Utilization of expandable reamer blades in rigid earth-boring tool bodies

An earth-boring tool includes a tool body of a fixed-blade reaming apparatus configured to be coupled within the drilling assembly. The tool body has a longitudinal axis and at least one reamer blade configured to be outwardly extendable for use in an expandable reamer and attachable on a fixed-blade reamer. The at least one reamer blade is attached to the tool body in an immovable manner relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

TECHNICAL FIELD

The present disclosure relates generally to downhole tools for use in subterranean wellbores and, more specifically, to removable reamer blades configured for rigid attachment to earth-boring tool bodies, such as reamers and drill bits.

BACKGROUND

A variety of approaches have been employed for enlarging a diameter of a wellbore. One approach used to enlarge a subterranean wellbore includes using eccentric and bi-center bits. For example, an eccentric bit with a laterally extended or enlarged cutting portion is rotated about its axis to produce an enlarged wellbore diameter. A bi-center bit assembly employs two longitudinally superimposed bit sections with laterally offset axes, which, when rotated, produce an enlarged wellbore diameter.

Expandable reamers may also be used to enlarge subterranean wellbores and may include blades that are slidably, pivotably or hingedly coupled to a tubular body and actuated by way of hydraulic pressure. The blades of these currently available expandable reamers utilize pressure from inside a tool body of the expandable reamer to force the blades, carrying cutting elements, radially outward to engage the formation material defining a wall of the wellbore. The blades in these expandable reamers are initially retracted to permit the expandable reamer to be run through the wellbore on a drill string and, once the expandable reamer is positioned at a desirable location within a wellbore (e.g., beyond the end of a casing section), the blades are extended so the bore diameter may be increased.

BRIEF SUMMARY

In some embodiments, the present disclosure includes an earth-boring tool, comprising a tool body configured to be coupled with another component in a drill string, and at least one reamer blade attached to the tool body and carrying a cutting structure, the tool body having a longitudinal axis. The at least one reamer blade is configured for use in an expandable reaming apparatus and includes at least one feature configured to engage a complementary feature of the expandable reaming apparatus while allowing movement of the at least one reamer blade between a refracted position and an extended position with respect to the expandable reaming apparatus. The at least one reamer blade is substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

In additional embodiments, the present disclosure includes a method of forming an earth-boring tool, comprising providing a tool body having a longitudinal axis and configured to be coupled within another component in a drill string; and attaching at least one reamer blade carrying a cutting structure to the tool body. The at least one reamer blade is configured for use in an expandable reaming apparatus and includes at least one feature configured to engage a complementary feature of the expandable reaming apparatus while allowing movement of the at least one reamer blade between a refracted position and an extended position with respect to the expandable reaming apparatus. The at least one reamer blade is substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore. Attaching the at least one reamer blade carrying a cutting structure to the tool body further comprises positioning a mounting surface of the at least one reamer blade to be radially inward the tool body and positioning the cutting structure of the at least one reamer blade to be radially outward the tool body. The method includes affixing the at least one reamer blade to the tool body, wherein the at least one reamer blade is substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

In yet other embodiments, the present disclosure includes a method of forming an earth-boring tool comprising removing at least one reamer blade from an expandable reaming apparatus and attaching the at least one reamer blade to a tool body, wherein the at least one reamer blade is substantially immovable in relation to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

DETAILED DESCRIPTION

The illustrations presented herein are not meant to be actual views of any particular cutting element, structure, or device, but are merely idealized representations that are used to describe embodiments of the disclosure.

Any headings used herein should not be considered to limit the scope of embodiments of the present disclosure as defined by the appended claims and their legal equivalents. Concepts described in any specific heading are generally applicable in other sections throughout the entire specification.

A number of references are cited herein, the entire disclosure of each of which is incorporated herein in its entirety by this reference for all purposes. Further, none of the cited references, regardless of how characterized herein, is admitted as prior art relative to the present disclosure of the subject matter claimed herein.

FIG. 1illustrates an example of a prior art expandable reamer10used in a bottom-hole assembly (BHA) to enlarge a portion of a wellbore. The expandable reamer10has three sliding blades12(two of which are visible inFIG. 1) positionally retained in a circumferentially spaced relationship in a generally cylindrical tubular body14of the expandable reamer10. The blades12are movable relative to the tubular body14during use of the expandable reamer10between a retracted position and an extended position responsive to application of hydraulic pressure.

The blades12and adjacent regions of the tubular body14may have complementary mating features that retain the blades12within the tubular body14, but allow the blades12to move relative to the tubular body14between the extended and refracted positions. For example, one of the blades12and the tubular body14may include elongated channel recesses, or “grooves,” therein, and the other of the blades12and the tubular body14may include complementary elongated protrusions that extend into the grooves. In other words, the tubular body14may include blade tracks, and the blades12may include features that engage in a mating configuration with the blade tracks in such a manner as to retain the blades12within the tubular body14while allowing the blades12to slide along the blade tracks between the extended and refracted positions. In this manner, the blades12include at least one feature configured to engage a complementary feature of the expandable reamer10allowing movement of the blades12between a refracted position and an extended position with respect to the tubular body14of the expandable reamer10.

FIGS. 2 through 4illustrate an example embodiment of a removable reamer blade12of an expandable reamer apparatus, which may be attached in a fixed, non-movable configuration to a body of an earth-boring tool, in accordance with embodiments of the present disclosure. Such embodiments allow expandable reamer blades to be used in multiple applications. The blades12include opposing lateral sides15(FIGS. 2 and 4), one of which is a rotationally leading side and the other of which is a rotationally trailing side during use, and have a cutting surface16on a radially outward side of the blade12and a mounting surface18on a radially inward side of the blade12. The blades12also have opposing longitudinal ends19. A body of each blade12may comprise a metal alloy, such as steel, or it may comprise a composite material such as ceramic-metal (cermet) composite material. As an example of such a ceramic-metal composite material, the blades12may comprise metal carbide particles (e.g., tungsten carbide particles) dispersed throughout and cemented within a metal matrix material (e.g., cobalt or a cobalt alloy).

The blades12may each comprise a cutting structure20on the cutting surface16for engaging formation material of a wall of a wellbore. The cutting structure20may comprise a deposit of hardfacing material (not shown) disposed over at least a portion of the blade12. In additional embodiments, the blades12may each carry a plurality of cutting elements22(shown inFIGS. 5 through 7) for engaging the wall of the wellbore. The cutting elements22may be polycrystalline diamond compact (PDC) cutters or other cutting elements known to a person of ordinary skill in the art and as generally described in the references identified above.

Referring now toFIG. 5, in accordance with embodiments of the present disclosure, reamer blades, such as the reamer blades12, which are configured to be used in an expandable reamer, such as the expandable reamer10, are rigidly secured in a non-movable, fixed manner to a tool body24of a downhole tool to form a fixed-blade reaming apparatus26that may be used to enlarge a portion of a wellbore. It is to be recognized that the tool body24lacks an activation mechanism; specifically, the tool body24does not have a mechanism for moving the blade12from a refracted position to an extended position with respect to the tool body24. Additionally, the blades12are unresponsive to hydraulic pressure within the tool body24, rendering the blades12immovable relative to the tool body24, even during use of the fixed-blade reaming apparatus26in the formation of a subterranean wellbore. The tool body24of the fixed-blade reaming apparatus26may have a lower end28and an upper end30with a centerline or longitudinal axis L extending therebetween (shown inFIG. 7). The terms “lower” and “upper,” as used herein with reference to the ends28,30, refer to the typical positions of the ends28,30relative to one another when the fixed-blade reamer26is positioned within a wellbore. In some embodiments, as shown inFIG. 5, the tool body24may be substantially tubular, with a drilling fluid flow path32extending longitudinally through an inner bore34of the tool body24between the lower and upper ends28,30. In embodiments wherein a tubular tool body24is utilized, the drilling fluid flow path32may direct fluid substantially through the inner bore34of the tool body24.

The lower end28of the tool body24may include a set of threads (e.g., a threaded male pin member) (not shown) for connecting the lower end28to another section of drill string or a component of a bottom-hole assembly. Similarly, the upper end30of the tool body24may include a set of threads (e.g., a threaded female box member) for connecting the upper end30to a section of a drill string or another component of a bottom-hole assembly.

The fixed-blade reamer26is shown having three blades12(two of which are visible inFIG. 5) positionally retained in circumferentially spaced, longitudinally extending slots36in the tool body24of the fixed-blade reamer26. The blades12may be configured as described previously with reference toFIGS. 2 through 4. It is to be appreciated that one, two, three, four, five, or more than five blades12may be affixed to the tool body24within corresponding slots36. Moreover, while the blades12are symmetrically circumferentially positioned along the tool body24in the embodiment ofFIG. 5, the blades12may also be positioned circumferentially asymmetrically around the tool body24. Additionally, the blades12may be positioned at the same longitudinal position along the tool body24, or at different longitudinal positions.

Referring now toFIG. 6, a perspective, cross-sectional view of the tool body24is shown. The reamer blades12are rigidly secured to the tool body24in the slots36. The slots36may each include a bottom surface38and laterally opposing sidewalls40formed in the tool body24. The slots36may also be configured with one or more blade tracks42formed therein for allowing slidable insertion of the blades12into the tool body24and also for radially retaining the blades12in the tool body24after the blades12are inserted into the tool body24and fixedly attached thereto. The blade tracks42may comprise recesses or channels, as shown inFIG. 6. The recesses or channels may extend along the tool body24in a longitudinal direction that is also oriented at an acute angle α to the longitudinal axis L of the tool body24, as shown inFIG. 7. In other words, the blade tracks42may extend longitudinally along the tool body24on a slanted slope having the acute angle α with respect to the longitudinal axis L of the tool body24. Referring again toFIG. 6, each blade track42may include a pair of grooves44formed in the lateral sidewalls40of the slot36and axially extending along the blade track42proximate the bottom surface38of the slot36. The grooves44may have a dovetail cross-sectional shape in some embodiments. The blades12may be held in place along the blade tracks42by guides46formed on the blades12proximate the mounting surface18(also shown inFIGS. 3 and 4). Each guide46comprises a rail48(e.g., an elongated protrusion) oppositely located on lateral sides15of the blade12. The rails48have a size and cross-sectional shape substantially matching the size and cross-sectional shape of the grooves44of the blade track42in order to allow slidable insertion of the blades12into the slots36. Referring again toFIG. 4, each guide46may have an included angle θ that is selected to prevent binding with the mating grooves44of the blade track42as the blade12is inserted into position in the blade track42. Referring again toFIG. 6, the pair of grooves44are configured such that a width W1of the slot36within the grooves44is greater than a width W2of the slot36radially outward from the pair of grooves44. Thus, a blade12slidably inserted in the blade track42within a slot36of the tool body24is substantially radially retained in the blade track42by interference between the rails48and a portion of the tool body24radially outward of the pair of grooves44.

As illustrated inFIG. 7, the extent to which each blade12extends radially outward from an outer surface of the tool body24may be predetermined by the longitudinal placement of the blade12along the track42. With continued reference toFIG. 7, one or more of an upper and lower stabilizer block50,52may be affixed to the tool body24. The stabilizer blocks50,52may be configured as described in U.S. Patent Publication No. 2010/0212970, to Radford et al., which was published Aug. 26, 2010, now U.S. Pat. No. 8,181,722, issued May 22, 2012, the entire disclosure of which is incorporated herein in its entirety by this reference. Upper stabilizer block50may be attached to the tool body24in a manner causing the stabilizer block50to abut a longitudinal end19of the reamer blade12. As the upper stabilizer block50is attached to the tool body24in a non-movable, fixed position, the upper stabilizer block50may prevent the blade12from sliding along the track42, thereby rigidly retaining the blade12in position on the tool body24. Additionally, one or more stop blocks54may be secured to the tool body24in the slot36in a manner to abut a longitudinal end19of the blade12opposite the stabilizer block50. The size and shape of the stabilizer block50, together with the size and shape of the one or more stop blocks54, may be selectively configured to position the blade12in a fixed manner at a any desirable position along the track42, which position will at least partially determine the distance to which the blade12extends radially outward from the tool body24, and, hence, the diameter to which a wellbore may be reamed using the reamer26. Thus, the blades12may be rigidly affixed to the tool body24collectively by the upper stabilizer block50, the engagement of the rails48with the grooves44, and, optionally, the one or more stop blocks54.

In view of the above, the distance to which the blade12extends radially outward from an outer surface of the tool body24may be controlled or predetermined by a variety of factors. For example, in some embodiments, the radial position of the blade12may be controlled by selectively designing and configuring one or more of the size, shape, and location of the upper stabilizer block50. In additional embodiments, the radial position of the blade12may be controlled by selectively designing and configuring the length of the blade track42as well as the acute angle a of the slanted slope of the blade track42with respect to the longitudinal axis L of the tool body24. In additional embodiments, the radial position of the blade12may be controlled by selectively designing and configuring a number and size of stop blocks54employed to abut the longitudinal end of the blade12opposite the upper stabilizer block50. In yet additional embodiments, any combination of the foregoing factors may be used to selectively control the distance to which the blades12extend from an outer surface of the tool body24.

In additional embodiments, the reamer blades12may have other types and configurations of mating features for mechanical retention of the blades12within the tubular body24. Moreover, the bottom surface38of the blade slots36may alternatively extend substantially parallel with the longitudinal axis L of the tool body24. It is to be appreciated that any type of reamer blade configured for use in an expandable reaming apparatus may be rigidly affixed to a fixed-blade reaming tool in accordance with additional embodiments of the present disclosure.

In yet additional embodiments, as shown inFIGS. 8 and 9, two consecutive blades12may be longitudinally affixed to the tool body24in a “stacked” configuration. A first stacked blade12may be oriented at a first angle a with respect to the longitudinal axis L of the tool body, and a second stacked blade12′ may be oriented at a second angle β with respect to the longitudinal axis L of the tool body24. The first and second angles α, β may be equivalent (not shown). In alternative embodiments, as shown inFIG. 8, the first angle α may be greater than the second angle β with respect to the longitudinal axis L; or, as shown inFIG. 9, the first angle a may be less than the second angle β with respect to the longitudinal axis.

In the embodiment ofFIGS. 5 through 9, the blades12are locked in position within the tubular body24in a manner that prevents the blades12from sliding along the tracks42using the upper stabilizer block50. Other means for locking the blades12in position on the tracks42also may be employed. For example, in alternative embodiments, the blades12may be rigidly affixed to the tool body24by welding the blades12to the tubular body24.FIG. 10illustrates a simple lateral cross-sectional view of a reamer blade12having a cutting surface16, a mounting surface18, and opposing lateral sides15. The blade12is configured for use with an expandable reamer, such as the expandable reamer10ofFIG. 1. Thus, the blade12may include rails and the tool body24may include mating tracks, as discussed above with reference toFIGS. 2 through 4. The blade12is disposed in a longitudinally extending slot36in the tool body24. The slot36has a bottom surface38and laterally opposing sidewalls40. As shown inFIG. 10, a weld groove56is formed in the tool body24adjacent the lateral sidewalls40of the slots36. After the blade12is disposed in the slot36and located at a desirable position relative to the tool body24along the track, a weld58is formed in the weld groove56in a manner that immovably affixes the blade12to the tool body24.

Referring now toFIG. 11, a simple lateral cross-sectional view of the reamer blade12is shown mechanically fastened to the tool body24according to another embodiment of the present disclosure. The blade12may be configured, as described above, having a cutting surface16, a mounting surface18, and opposing lateral sides15. The blade12is configured for use with an expandable reamer, such as the expandable reamer10ofFIG. 1. Thus, the blade12may include rails and the tool body24may include mating tracks, as discussed above with reference toFIGS. 2 through 4. The blade slot36may comprise a bottom surface38and laterally opposing sidewalls40. As depicted, the blade12may have one or more transverse bores60extending therethrough between the opposing lateral sides15of the blade12. When the blade12is received in the slot36in its desired position, the transverse bore60is aligned with a blind bore62extending into a lateral sidewall40of the slot36on one side15of blade12and with an open bore64extending into a lateral sidewall40on an opposing side of blade12. A lock rod66is inserted through each of the open bore64and the aligned transverse bore60and into the aligned blind bore62so that a distal end68of lock rod66is received and locked within the aligned blind bore62. A proximal end70of each lock rod66resides completely within the open bore64when the lock rod66is fully inserted into the blind bore62. Thus, the lock rod66prevents the blade12from moving relative to the tool body24along the blade track. Instead of a lock rod66, a bolt, screw, or any other type of mechanical retaining feature may be used to provide mechanical interference securing the blade12in a fixed position along the blade track.

Other configurations for mechanically attaching the blades12to the tool body24are within the scope of the embodiments disclosed herein. For example, instead of blind bore62, the distal end68of the lock rod66may be received in a second open bore aligned with the transverse bore60. In other embodiments, the transverse bore60may extend longitudinally through the blade12and may be aligned with one or more bores, including open bores and/or blind bores, in longitudinally opposing sides40of the slot36. Any mechanical means of fastening the blade12to the tool body24is within the scope of the embodiments disclosed herein, including, by way of non-limiting examples, bolts, screws, retention pads, shrink fitting, press fitting, male and female elements formed on mating portions of the blade12and tool body24, and other fasteners.

In other embodiments, as illustrated inFIG. 12, the blade12may be rigidly affixed to the tool body24by brazing the blade12to the tool body24within the slot36. The blade12may be configured, as described above, having a cutting surface16, a mounting surface18, and opposing lateral sides15. The blade12is configured for use with an expandable reamer, such as the expandable reamer10ofFIG. 1. Thus, the blade12may include rails and the tool body24may include mating tracks, as discussed above with reference toFIGS. 2 through 4. The slot36may comprise a bottom surface38and laterally opposing sidewalls40. A brazing alloy72may be disposed between the opposing lateral sidewalls40of the blade slot36and mating opposing lateral sides15of the blade12, as shown inFIG. 12. For example, the brazing alloy72may be heated to a temperature sufficient to melt the brazing alloy72, which then may be allowed to infiltrate into a gap at the interface between the blade12and the tool body24, after which the brazing alloy72may be allowed to cool and solidify. The brazing alloy72thus bonds and locks the blade12to the tool body24in an immovable manner. As known in the art, a flux may be used to protect the brazing alloy72from oxidation during the brazing process. It is to be appreciated that, in additional embodiments, the blades12may be rigidly affixed to the tool body24using any combination of the methods and configurations described above.

In additional embodiments, blades12configured for use with an expandable reamer apparatus may be rigidly coupled to earth-boring tools other than reamers.

For example,FIG. 13illustrates an earth-boring rotary drill bit76to which a reamer blade12, configured as previously described herein, is rigidly affixed. The reamer blade12is attached to a lateral side74or “gage portion” of the earth-boring rotary drill bit76in a manner to allow simultaneously drilling and reaming of a wellbore. For example, longitudinally extending blade slots (not shown) having tracks therein for engaging rails or other features on the blade12, configured similarly to blade slots36as previously described herein, may be formed in the lateral side74of the drill bit76, and may include a bottom surface and laterally opposing sidewalls with one or more blade tracks formed therein for allowing slidable insertion of the blades12into the lateral side74of the drill bit76and for radially retaining the blades12in the gage portion74of the bit76. The blade tracks may extend longitudinally along the gage portion74on a slanted slope having an acute angle with respect to a longitudinal axis of the drill bit76, in a manner similar to that described previously with reference toFIG. 7. Each track may include a pair of grooves formed in the lateral sidewalls of the slot and axially extending along the blade tracks proximate the bottom surface of the slot. The blades12may be held in place along the blade tracks by guides, each guide comprising a single rail oppositely located on lateral sides15of the blade12and matching the grooves in order to allow slidable placement of the blade12within the slot of the drill bit76.

Additionally, a stabilizer block may be affixed to the drill bit76in a manner to abut a longitudinal end19of the reamer blade12, preventing the blade12from sliding along the track once the stabilizer block has been affixed. The relative placement of the stabilizer block and blade12may determine the lateral extent to which the blade12extends from the gage portion74of the drill bit76. Additionally, one or more stop blocks, similar to stop blocks54, illustrated inFIG. 7, may be secured to the drill bit76in the slot in a manner to abut a longitudinal end19of the blade12opposite the stabilizer block, rigidly affixing the blade12in place on the track. Thus, similar to the manner described above in reference toFIG. 7, the lateral extent to which the blades12extend from the lateral side74of the drill bit76may be controlled or predetermined by a variety of factors, including the size and position of the stabilizer block, the length of the blade tracks as well as the acute angle of the slanted slope, the number and size of any stop blocks employed, or any combination of the foregoing factors.

In other embodiments, the blades12may alternatively be rigidly affixed to the drill bit76by using any of the methods previously described with reference toFIG. 7for securing the blades12to the tool body24of the reamer26.

It is to be appreciated that an earth-boring tool may be formed according to the embodiments disclosed herein. Reamer blades configured for use with expandable reaming apparatuses are specially designed and configured to be outwardly expandable responsive to hydraulic pressure. Reamer blades designed for such purposes are expensive, and the applicants have devised a method of maximizing the value of such reamer blades by utilizing the blades in an earth-boring tool that does not have a mechanism for moving the blade12from a retracted position to an extended position with respect to the tool body. For example, reamer blades configured for use in an expandable reamer, such as blades12described previously herein, may be removed from the expandable reamer and rigidly attached to a tool body in a manner wherein the blades12are immovably affixed to the tool body. The tool body formed by this method may be substantially identical to tool body24, described previously in relation toFIGS. 5 through 7, or, in other embodiments, the fixed-blade tool body may be substantially identical to drill bit76, as shown inFIG. 13, wherein the blade12is attached to a gage portion74of the drill bit76.

Moreover, an earth-boring tool may be formed from worn or damaged blades12from an expandable reaming apparatus. The worn or damaged reamer blades12may be removed from the expandable reamer and subsequently repaired. After the blade12is repaired, the blade12may be rigidly affixed to the earth-boring tool body in a manner wherein the blade12is immovably affixed to the tool body, as previously described herein, wherein the tool does not have a mechanism for moving the blade12from a refracted potion to an extended position with respect to the tool body. The blade12may be immovably affixed to the tool body using any of the attachment methods and/or configurations described above, including welding, brazing, and bolting. Additionally, as described above, the blade12may be immovably affixed to the tool body by rigidly affixing a retention block to the tool body in a manner to abut a longitudinal end of the blade12.

The embodiments disclosed herein enable a reamer blade configured for use in an expandable reamer to be rigidly affixed to a reamer or other type of earth-boring tool in a manner wherein the blade is immovably attached thereto.

Additional non-limiting example embodiments of the present disclosure are set forth below.

Embodiment 1: An earth-boring tool, comprising: a tool body configured to be coupled with another component in a drill string, the tool body having a longitudinal axis; and at least one reamer blade attached to the tool body and carrying a cutting structure, the at least one reamer blade configured for use in an expandable reaming apparatus and having at least one feature configured to engage a complementary feature of the expandable reaming apparatus while allowing movement of the at least one reamer blade between a retracted position and an extended position with respect to the expandable reaming apparatus, the at least one reamer blade being substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

Embodiment 2: The earth-boring tool of Embodiment 1, wherein the tool body comprises at least one substantially longitudinally extending slot for receiving the at least one reamer blade therein, the at least one slot including: a bottom surface configured to abut a mounting surface of the at least one reamer blade; and opposing lateral sidewalls substantially extending from the bottom surface to an outer surface of the tool body.

Embodiment 3: The earth-boring tool of Embodiment 1 or Embodiment 2, wherein the at least one slot further comprising a pair of grooves formed in the opposing lateral sidewalls of the at least one slot proximate the bottom surface and extending longitudinally along at least a portion of a length of the at least one slot, wherein a width of the at least one slot within the pair of grooves is greater than a width of the at least one slot radially outward the pair of grooves, the pair of grooves being configured to receive therein a corresponding pair of rails formed on opposite lateral sides of the at least one reamer blade proximate the mounting surface, wherein interference between the pair of rails and the tool body radially outward the pair of grooves substantially prevents radial movement of the at least one reamer blade in relation to the tool body.

Embodiment 4: The earth-boring tool of any one of Embodiments 1 through 3, further comprising a retention block rigidly abutting a longitudinal end of the at least one reamer blade, wherein the retention block substantially preventing one or more of radial and longitudinal movement of the at least one reamer blade in relation to the tool body.

Embodiment 5: The earth-boring tool of any one of Embodiments 1 through 4, wherein the cutting structure comprises one or more cutting elements.

Embodiment 6: The earth-boring tool of any one of Embodiments 1 through 5, wherein the cutting structure comprises a deposit of hardfacing alloy.

Embodiment 7: The earth-boring tool of any one of Embodiments 1 through 6, wherein the tool body comprises a drill bit, the at least one reamer blade being attached to a gage portion of the drill bit in a manner to prevent movement of the at least one reamer blade in relation to the drill bit.

Embodiment 8: A method of forming an earth-boring tool, comprising: providing a tool body configured to be coupled within another component in a drill string, the tool body having a longitudinal axis; and attaching at least one reamer blade carrying a cutting structure to the tool body, the at least one reamer blade configured for use in an expandable reaming apparatus and having at least one feature configured to engage a complementary feature of the expandable reaming apparatus while allowing movement of the at least one reamer blade between a refracted position and an extended position with respect to the expandable reaming apparatus, the at least one reamer blade being substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore, wherein attaching the at least one reamer blade carrying a cutting structure to the tool body further comprises: positioning a mounting surface of the at least one reamer blade to be radially inward the tool body and positioning the cutting structure of the at least one reamer blade to be radially outward the tool body; and affixing the at least one reamer blade to the tool body, wherein the at least one reamer blade is substantially immovable relative to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

Embodiment 9: The method of Embodiment 8, further comprising forming at least one longitudinally extending slot in the tool body and configuring the at least one slot to receive the at least one reamer blade therein.

Embodiment 10: The method of Embodiment 9, further comprising: forming a pair of longitudinally extending grooves in the tool body on opposing lateral sides of the at least one slot proximate a bottom surface of the at least one slot, wherein a width of the at least one slot within the pair of grooves is greater than a width of the at least one slot radially outward of the pair of grooves; configuring the bottom surface to abut the mounting surface of the at least one reamer blade; placing the at least one reamer blade in the at least one slot, the at least one reamer blade having a pair of rails formed on opposite lateral sides of the at least one reamer blade proximate the mounting surface, the pair of rails corresponding to the pair of grooves, further comprising locating the pair of rails within the corresponding pair of grooves, wherein interference between the pair of rails and a portion of the tool body radially outward of the pair of grooves substantially prevents radial movement of the at least one reamer blade in relation to the tool body.

Embodiment 11: The method of any one of Embodiments 8 through 10, further comprising rigidly affixing a retention block to the tool body, wherein the retention block abuts a longitudinal end of the at least one reamer blade such that the retention block substantially prevents one or more of radial and longitudinal movement of the at least one reamer blade in relation to the tool body.

Embodiment 12: The method of any one of Embodiments 8 through 11, wherein rigidly affixing the retention block to the tool body comprises one of welding, brazing and bolting the retention block to the tool body.

Embodiment 13: The method of Embodiment 11 or Embodiment 12, further comprising abutting one or more stop blocks against a longitudinal end of the at least one reamer blade opposite the longitudinal end of the at least one reamer blade abutting the retention block.

Embodiment 14: The method of any one of Embodiments 9 through 13, further comprising one of welding, brazing and bolting the at least one reamer blade to the tool body within the at least one slot.

Embodiment 15: The method of any one of Embodiments 8 through 14, wherein the tool body comprises a drill bit, and attaching the at least one reamer blade carrying a cutting structure to the tool body further comprises attaching the at least one reamer blade to a gage portion of the drill bit.

Embodiment 16: A method of forming an earth-boring tool, comprising: removing at least one reamer blade from an expandable reaming apparatus; and attaching the at least one reamer blade to a tool body, wherein the at least one reamer blade is substantially immovable in relation to the tool body during use of the earth-boring tool in the formation of a subterranean wellbore.

Embodiment 17: The method of Embodiment 16, wherein the tool body comprises a drill bit, and attaching the at least one reamer blade to the tool body further comprises attaching the at least one reamer blade to a gage portion of the drill bit.

Embodiment 18: The method of Embodiment 16 or Embodiment 17, further comprising repairing the at least one reamer blade prior to attaching the at least one reamer blade to the tool body.

Embodiment 19: The method of any one of Embodiments 16 through 18, wherein attaching the at least one reamer blade to the tool body comprises one of welding, brazing, and bolting.

Embodiment 20: The method of any one of Embodiments 16 through 19, further comprising affixing a retention block to the tool body abutting at least a portion of the at least one reamer blade, the retention block substantially preventing at least one of radial and longitudinal movement of the at least one reamer blade in relation to the tool body.

While certain illustrative embodiments have been described in connection with the figures, those of ordinary skill in the art will recognize and appreciate that embodiments of the present disclosure are not limited to those embodiments explicitly shown and described herein. Rather, many additions, deletions, and modifications to the embodiments described herein may be made without departing from the scope of embodiments of the present disclosure as hereinafter claimed, including legal equivalents. In addition, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being encompassed within the scope of embodiments of the present disclosure as contemplated by the applicants.