan E Scott

Danny Eugene Scott

Nicholas J Lyons

Jimmy Wayne Eason

Suresh G Patel

Marcus R Skeem

Eric E McClain

Van Jordan Brackin

Robert M Welch

Christopher Joseph Cleboski

James C Green

Ben L Kirkpatrick

Andrew R Warner

J Miguel Bilen

Victor L Reddick, Jr

A method of forming a casing bit includes positioning a cutting element adjacent an outer surface of a casing bit body. The cutting element has a superhard material and a bonding material that is used to bond the cutting element to a body of the casing bit. The bonding material may be a weldable or brazable metal alloy, and a welding process or a brazing process, respectively, may be used to bond the cutting elements to body of the casing bit. Casing bits fabricated using such methods may exhibit reduced bond strength between the cutting elements and the casing bit body.

Methods of attaching cutting elements to casing bits and related structures

An earth-boring tool includes a bit body, a plurality of first cutting elements, and a plurality of second cutting elements. Each of the first cutting elements includes a discontinuous phase dispersed within a continuous matrix phase. The discontinuous phase includes a plurality of particles of superabrasive material. Each of the second cutting elements includes a polycrystalline diamond compact or tungsten carbide. A method of forming an earth-boring tool includes disposing a plurality of first cutting elements on a bit body and disposing a second plurality of second cutting elements on the bit body. Another method of foaming an earth-boring tool includes forming a body having a plurality of first cutting elements and a plurality of cutting element pockets and securing each of a plurality of second cutting elements within each of the cutting element pockets.

Diamond impregnated cutting structures, earth-boring drill bits and other tools including diamond impregnated cutting structures, and related methods

Processes for pre-sharpening cutting structures comprising particles of superabrasive material such as diamond grit, dispersed in a metal matrix material such as cemented tungsten carbide. Matrix material may be removed from a surface of a cutting structure to a desired depth to expose superabrasive particles within the matrix material adjacent the surface, and to increase exposure of partially exposed superabrasive particles at the surface. Electrodischarge machining (EDM), laser machining, electrolytic etching and chemical etching may also be employed. Pre-sharpened cutting structures are also disclosed.

Methods for pre-sharpening impregnated cutting structures for bits, resulting cutting structures and drill bits so equipped

A diamond impregnated drill bit features layered encapsulation of the diamond grit where the innermost layer is hardest or most abrasion resistant while succeeding layers are generally softer and less wear resistant. This can be accomplished by manipulating several variables in the encapsulation layers such as particle size or hard particle concentration. The outer layers can have added binder to make them softer. The encapsulated grit can be sintered or pre-sintered to make it less friable when handled.

Impregnated bit with improved grit protrusion

Earth-boring tools and components thereof include a particle-matrix composite material having encapsulated diamond particles embedded within a matrix material. Diamonds in the particles comprise less than about 25% by volume of the composite material, the matrix material comprises less than about 50% by volume of the composite material, and encapsulant material surrounding the diamonds at least substantially comprises a remainder of the volume of the composite material. Methods of forming at least a portion of an earth-boring tool include embedding encapsulated diamond particles in a volume of matrix material to form a particle-matrix composite material. The composite material is formed in such a manner as to cause diamonds to comprise less than about 25% of the composite material, the matrix material to comprise less than about 50% of the composite material, and encapsulant material surrounding the diamonds to at least substantially comprise a remainder of the composite material.

Encapsulated diamond particles, materials and impregnated diamond earth-boring bits including such particles, and methods of forming such particles, materials, and bits

A method of constructing an earth-boring, diamond-impregnated drill bit has a first step of coating diamond grit with tungsten to create tungsten-coated diamond particles. These coated particles are then encapsulated in a layer of carbide powder held by an organic green binder material. The encapsulated granules are then mixed along with a matrix material and placed in a mold. The matrix material includes a matrix binder and abrasive particles. The mixture is heated in the mold at atmospheric pressure to cause the matrix binder to melt and infiltrate the encapsulated granules and abrasive particles.

Growing community of inventors

Willis, TX, United States of America

Wesley Dean Fuller