Rolling cutter drill bits

Abstract: A steel tooth rolling cutter earth boring drill bit comprises a bit body (12) with a threaded upper end (24) for attachment to the end of a drill string, and a lower end comprising three legs (14, 16) extending downwardly from the bit body and with a rolling cutter (18, 20, 22) rotatably mounted on each leg. A layer of wear resistant material is applied to a portion of each rolling cutter and comprises wear resistant particles in a substantially steel matrix (38). The steel matrix (38) is integrally formed with the cutter in a rapid, solid state densification powder metallurgy (RSSDPM) process, and comprises a duplex microstructure comprising from about 10 to 40 volume percent austenite (42) and from about 60 to 90 volume percent martensite (40). The duplex microstructure may be achieved by incorporating a minor fraction of pure nickel and/or manganese powder in the powder mix used in the process, thereby providing nickel or manganese enrichment of the austenitic zones of the matrix.

Description: This invention relates to steel tooth rolling cutter drill bits utilised for drilling boreholes in the earth for the minerals mining industry. Hardmetal inlays or overlays are employed in rock drilling bits as wear and deformation resistant cutting edges and faying surfaces. These typically comprise composite structures of hard particles in a more ductile metal matrix. The hard particles may be metal carbides, such as either the cast WC/W2C eutectic or monocrystalline WC, or may themselves comprise a finer cemented carbide composite material. Often, a combination of hard particle types is incorporated in the materials design, and particle size distribution is controlled to attain desired performance under rock drilling conditions, such as disclosed in U.S. Patents No. 3,800,891; 4,726,432; and 4,836,307. The matrix of these hardmetal systems may be iron, nickel, or copper based, but whether formed by weld deposition, brazing, plasma spraying, or infiltration, the matrix microstructure is invariably a solidification product. During fabrication, the hard phase(s) remain entirely or at least partially solid, but the matrix phase(s) grow from a melt during cooling and thus are limited by thermodynamic, kinetic, and heat transport constraints to narrow ranges of morphology, constituency and crystal structure. The strongest commonly employed hardmetals in rolling cutter rock bit cutting structures are made by weld application of sintered tungsten carbide based tube metals or composite rods utilizing iron based matrix systems. These hardmetal deposits undergo heat treatment prior to use, resulting in matrices which are essentially alloy steels by chemistry. Microstructurally the matrix is comprised of tempered martensite with minor amounts of carbide precipitates and retained austenite. Any austenite in the microstructure occupies the internecine spaces between martensite lathes or plates. The intrinsic difficulty in the control of heat input during weld deposition of hardfacing overlays results in matrix variation due to alloying effects arising from melt incorporation of sintered carbide hard phase constituents as well as substrate material. Partial melting of cemented carbide constituents resulting in "blurring" of the hard phase boundaries and the incorporation of cobalt and WC particles into the matrix. As a practical matter, process control is challenged to maintain "primary" hardmetal microstructural characteristics such as constituency and volume fraction relationships of hard phases. Secondary characteristics such as matrix microstructure are derivative and cannot be readily regulated. The advent of rapid, solid state densification powder metallurgy (RSSDPM) processing of composite structures has enabled the fabrication of hardmetal inlays/overlays which potentially include a range of compositions and microstructures not attainable by solidification. In addition, RSSDPM processing also provides more precise control of microstructural features than that attainable with fused overlays. Such fabrication methodologies for rock bits are disclosed in U.S. Patents Nos. 4,554,130; 4,592,252; and 4,630,692. Also disclosed therein and also in U.S. patent No. 4,562,892 are some preferred embodiments of drill bits with wear resistant hardmetal overlays which exploit the flexibility and control afforded by RSSDPM. Although many unique hardmetal formulations are made possible by RSSDPM, most will not be useful as rock bit hardmetal inlays because they lack the necessary balance of wear resistance, strength, and toughness. Unique RSSDPM composites can exhibit similarly unique failure progressions which disadvantage them for use in drilling service. For example, a RSSDPM "clone" of a conventional weld applied hardmetal made from 60 wt% cemented carbide pellets (30/40 mesh WC-7%Co), and 40 wt% 4620 steel powder, was found to have lower wear resistance than expected due to selective hard phase pullout caused by shear localisation cracking in the matrix. The presence of sharpened interfaces combined with the formation of ferrite "halos" around carbide pellets lead to deformation instability under high strain conditions. Even though the primary characteristics normally used to evaluate hardmetal (volume fractions, pellet hardness, matrix hardness, and porosity) were superior to conventional material, the RSSDPM clone exhibited an unexpected weakness. In another experiment, a RSSDPM formulation similar to the above example but adding a few percent of fine (<7 micrometer) WC powder was intended to mimic the precipitation induced dispersion strengthening of matrix in conventional hardmetal. However, rapid surface diffusion in the powder preform prior to hot pressing caused transformation of the fine WC to brittle eta type carbide in the final composite. In this case, an unexpected reaction led to compromise of the intended matrix strengthening mechanism. The potential benefits of RSSDPM hardmetal inlays are thickness and microstructural uniformity, low defect and porosity levels, and stability of hard phases/hardness retention. In order to realise these benefits, special chemistry and microstructural design of the hardmetal matrix are required to provide appropriate deformation characteristics under high unit loads experienced at tooth crests. US-A-4 556 424 discloses separate inserts for tri-cone rotary drill bits, each insert being formed from a material comprising wear resistant particles in a substantially steel matrix. In an initial state the major phase of the steel matrix is austenitic, but the matrix is metastable so that the subsequent application of mechanical forces to the inserts, at ambient temperature, transforms the matrix to a microstructure in which the major phase is martensitic. According to the invention there is provided a steel tooth rolling cutter earth boring drill bit comprising a bit body with a threaded upper end for attachment to the end of a drill string, and a lower end comprised of a plurality of legs extending downwardly from said bit body and with a rolling cutter rotatably mounted on at least one of said legs, said rolling cutter incorporating wear resistant material comprised of wear resistant particles in a substantially steel matrix, characterised in that the wear resistant material is in the form of a layer of such material on a portion of the rolling cutter, and in that said steel matrix has a duplex microstructure comprising from about 10 to 40 volume percent austenite and from about 60 to 90 volume percent tempered martensite. In the present invention, the use of a duplex matrix microstructure comprising austenitic zones within a tempered martensite continuum provides high strength and toughness. One way of achieving such a duplex microstructure is by incorporating a minor fraction of pure nickel and/or manganese powder in the matrix of an inlay powder mix, to promote austenite stabilization, wherein the principal matrix constituent is an alloy steel powder such as AISI 4600. Addition of these elements can help provide high strength and toughness in the matrix while inhibiting the formation of ferrite halos around WC-Co cemented carbide pellets. During densification and carburization, inter-diffusion causes composition gradients to develop along nickel and/or manganese steel particle boundaries resulting in nickel and/or manganese rich zones with no distinct interface. After hardening, and tempering, the hardmetal matrix microstructure reflects the austenite stabilisation effects of nickel and/or manganese, comprising a dispersion of nickel and/or manganese austenitic pools in a sea of tempered martensite. Austenitic zones merge into martensitic material gradually, by increasing lath density. The result is a hardmetal inlay comprised of wear resistant particles in a substantially steel matrix having a duplex microstructure comprising about 10 to 40 volume percent austenite and 60 to 90 volume percent tempered martensite. The following is a detailed description of preferred embodiments of the invention, reference being made to the accompanying drawings in which: Figure 1 shows a typical steel tooth rolling cutter earth boring drill bit. Figure 2 shows a cross section view of a tooth and the surface of the rolling cutter of a drill bit of the present invention. Figure 3 is a 50x photo-micrograph of the microstructure of the hardmetal inlay of the present invention. Figure 4 is a 1250x photo-micrograph of the microstructure of the steel alloy matrix of the hardmetal inlay of the preferred embodiment of the present invention. A typical steel tooth rolling cutter drill bit is shown as numeral 10 of Figure 1. The bit has a body 12 with three legs (only two are shown) 14, 16. Upon each leg is mounted a rolling cutter 18, 20, 22. During operation, the bit 10 is secured to drill pipe (not shown) by threads 24. The drill pipe is rotated and drilling fluid is pumped through the drill pipe to the bit 10 and exists through one or more nozzles 26. The weight of the drilling string forces the cutting teeth 28 of the cutters 18, 20, 22 into the earth, and as the bit is rotated, the earth causes the cutters to rotate upon the legs effecting a drilling action. Typically, the cutting teeth 28 are coated with some form of wear resistant material to help maintain the tooth sharpness as the bit 10 drills through the earth. Each rolling cutter 18, 20, 22 is formed by rapid, solid state densification powder metallurgy (RSSDPM). The process involves combining steel powders and wear resistant materials in a mold and making a finished part with a two step densification process. An exemplary solid state densification process is explained in detail by Ecer in the previously referenced U.S. Patent No. 4,562,892. Figure 2 shows a cross section view of a tooth 30 and the surface 32 of the rolling cutter of a drill bit of the present invention. The hardmetal inlay 34 is shown made into both the tooth 30 and the surface 32 of the rolling cutter. A 50x photo-micrograph of the microstructure of this hardmetal inlay is shown in Figure 3. The major constituents of the hardmetal inlay are the tungsten carbide and/or tungsten carbide/cobalt hard particles 36, tungsten monocarbide 37, and an alloy steel matrix 38. The steel matrix has a duplex microstructure comprising about 10 to 40 volume percent austenite and 60 to 90 volume percent tempered martensite. As shown in Figure 4, (a 1250x photo-micrograph of the microstructure of the steel alloy matrix of the preferred embodiment) the steel matrix 38 has a duplex microstructure consisting of 75 to 85 volume percent tempered martensite 40 (the structures which are dark in appearance), and 15 to 25 volume percent austenite 42 (the structures which are light in appearance). In one form of the preferred embodiment, a RSSDPM hardmetal inlay has a total of 50 volume percent hard phase, made up of 43 volume percent cemented carbide pellets (WC-7.5 wt%Co, 250 to 590 micrometer grain size range) and 7 volume percent tungsten monocarbide (74 to 177 micrometer grain size range); the 50 volume percent matrix would comprise the continuum constituent with a mean free path between hard particles of about 200 micrometers. The duplex matrix microstructure, comprising about 15 to 25 volume percent austenite 42 and 75 to 85 volume percent tempered martensite 40, would reflect an austenite zone size distribution of 1 to 50 micrometers and a mean free path between austenite zones of about 25 micrometers. In a second form of the preferred embodiment, a RSSDPM hardmetal inlay has a total of 65 volume percent hard phase, made up of 45 volume percent cemented carbide pellets (WC-15 wt%Co, 420 to 590 micrometer grain size range) and 20 volume percent cemented carbide pellets (WC-16 wt%Co, 74 to 177 micrometer grain size range); the 35 volume percent matrix would comprise the continuum constituent with a mean free path between hard particles of about 75 micrometers. The duplex matrix microstructure, comprising about 15 to 25 volume percent austenite 42, and 75 to 85 volume percent tempered martensite 40, would reflect a typical austenite zone size distribution of .5 to 40 micrometers and a mean free path between austenite zones of about 20 micrometers. Under the high stress conditions present at the cutting edge of a drill bit tooth 30, the strain response of a hardmetal inlay containing such a duplex matrix microstructure reflects a relatively high yield strength and a high work hardening rate. This combination provides excellent support for the hard particles in the composite as well as high apparent toughness. It tends to discourage shear localisation by the mechanism of local hardening at high strain contact sites, and by the discontinuity of austenitic ductile regions. The latter effect is concomitant to the inhibition of low strength ferrite halos around WC-Co cemented carbide particles.

Claims: A steel tooth rolling cutter earth boring drill bit comprising a bit body with a threaded upper end for attachment to the end of a drill string, and a lower end comprised of a plurality of legs extending downwardly from said bit body and with a rolling cutter rotatably mounted on at least one of said legs, said rolling cutter incorporating wear resistant material comprised of wear resistant particles in a substantially steel matrix, characterised in that the wear resistant material is in the form of a layer of such material on a portion of the rolling cutter, and in that said steel matrix has a duplex microstructure comprising from about 10 to 40 volume percent austenite and from about 60 to 90 volume percent tempered martensite. A drill bit according to Claim 1, wherein said wear resistant material is integrally formed with said cutter in a rapid, solid state densification powder metallurgy process. A drill bit according to Claim 1, wherein said duplex microstructure is comprised of from about 15 to 25 volume percent austenite and from about 75 to 85 volume percent tempered martensite. A drill bit according to Claim 3, wherein the austenite is comprised of zones with a size distribution of from about 0.5 to 50 micrometers. A drill bit according to Claim 3, wherein the austenite is comprised of zones spaced by a free mean path of from about 20 to 25 micrometers. A drill bit according to Claim 1, wherein the steel matrix includes nickel. A drill bit according to Claim 6, wherein the nickel is in the form of nickel enrichment of the austenitic zones of the matrix. A drill bit according to Claim 1, wherein the steel matrix includes manganese. A drill bit according to Claim 8, wherein the manganese is in the form of manganese enrichment of the austenitic zones of the matrix.

Inventors: DRAKE ERIC F, SRESHTA HAROLD A, DRAKE, ERIC F., SRESHTA, HAROLD A.
Applicants: CAMCO INT, CAMCO INTERNATIONAL INC.
Application year: 1996
Main classification: C22C29
IPC codes: B22F7, C22C33, E21B10, C22C29