Patent ID: 12241312

DETAILED DESCRIPTION

Embodiments of this disclosure generally relate to devices, systems, and methods for increasing operational lifetime and/or decreasing downtime in a cutting tool. More particularly, embodiments of the present disclosure relate to devices, systems, and methods for positioning a replaceable cutting element segment on a cutting tool, where the segment has a higher wear or erosion resistance than a body or blade material of the cutting tool.

In some embodiments, a cutting tool according to the present disclosure has one or more cutting elements to remove material in a downhole environment. During cutting operations, the area at or near the cutting element may experience high abrasion and/or erosion conditions. A cutting tool according to the present disclosure may include one or more segments of a high wear and erosion resistance material positioned adjacent to or fully or partially around the cutting element to increase the operational lifetime and reparability of the cutting tool.

FIG.1shows one example of a drilling system100for drilling an earth formation101to form a wellbore102. The drilling system100includes a drill rig103used to rotate a drilling tool assembly104that extends downward into the wellbore102. The drilling tool assembly104may include a drill string105, a bottomhole assembly (“BHA”)106, and a bit110, attached to the downhole end of drill string105.

The drill string105may include several joints of drill pipe108a connected end-to-end through tool joints109. The drill string105transmits drilling fluid through a central bore and transmits rotational power from the drill rig103to the BHA106. In some embodiments, the drill string105further includes additional components such as subs, pup joints, etc. The drill pipe108provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through nozzles, jets, or other orifices in the bit110and/or the BHA106for the purposes of cooling the bit110and cutting structures thereon, and for transporting cuttings out of the wellbore102.

The BHA106may include the bit110or other components. An example BHA106may include additional or other components (e.g., coupled between to the drill string105and the bit110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or dampening tools, other components, or combinations of the foregoing. The bit110may also include other cutting structures in addition to or other than a drill bit, such as milling or underreaming tools.

In general, the drilling system100may include other drilling components and accessories, such as make-up/break-out devices (e.g., iron roughnecks or power tongs), valves (e.g., kelly cocks, blowout preventers, and safety valves), other components, or combinations of the foregoing. Additional components included in the drilling system100may be considered a part of the drilling tool assembly104, the drill string105, or a part of the BHA106depending on their locations in the drilling system100.

The bit110in the BHA106may be any type of bit suitable for degrading formation or other downhole materials. For instance, the bit110may be a drill bit suitable for drilling the earth formation101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits, roller cone bits, and percussion hammer bits. In some embodiments, the bit110is an expandable underreamer used to expand a wellbore diameter. In other embodiments, the bit110is a mill used for removing metal, composite, elastomer, other downhole materials, or combinations thereof. For instance, the bit110may be used with a whipstock to mill into a casing107lining the wellbore102. The bit110may also be used to mill away tools, plugs, cement, other materials within the wellbore102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface, or may be allowed to fall downhole.

FIG.2is a perspective view of the downhole end of a bit210, according to some embodiments of the present disclosure. The bit210inFIG.2is an example of a fixed-cutter or drag bit, and includes a bit body212, and a plurality of blades214extending radially and azimuthally therefrom. One or more of the blades214—and potentially each blade214—may have a plurality of cutting elements216connected thereto. In some embodiments, at least one of the cutting elements216has a planar cutting face. A planar cutting face may be used to shear the downhole materials, and such a cutting element may be considered a shear cutting element. In other embodiments, at least one of the cutting elements216has a non-planar cutting face. A non-planar cutting face may shear, impact/gouge, or otherwise degrade the downhole materials. Examples of non-planar cutting elements (i.e., cutting elements having a non-planar cutting face) include cutting elements with conical, ridged, domed, saddle-shaped, chisel-shaped, or other non-planar cutting faces. In some embodiments, the bit210includes one or more stabilizer pads218. A stabilizer pad218may be located on a blade214or at other locations other than a blade214, such as on the bit body212.

InFIG.2, the bit210is coupled to a rotary steerable system (“RSS”)211that may be used to steer the bit210when forming or enlarging a wellbore. The RSS211may include one or more steering devices220that are selectively actuatable to steer the bit210. In some embodiments, the steering device220includes one or more pistons222that are actuatable to move in a radially outward direction relative to a longitudinal axis224of the bit210and RSS211. The RSS211may apply a force at an angle relative to the drilling direction of the bit210to deflect the drilling direction. For instance, the pistons222may apply a force at an angle that is about perpendicular to the longitudinal axis224, or that is within 5°, 15°, or 30° of being perpendicular to the longitudinal axis224. In some embodiments, the steering device220is or includes an actuatable surface or ramp that moves in a radial direction relative to the longitudinal axis224. The bit210and RSS211may rotate about the longitudinal axis224, and the one or more steering devices220may actuate in a timed manner with the rotation to steer the bit and form a directional wellbore, or to maintain a straight wellbore.

In some embodiments, a portion of the steering device220(e.g., a piston222or housing of the piston222is radially within an RSS body226when the steering device220is in a retracted position. In some embodiments, at least a portion of the steering device220(e.g., a piston222and/or a housing of the piston222) may protrude from an RSS body226when the steering device220is in an expanded or retracted position. In some embodiments, one or more portions of the RSS211may experience greater wear and/or impact during operation.

The cutting elements216of the bit210may experience different wear rates in different regions of the bit body212or blades214. In some embodiments, the cutting elements216of the bit210experience different wear rates at a cone region228, a nose region230, a shoulder region232, or a gage region234of the blades214. For example, the cutting elements216of the nose region230may experience higher wear rates than the cutting elements216of the gage region234. In other examples, the cutting elements216of the shoulder region232experience higher wear rates than the cutting elements216of the nose region230.

In some embodiments, the bit body212, the blades214, the RSS body226, or combinations thereof include one or more body materials. The bit208and/or the RSS211may be or include a second material that is harder and/or has higher wear or erosion resistance than the body material. Conventionally, the second material may be a hardfacing material that is manually applied to the bit body212, blades214, or RSS body226. Hardfacing may be applied to a steel bit to increase the wear and/or erosion resistance of certain areas on the bit and/or blades. Hardfacing is conventionally a manual process that melts hardfacing rods. The melted material is applied to the bit, and the material cools on the bit to have a final geometry. The hardfacing may be applied in layers. As a manual process, hardfacing is variable and may have defects that result in premature failure of the hardfacing and/or the hardfaced components at or near the defects. For example, the hardfacing may fail at boundaries, along compositional changes, at layers, or other inconsistencies in the hardfacing material. In other examples, the hardfacing delaminates from the bit and/or blades due to insufficient bond strengths between the hardfacing material and the bit and/or blades. In some embodiments of a cutting tool according to the present disclosure, one or more portions of a bit210and/or RSS211include gage protection or other inserts positioned in the bit and/or blades and affixed to the bit and/or blade. The inserts may have a higher wear and/or erosion resistance than adjacent bit material to prolong the operational lifetime of a tool that may not include hardfacing.

FIG.3is a perspective view of a crown another embodiment of a bit310with a bit body312that includes a plurality of blades. In some embodiments, the bit body312includes one or more primary blades314-1and one or more secondary blades314-2. In some embodiments, the primary blades314-1and secondary blades314-2both extend to the gage region334of the bit310, but the primary blades314extend radially inward to be nearer the longitudinal axis324of the bit310when compared to the secondary blades314. In some embodiments, tertiary blades are also included, which extend to the gage region, but are farther from the longitudinal axis324than are the secondary blades314-2.

In some embodiments, a bit310includes at least one primary blade314-1, secondary blade314-2, or tertiary blade (collectively, blades314), that includes one or more segments336-1,336-2(collectively segments336) coupled thereto. In some embodiments, the segments336are replaceable cutting element segments, and include one or more cutter pockets338therein. The segments336may define cutter pockets338that include a sidewall and optionally a base. In some embodiments, a cutting element340is positioned in the cutter pocket338. While shear cutting elements340are shown inFIG.3, the cutting element340may be any cutting element (e.g., a non-planar cutting element) described herein.

In some embodiments, a first segment336-1is coupled to a blade314(e.g., primary blade314-1). The first segment336-1may be connected to the blade314by one or more connection mechanisms. For example, the first segment336-1may be connected to the blade314by welding, brazing, an adhesive, mechanical fastener(s) (e.g., bolts, screws, pins, clips, clamps, or other mechanical fasteners), mechanical interlock (e.g., grooves, dovetails, posts, recesses, ridges, other surface features, or other mechanical interlocks), other mechanisms, or combinations thereof. In some embodiments, the first segment336-1is brazed or welded to the blade314. In other embodiments, the first segment336-1is at least partially coupled to the blade314with a mechanical interlock and partially with braze or weld.

In the same or other embodiments, a second segment336-2is coupled to the same blade314that has the first segment336-1coupled thereto. The second segment336-2may be coupled to the blade314by the same or different connection mechanism as the first segment336-1. For example, the forces experienced by the first segment336-1in a first portion of the blade314may be different that the forces experienced by the second segment336-2in a second portion of the blade314. In some examples, the forces applied during a cutting operation are, for instance, different at the nose or cone regions of the blade314(and at the first segment336-1) than at the shoulder region of the blade314(and at the second segment336-2). In some embodiments, different connection mechanisms are used at least partially due to the differing forces experienced during cutting operations.

In some embodiments, a segment336includes or is made of a segment material. The segment material may be different from a bit body material or a blade material. For example, the segment material may include a ceramic, carbide, diamond, or ultrahard material that is different than a ceramic, carbide, metal, metal alloy, or other material of the bit body or blade314. An “ultrahard material” is understood to refer to those materials known in the art to have a grain hardness of 1,500 HV (Vickers hardness in kg/mm2) or greater. Such ultra-hard materials can include those capable of demonstrating physical stability at temperatures above 750° C., and for certain applications above 1,000° C., that are formed from consolidated materials. In some embodiments, the ultrahard material has a hardness values above 3,000 HV. In other embodiments, the ultrahard material has a hardness value above 4,000 HV. In yet other embodiments, the ultrahard material has a hardness value greater than 80 HRa (Rockwell hardness A). In some examples, the segment material includes a carbide material (e.g., tungsten carbide, tantalum carbide, titanium carbide, etc.). According to some embodiments, a carbide material forming the segment(s)336is infiltrated and/or sintered, or a cemented carbide material. In some embodiments, the carbide material is sintered and cemented (e.g., a sintered tungsten carbide including a binder and formed by additive manufacturing). In yet other examples, the segment material includes ultrahard particles embedded in a matrix material.

In some embodiments, the bit body material and/or blade material is a material with a lower erosion and/or wear resistance than the segment material. In other embodiments, the bit body material and/or blade material is a material with higher toughness than the segment material. In some examples, the bit body material and/or blade material includes a steel alloy and the segment material includes a tungsten carbide. The steel alloy may have a higher toughness than the tungsten carbide, which is more brittle, and the tungsten carbide may provide greater wear and/or erosion resistance during cutting operations.

As the segments336may experience shear and/or compressive forces during cutting operations, the connection of the segments336with the blade314-1,314-2may include a variety of geometries and/or connection mechanisms.FIG.4is an exploded perspective view of the embodiment of a bit310inFIG.3, in which the segments336are connectable to a blade314. The blade314may be a primary blade314-1as shown inFIG.4, or a secondary or tertiary blade in other embodiments.

In some embodiments, a void or recess342is formed in the blade314, and configured to receive one or more of the segments336. For instance, inFIG.4, a recess342is formed in a rotationally leading face of the blade314, and the first segment336-1and the second segment336-2is positioned at least partially within the recess342and connected to the blade314at an interface.

In some embodiments, the interface includes one or more back surfaces344and one or more side surfaces346-1,346-2. A back surface344may provide support to a segment336. In particular, the back surface344may be formed in a blade314and configured to support a rear surface337of one or more of the segments336. The rear surface337of the segments336may be opposite the rotationally leading surface339of the segments336. The side surfaces346-1,346-2may provide support to the segments336along one or more longitudinal and/or radial surfaces of the segments336. The longitudinal and/or radial surfaces of the segments336may extend between the rear surface337and the rotationally leading surface339of a segment336. For example, the first side surface346-1may be oriented about normal to the longitudinal axis324, and during cutting operations, the first segment336-1may experience a longitudinal, compressive force from the formation and transmit that compressive force to the first side surface346-1, which extends radially along the blade314. The first side surface346-1may support the first segment336-1while receiving the compressive force. In other embodiments, the first side surface346-1is oriented at a different angle relative to the longitudinal axis324, or is curved or have some other contour, shape, or orientation.

In the same or other embodiments, the second side surface346-2defining the recess342is oriented at an angle to the longitudinal axis324to provide support in the radial direction to the second segment336-2. For example, during cutting operations, the second segment336-2may experience a compressive force optionally in both the longitudinal direction (in the direction of the longitudinal axis324) and in a radial direction (normal to and toward the longitudinal axis324). The second side surface346-2may extend in both radial and longitudinal directions and support the second segment336-2while receiving the longitudinal and radial compressive force. In some embodiments, the second side surface346extends longitudinally to be parallel to the longitudinal axis324, is perpendicular to the longitudinal axis324, is be curved, or has some other contour, shape, or orientation. Thus, the first and second side surfaces346-1,346-2may be planar or non-planar.

In some embodiments, the back surface344supports the rear surface337of a segment336as the bit310rotates in the rotational direction (so that the leading surface339rotationally leads the rear surface337) about the longitudinal axis324. Shear, frictional, or other forces on the blades314from the formation or other downhole material may oppose the direction of movement of the bit310—including the segments336—during cutting operations. The back surface344defining the recess342may provide a compressive support against the shear and other forces from the formation. In some embodiments, the back surface344is planar, curved, or otherwise configured. In at least some embodiments, the back surface344is angled toward the rotational direction such that shear force applied to the segment336-1,336-2is partially directed toward the bit body. For instance, the downhole end portion of the back surface344(i.e., the portion nearest the top of the blade314) may be inclined toward (and nearer) the rotationally leading face of the blade314. In other embodiments, the uphole end portion of the back surface344is inclined toward the rotationally leading face of the blade314.

In some embodiments, the segments336are connected at the interface with the recess (and at the back surface344and/or side surfaces346) with a connection mechanism. InFIG.4, the connection mechanism includes mechanical interlocking features348. In some embodiments, the mechanical interlocking features348include complementary recesses and posts. For instance, one or more recesses may be formed in the blades314and one or more complementary posts in the segments336, or one or more recesses may be formed in the segments336and one or more posts in the blades314. In another one or more embodiments, recesses are formed in each of the segments336and in the blades314, and one or more complementary posts are formed separately and inserted into the recesses in both the segments336and the blades314. In other embodiments, the mechanical interlocking features348include dovetails, tapered dovetails, ridges, grooves, or other surface features that limit and/or prevent the movement of a segment336relative to the blade314in one or more directions.

In some embodiments, the mechanical interlocking features348are positioned in a side surface346defining the recess342. In the same or other embodiments, one or more mechanical interlocking features348are positioned in the back surface344defining the recess342. In at least one embodiment, mechanical interlocking features348are positioned in both the side surfaces346and the back surface(s)344defining the recess342. For example, a dovetail feature in the back surface344may allow a segment336to slide along the dovetail, and potentially until a post engages with a recess in a side surface346. In some embodiments, mechanical interlocking features348or other surface features assist in aligning a segment336with a location within the recess342. In some examples, mechanical interlocking features348limit and/or prevent movement of a segment336relative to the blade314-1during a brazing, welding, or other attachment process. In other examples, a first segment336-1and a second segment336-2have different mechanical interlocking features348, or have different shapes, to preventing incorrect placement and installation of the segments336.

In some embodiments, at least a portion of the side surfaces346is planar. A planar side surface346may provide a stronger connection between the interface of the recess342and the replaceable segments336. For example, the planar side surface346adjacent the segments336of the embodiment shown inFIG.4allows for more reliable brazing of the first segment336-1to the blade314and of the second segment336-2to the blade314. In other embodiments, a planar side surface346reduces or eliminates stress concentrations within the corresponding side surface346. In some embodiments, there is a discontinuous angle between a first side surface346-1and a second side surface346-2.

FIG.5is an exploded view of another embodiment of a bit410having a segment436positioned in a recess442in a blade414. Although the blade414is shown as a secondary blade, the segment436may be used in connection with a primary, tertiary, or other blade. In some embodiments, at least part of an interface defined by a recess442within the blade414and the segment426is curved. For instance, a full or partial portion of a side surface446may be curved or otherwise non-planar. In other examples, a portion of the side surface446is curved and another portion of the side surface446is planar.

In some embodiments, a curved portion of the side surface446has a radius of curvature in a range having an upper value, a lower value, or upper and lower values including any of 5 mm, 20 mm, 40 mm, 50 mm, 60 mm, 80 mm, 100 mm, or any values therebetween. For example, the curved portion of the side surface446may have a radius of curvature greater than 5 mm. In other examples, the curved portion of the side surface446has a radius of curvature less than 100 mm. In yet other examples, the curved portion of the side surface446has a radius of curvature between 5 mm and 100 mm. In further examples, the curved portion of the side surface446has a radius of curvature between 10 mm and 80 mm. In yet further examples, the curved portion of the side surface446has a radius of curvature 25 mm. In still other embodiments, the radius of curvature of the side surface446is less than 5 mm or greater than 100 mm. Additionally, the radius of curvature of the side surface446may vary or may be constant.

In some embodiments, a segment436is connected to the blade414with a mechanical fastener, either alone or in combination with other connection methods. For example, a segment436and blade414may include one or more mechanical fastener connection locations450. For example, a mechanical fastener connection location450may include a threaded hole (blind hole or through hole) to receive a threaded mechanical fastener, or an unthreaded through hole. In the same or other examples, a mechanical fastener connection location450includes a hole or recess with a shoulder (e.g., a countersunk bore having a first diameter and a larger second diameter with a step therebetween) to receive a nut, the head of a bolt, or other complimentary mechanical fastener. In at least one example, a mechanical fastener connection location450in a segment436has a shoulder to engage with a head of a threaded bolt, and a mechanical fastener connection location450in a blade414has a threaded bore to engage with threads of the threaded bolt. The threads may engage to allow the head of the bolt to compress the segment436toward the interface with the blade414.

FIG.6is a perspective exploded view another embodiment of a bit510with a modular or replaceable segment536configured to connect to a primary blade, a secondary blade, or some other blade514, using one or more mechanical fastener connections. The segment536may be compressed against a back surface544and/or side surface546by mechanical fasteners. In some embodiments, a resilient, energy absorption layer552is positioned between the segment536and the blade514. The resilient layer552may be any material that may deform under compression between the segment536and the blade514. For example, the resilient layer552may include an elastically compressible material, such as a spring steel, titanium alloy, other metal alloy, a polymer, a composite material, or other material, that may deform plastically or elastically. In some embodiments, the resilient layer has a bulk elastic modulus below 630 GPa. In other examples, the resilient layer552includes a geometry that allows for compression of the resilient layer552. For example, the resilient layer552may include a leaf spring geometry to apply a reactive force to the compression of a mechanical fastener.

According to some embodiments, mechanical fasteners may loosen during cutting operations due, at least partially, to vibrations incurred during cutting of the formation, casing, or other material. In some embodiments, a resilient layer552may limit and/or prevent the “walking out” of a mechanical fastener during cutting operations. In other embodiments, a resilient layer552may dampen the transmission of vibration from the segment536to the blade514, thereby reducing fatigue damage to the blade514. In the same or other embodiments, an elastic or inelastic resilient layer552may absorb impacts between the segment536and the blade514, reducing damage to the segment536and/or blade514. In further embodiments, a resilient layer552may provide a compliant layer between the segment536and the blade514that may reduce stress concentrations that arise from any mismatch between contact faces of the segment536and the blade514.

In other embodiments, a resilient or other layer is part of the segment.FIG.7is a side view of another embodiment of a segment636having two materials bonded to one another. The segment636may include a segment material and a substrate material that are metallurgically bonded or mechanically fastened. In some embodiments, a segment636is additively manufactured with a segment material layer654deposited on and bonded to a substrate material layer656. The substrate material layer656may be a metal alloy, such as steel, aluminum, titanium, or other metal alloy. In some embodiments, the substrate material is a weldable material. For example, a segment636with a steel substrate material layer656may be weldable to a weldable material (e.g. steel) of a blade of a bit or other cutting tool.

In some embodiments, the segment636includes one or more cutter pockets638, which have cutting elements640positioned therein. In some embodiments, the cutter pockets638are located at least partially in the segment material layer654of the segment636. In other embodiments, the cutter pocket638is located entirely in the segment material layer654of the segment636. In yet other embodiments, the cutter pocket638is located at least partially in the substrate material layer656of the segment636. In some embodiments, a thickness of the substrate material layer656is at least 0.05 in. (1.27 mm), at least 0.1 in. (2.54 mm), at least 0.2 in. (5.08 mm), or at least 0.3 in. (7.62 mm). In other embodiments, the substrate material layer656is less than 0.05 in. (1.27 mm).

In some embodiments, a segment includes side and rear surfaces defining a cutter pocket within the segment. In other embodiments, a segment has a side surface extending fully and no rear surface, so that the cutter pocket extends fully through the segment from a first face to an opposing second face, such that the cutter pocket is open on both sides. In such embodiments, the blade defines at least a portion of the cutter pocket (e.g., a rear surface and/or a portion of one or more side surfaces), and the cutting element is at least partially connected directly to the blade of the bit, without the segment forming a purely indirect connection between the cutting element and the blade.

FIG.8-1is an exploded perspective view of an example embodiment of a bit710with cutter pockets738formed in a blade714(e.g., primary blade, secondary blade, tertiary blade, etc.) of the bit710, while a protective segment is positioned adjacent the cutter pockets738and the cutting elements740. In some embodiments, the protective segment includes a faceplate758that couples to a leading face of the blade714of the bit710. The faceplate758may be may be similar in some respects to segments described in relation toFIG.2throughFIG.7. For example, a faceplate758may include a segment material, such as tungsten carbide. In other examples, a faceplate758includes a substrate material that is optionally a weldable material. In yet other examples, a faceplate758includes one or more mechanical fasteners or connection locations to facilitate coupling of the faceplate758to the blade714.

The faceplate758may be positioned at an interface with the blade714, and optionally within a recess742formed in the leading surface of the blade714. While the faceplate758is shown positioned adjacent the leading face of a primary blade714, in other embodiments, the faceplate758is positioned adjacent other blades of the bit710(e.g. secondary blades), or on other surfaces of a blade (e.g., a top surface as shown inFIG.8-2). In some embodiments, the recess742may define an interface including a back surface744and a side surface746. In some examples, at least a portion of the side surface746is curved or non-planar. In other examples, at least a portion of the side surface746is planar.

In some embodiments, the back surface744of the interface between the faceplate758and the blade714has part of one or more cutter pockets738positioned therein. For example, a base, back, or rear surface of the cutter pocket738may be at least partially within the blade714. In some examples, at least some of a depth of the cutter pocket738is located in the blade714, so that the side surface of the cutter pocket738is at least partially formed by the blade714and at least partially by the faceplate758. The blade714and the faceplate758may therefore cooperatively define the cutter pocket738when the faceplate758is positioned relative to the blade714to align respective portions of the cutter pocket738.

In some embodiments, a cutting element740is positioned in the cutter pocket738and is connected to both the blade714and to the faceplate758. For example, the cutting element740may be brazed into the cutter pocket738such that the cutting element740is brazed to both the blade714and to the faceplate758. In other embodiments, the cutting element740is brazed to the blade714and not to the faceplate758. In yet other embodiments, the cutting element740is brazed to the faceplate758and not to the blade714. In still other embodiments, attachment mechanisms other than brazing are used to couple the cutting element740to the blade714, the faceplate758, or both.

In at least some embodiments, the faceplate758is pre-formed to replace hardfacing applied by conventionally welding/melting process. In this context, a “pre-formed” faceplate758has a shape suitable for application, adhesion, or coupling to a bit or other downhole tool, even in the absence of melting the material. Thus, in contrast to conventional hardfacing that is melted to be applied to the bit, the pre-formed faceplate758has a defined shape apart from the downhole tool that is generally similar to the shape of the faceplate758when coupled to the downhole tool. Additionally, while conventional hardfacing adheres to a downhole tool using material within the hardfacing itself, a pre-formed faceplate758may be attached by a separate material (e.g., braze, solder, etc.) or a separate mechanism (e.g., mechanical fasteners).

The faceplate758may be formed from carbide, ceramic, matrix, metal, metal alloy, or other materials having a higher abrasion or erosion resistance than materials forming the blade714. By way of example, a casting, infiltration, molding, additive manufacturing, sintering, machining, or other process, or a combination of the foregoing, may be used to produce faceplate758made at least partially, and potentially fully, of a sintered, cemented tungsten carbide material. The faceplate758may be coupled to a blade of a steel body bit. Due to the higher abrasion and erosion resistance of the sintered, cemented tungsten carbide material as compared to the steel material of the blade, the faceplate758may act as a pre-formed, and potentially replaceable material that may replace hardfacing material to protect areas of the blade of the bit710adjacent the cutting elements740. This may allow the operational life of the bit710to be extended as wear from contact with formation and other materials, and erosion from fluid flow from nozzles or a wellbore, may be reduced. As wear of the faceplate758increases beyond an acceptable level, the faceplate758may be removed and replaced. Optionally, the cutting elements740may also be removed; however, in at least some embodiments, one or more of the cutting elements740may remain coupled to the blade714while the faceplate758is removed, and optionally while a replacement faceplate758is attached. In at least some embodiments, the faceplate758is coupled to the blade714by brazing, welding, or mechanical fastening. The faceplate758may optionally be coupled with a braze material that is different than the braze material used for brazing the cutting elements740. In at least one embodiment, the braze material used to braze the faceplate758to the blade714has a higher melting temperature than the braze material used to braze the cutting elements740within the cutter pockets738.

FIG.8-2is a schematic, partial cross-section of another example of a blade714having multiple faceplates coupled to the blade714. In the embodiment shown inFIG.8-2, a first pre-formed faceplate758-1is shown as being coupled to a leading surface of the blade714, while a second pre-formed faceplate758-2is coupled to a top (or downhole or formation facing) surface of the blade714. The first pre-formed faceplate758-1may be similar to the faceplate758ofFIG.8-1, and is optionally positioned within a recess in the leading face of the blade714. As shown inFIG.8-2, the first faceplate758-1may form at least a portion of a side surface of a cutter pocket738into which a cutting element740is positioned, while the blade714may also form a portion of the side surface of the cutter pocket738, as well as a base of the cutter pocket738.

InFIG.8-2, a second faceplate758-2is coupled to the blade714in a manner similar to the first faceplate758-1, except that the second faceplate758-2is located at the top surface of the blade714, and optionally adjacent the cutting element740. In the particular embodiment shown, the second faceplate758-2may cover at least a portion of the cutting element740to also define a portion of the cutter pocket738; however, such an embodiment is merely illustrative. In other embodiments, the second faceplate758-2is positioned rotationally behind the cutting element740on the blade714. The second faceplate758-2may provide increased abrasion or erosion resistance to the top, formation-facing surface of the blade714as drilling occurs. In some embodiments, the second faceplate758-2is positioned at least partially within a recess formed in the top surface of the blade714; however, in other embodiments, the second faceplate758-2is wholly within a recess, or may not be within any recess at all.

FIG.9is an exploded view of another embodiment of a blade814with a faceplate coupled thereto. In some embodiments, the faceplate includes a plurality of faceplate segments858-1,858-2,858-3,858-4(collectively faceplate segments858) that are coupled to the blade814. In an example, a first faceplate858-1may be configured to be positioned adjacent to and/or protect a plurality of cutting elements840. The first faceplate858-1may be continuous across a distance adjacent to multiple cutting elements, and may reduce openings or edges that may be susceptible to increased erosion or wear rates. In other examples, at least one faceplate, such as the second faceplate segment858-2ofFIG.9, is configured to be positioned adjacent to and/or protect a blade adjacent a single cutting element840. As should be appreciated in view of the disclosure herein, a faceplate segment858may be positioned adjacent to and/or protect a blade adjacent any number of cutting elements840, including partial portions of cutting elements840. Third faceplate segment858-3, for instance, may be positioned adjacent half of a cutting element840. Fourth faceplate segment858-4is shown as being positioned adjacent to and/or to protect a blade adjacent one and a half cutting elements840.

In some embodiments, having separate faceplates that are not connected to one another may allow for the relief of residual thermal or other mechanical stress in the faceplate. Allowing the second faceplate segment858-2to thermally expand or contract independently of the third faceplate segment858-3may reduce the likelihood of failure of the second faceplate segment858-2and/or third faceplate segment858-3. In other embodiments, having separate faceplates or faceplate segments that are not connected to one another may allow for the replacement or repair of individual faceplates as different regions of the blade814may experience different amounts of erosion or wear.

In some examples, the fourth faceplate segment858-4located on the nose region830of the blade814may experience a different wear/erosion rate than the second faceplate segment858-2located on the shoulder region832of the blade814. In other examples, the gage region834of the blade814may experience a substantially equal wear rate along a length of the gage834. In such examples, the gage region834may have a continuous first faceplate segment858-1such that there are no spaces or openings in the first faceplate segment858-1to increase operational lifetime of the gage region834with less risk of disproportionate wear/erosion on the first faceplate segment858-1.

In some embodiments, a faceplate has a different geometry based on the type of cutting element the faceplate protects. For example, a faceplate may have a first geometry when configured to protect a shear cutting element and another faceplate may have a second geometry when configured to protect a non-planar cutting element. A blade814with a plurality of faceplates may allow for one of more of the faceplates858to be changed, allowing the blade814and/or associated bit to be customized to the material to be degraded. A variety of faceplates and combinations of faceplate segments allow a single bit and/or blade design to be modular. In at least some embodiments, the faceplates or faceplate segments may provide pre-formed, hardened elements that replace hardfacing applied to one or more areas of the blade surface on a steel or other bit. As should be appreciated in view of the disclosure herein, the separable, modular segments ofFIG.9may also be used in connection with faceplates used on regions other than a rotationally leading surface, including with a faceplate on a top surface of a blade as discussed with respect toFIG.8-2.

FIG.10is a side view of another embodiment of a bit910having a pre-formed, wear resistant insert960positioned in a gage region934of the bit910. The insert960may include a segment material as described herein. In some embodiments, the insert960is positioned in the blade914to provide increased wear resistance in comparison to a body material of the blade914. The insert960may be located in the blade in a void or recess, similar to the void or recess described in relation toFIG.4. The insert960may provide a surface without pockets, or without pockets for cutting elements (in contrast to the cutting element-bearing segments of the embodiments describe in relation toFIG.2throughFIG.7) and/or be located on a non-cutting portion of the bit910(in contrast to the faceplate758located adjacent the cutting elements740inFIGS.8-1and8-2). While embodiments include an insert960brazed into the blade914, in other embodiments, an insert960is connected to the blade914using welding, an adhesive, a mechanical fastener (such as a bolt, screw, pin, clip, clamp, or other mechanical fasteners), a mechanical interlock (such as grooves, dovetails, posts, recesses, ridges, other surface features, or other mechanical interlocks), other mechanisms disclosed herein or known in the art, or combinations thereof

In other embodiments, pre-formed segments (including pre-formed hardened segments in lieu of hardfacing) are used in conjunction with cutting tools other than bits. For example,FIG.11is a side view of an embodiment of a downhole cutting tool1062illustrative of an expandable milling tool or underreamer, with a plurality of segments1036-1,1036-2. A downhole cutting tool1062may be used in milling applications to remove casing from a wellbore or other downhole environment, or in underreaming applications to degrade formation or cement. The downhole cutting tool1062may have one or more cutting arms or blades1064. In some embodiments, the blades1064are selectively deployable at the intended location in the wellbore. The blades1064may have a plurality of cutting elements1040positioned on a radially outward portion of the blade1064, which portion is configured to remove casing and/or formation. For example, a combination of different cutting elements1040may be used on the blade1064depending on the location on the blade1064. In some examples, a first segment1036-1carries and/or protects one or more cutting elements1040that are configured to cut steel casing. In other examples, a second segment1036-2carries and/or protects one or more cutting elements1040configured to cut cement or earthen formation. In yet other examples, the blade1064has one continuous segment that carries a plurality of types of cutting elements1040, or a continuous segment or multiple segments carries a single type of cutting element1040. In some embodiments, multiple types of cutting elements carried by the blade1064include stabilizing or gage protection elements in addition to cutting elements.

In some embodiments, a downhole cutting tool1062experiences different wear rates in different locations on the blade1064due, at least partially to different areas of the blade1064interacting with different materials, carrying a higher burden for material removal, experiencing different vibrational/impact forces, or myriad other reasons. For example, the wear rate of the first segment1036-1while cutting casing may be greater than the second segment1036-2while cutting cement or earthen formation. In another example, the wear rate of the second segment1036-2may be greater than the first segment1036-1while both ream earthen formation. In at least one embodiment, it is beneficial to selectively replace or repair one of the segments1036-1,1036-2at a time.

Some embodiments of a cutting tool with a segment according to the present disclosure are manufactured according to a method such as illustrated inFIG.12. In some embodiments, a method1168includes forming a blade from a body material at1170. For example, the blade may be a bit blade, such as described in relation toFIG.2, or the blade may be a milling or reamer/underreamer blade, such as described in relation toFIG.11. The blade may be formed by a variety of methods, including but not limited to casting, machining, additive manufacturing, or combinations thereof. For example, a bit body may be cast with a blade protruding therefrom. In another example, a bit is machined with a blade integral with the bit body and protruding therefrom. In another example, a bit is cast or machined, and the blade is separately formed and welded or otherwise secured to the bit body. In yet another example, a bit body and blade are additively manufactured (collectively or separately). In at least some embodiments, forming the blade at1170also includes a blade with a void or recess therein. For instance, the blade may be cast, machined, or additively manufactured with a recess configured to receive a corresponding pre-formed segment that has higher wear and/or erosion resistance than the material of the blade and/or bit body.

In some embodiments, a recess defines an interface including one or more side surfaces and/or back surfaces, as described herein. The interface may include planar surfaces. In other embodiments, the interface includes at least one surface that is fully or partially curved or non-planar. In yet other embodiments, the interface is entirely curved or non-planar surfaces. According to at least some embodiments, forming the blade at1170includes forming full or partial cutter pockets.

The method1168may further include forming a segment from a segment material at1172. In some embodiments, the segment includes one or more full or partial cutter pockets. In other embodiments, the segment is a pre-formed, protective, hardened faceplate that forms at least a portion of a cutter pocket, while a base of the cutter pocket is formed by the blade. In yet other embodiments, the segment is an insert that lacks a cutter pocket and is positioned in the blade for increased wear resistance. Optionally, the segment is an insert with gage protection or stabilizing element pockets.

In some embodiments, forming the segment includes shaping the segment to have a shape complementary to the recess and interface with the blade to fill at least a portion of the recess. For example, the segment may complementarily fit the recess and mate with substantially the entire interface. In another example, the segment may complementarily fit a portion of the void and mate with less than the entire interface. In at least one example, the segment includes a plurality of segment portions that complementarily fit the void and mate with substantially the entire interface as a complete set of segment portions.

The segment may be formed of a segment material by a variety of methods, including but not limited to casting, machining, additive manufacturing, or combinations thereof. For example, a segment may be cast to have a complementary fit with at least a portion of the void. In another example, a segment is machined (e.g., in a green state) to complementarily fit at least a portion of the void. In yet another example, a segment is additively manufactured to have a complementary fit with at least a portion of the void. In at least one example, the segment is additively manufactured, cast, or molded to approximate final dimensions and machined to complementarily fit at least a portion of the void.

The method1168may further include positioning the segment relative to a blade (e.g. in a recess or blade) at1174and connecting the segment to the blade at1176. In some embodiments, connecting the segment to the blade includes the use of by welding, brazing, adhesive, a mechanical fastener (such as a bolt, screw, pin, clip, clamp, or other mechanical fasteners), mechanical interlock (such as grooves, dovetails, posts, recesses, ridges, other surface features, or other mechanical interlocks), or combinations thereof. In some embodiments, the segment is brazed to the blade. In other embodiments, the segment is at least partially retained with a mechanical interlock with the blade and partially retained with a braze joint between the segment and the blade. For example, a layer of braze between the segment and the blade may be approximately 0.004 in. (0.1 mm) in thickness.

In some embodiments, the segment and/or interface includes one or more surface features to space the segment and blade apart and create a gap into which the braze is positioned. For example, the segment may include one or more surface features that create a constant 0.002 in. (0.05 mm) to 0.006 in. (0.015 mm) gap between the blade and the segment. In some embodiments, the surface features provide a gap that is greater than or less than 0.004 in. (0.1 mm). For example, different brazes may flow more efficiently in a larger or smaller gap.

In the same or other embodiments, a segment is connected to the blade with a mechanical fastener and/or a resilient layer positioned between the segment and the blade, such as described in relation toFIG.6. In such embodiments, the resilient layer may provide vibration dampening and/or absorption to limit vibration damage to the segment, the blade, or the connection therebetween. In some embodiments, a segment is connected to the blade with by using a substrate of the segment. For instance, the segment may include a segment material bonded or otherwise coupled to a substrate material, as described herein in relation toFIG.7. The substrate material may be welded or brazed to a blade material, or may be coupled to the blade using mechanical fasteners.

In some embodiments, the method1168further includes positioning and connecting a cutting element in a cutter pocket of the segment and/or blade at1178. In some embodiments, positioning and connecting the cutting element in the cutter pocket occurs before connecting a pre-formed or replaceable segment to a blade. For example, a cutting element may be brazed into the cutter pocket of a segment (such as shown inFIG.4) before the segment is connected to the blade. In such examples, the subsequent connection of the segment with the blade indirectly affixes the cutting element to the blade. In another example, a faceplate is connected to the blade (seeFIG.8-1), and a cutting element is subsequently positioned in and connected to the cutter pocket formed by the blade and faceplate.

In embodiments utilizing braze materials and joints to connect the segment to the blade and using braze materials and joints to connect the cutting element to the cutter pocket and/or segment, either connection may be created first. For instance, a first brazing may include a relatively higher temperature braze, for example, greater than 1,600° F. (870° C.), and a second brazing may include a relatively lower temperature braze, for example, less than 1400° F. (760° C.). Performing the second braze at a lower temperature may limit and/or prevent damage to, or weakening of, the prior braze. In some embodiments, the melting temperature of the high temperature braze and low temperature braze is at least 100° F. (55° C.) apart from one another to limit damage to the prior braze. Methods of brazing may therefore include performing a lower temperature braze process at a temperature that is at least 100° F. (55° C.) lower than a high temperature braze process. In other embodiments, the high temperature braze and low temperature braze are performed at least 200° F. (110° C.) apart from one another to limit damage to the prior braze. In some embodiments, a segment and/or cutting element is heated to the lower brazing temperature to selectively facilitate repair and/or replacement of the segment and/or cutting element connected by the low temperature braze.

While embodiments of segments have been described herein with and without cutter pockets or with a portion of a cutter pocket therein, the segment itself may additionally have a range of geometries relative to the blade.FIG.13is a side cross-sectional view of another embodiment of a bit1210, according to the present disclosure. In some embodiments, a pre-formed, replaceable segment1236is optionally hardened relative to a blade material, and connected to the blade1214, which extends from a bit body1212. A cutting element1240may be positioned in and connected to the segment1236. In some embodiments, a size of the segment1236is defined by a vertical ratio and a horizontal ratio relative to a cutting tip1278of the cutting element1240. The cutting tip1278may be the outermost point of the cutting element1240from the bit body1212, such that the cutting tip1278is the first point of the cutting element1240to contact the material being removed during cutting operations.

In some embodiments, the blade1214has a blade height1280-1and the segment1236has a segment height1280-2. The blade height1280-1is measured from the bit body1212to the cutting point1278. The segment height1280-2is measured from the point of the segment1236closest to the bit body1212to the cutting point1278.

The vertical ratio is the ratio of the segment height1280-2to blade height1280-1. For example, a segment height1280-2that is one half of the blade height1280-1has a vertical ratio of 0.5. In some embodiments, the vertical ratio is in a range having an upper value, a lower value, or upper and lower values including any of 0.1, 0.25, 0.5, 0.75, 0.95, 1.0, or any values therebetween. For example, the vertical ratio may be greater than 0.1. In other examples, the vertical ratio is between 0.2 and 0.95. In yet other examples, the vertical ratio is between 0.3 and 0.95. In further examples, the vertical ratio is between 0.34 and 0.9. In at least one example, the vertical ratio is greater than 0.34. In still other embodiments, the vertical ratio is less than 0.1 or even greater than 1.0 (e.g., where the segment is inset into the bit body and extends the full blade height1280-1).

In some embodiments, the blade1214has a blade width1282-1and the segment1236has a segment width1282-2. The blade width1282-1is measured from the rearmost point of the blade1214to the cutting point1278. The segment width1282-2is measured from the rearmost point of the segment1236to the cutting point1278.

The horizontal ratio is the ratio of the segment width1282-2to blade width1282-1. For example, a segment width1282-2that is one half of the blade width1282-1has a horizontal ratio of 0.5. In some embodiments, the horizontal ratio is in a range having an upper value, a lower value, or upper and lower values including any of 0.1, 0.25, 0.5, 0.75, 0.95, 1.0, or any values therebetween. For example, the horizontal ratio may be greater than 0.1. In other examples, the horizontal ratio is between 0.2 and 0.95. In yet other examples, the horizontal ratio is between 0.3 and 0.95. In further examples, the horizontal ratio is between 0.37 and 0.9. In at least one example, the horizontal ratio is greater than 0.37. In still other embodiments, the horizontal ratio is less than 0.1 or greater than 1.0 (e.g., where the segment over hangs the blade1214). InFIG.13, the dashed lines on the base of the blade illustrate an example segment1236having a horizontal ratio equal to 1.0.

In at least one embodiment, a cutting tool according to the present disclosure has an increased operational lifetime relative to a conventional cutting tool. In some embodiments, a cutting tool with blades incorporating pre-formed, replaceable segments according to the present disclosure exhibits increased wear/erosion resistance relative to a conventional cutting tool. For instance, one or more segments may be located in places on the blade where wear and erosion are highest. When the segments wear, they may be removed and replaced to extend the operational life of the bit body and blades. For instance, phantom lines illustrate the use of example mechanical fasteners (e.g., complementary dovetail pins and sockets) that may be used in addition to, or instead of, braze, welding, or other fastening methods. In the same or other embodiments, a cutting tool with blades incorporating segments according to the present disclosure may allow for faster and/or easier repairs relative to conventional cutting tools in which the blades are integral with the body, or even in which the blades themselves are removable or replaceable.

Embodiments of cutting tools have been primarily described with reference to wellbore cutting operations; however, the cutting tools described herein may be used in applications other than the drilling of a wellbore. In other embodiments, cutting tools according to the present disclosure are used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, cutting tools of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements. Permissive terms “may” or “can” are used herein to indicate that features are present in some embodiments, but are optional and are not included in other embodiments within the scope of the present disclosure.

The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.