US4592252A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Rolling cutters for drill bits, and processes to produce same
Assignee: POWMET FORGINGS LLC
•
Filing: 1985-06-12
•
Granted: 1986-06-03
•
Expires: 2005-06-12
Abstract
Abstract A roller bit cutter comprises a tough, metallic, generally conical and fracture resistant core having a hollow interior, the core defining an axis; an annular, metallic, radial bearing layer carried by the core at the interior thereof to support the core for rotation, the bearing layer extending about the core axis; a wear resistant outer metallic layer on the exterior of the core; metallic teeth integral with the core and protruding outwardly therefrom, at least some of the teeth spaced about the axis; and an impact and wear resistant layer on each tooth to provide hard cutting edges as the bit cutter is rotated about the core.
Inventors
- 👤 Gunes M. Ecer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 12:11
CPC Classifications
E; E21; E21B; E21B10/00; E21B10/46; E21B10/50; E21B10/52; E21B10/08; E21B10/22; B; B22; B22F; B22F5/00; B22F2005/001
Claims Analysis
Total Claims: 45
Claim 1
Independent Claim
167 words
The method of producing a roller bit cutter, that includes the steps (a) providing a tough, metallic, generally conical and fracture resistant core having a hollow interior, the core defining an axis, (b) providing an annular, metallic, radial bearing layer carried by said core at the interior thereof to support the core for rotation, said bearing layer extending about said axis, (c) providing a wear resistant outer metallic layer on the exterior of the core, (d) the core including metallic teeth integral with the core and protruding outwardly therefrom, at least some of said teeth spaced about said axis, (e) and providing an impact and wear resistant layer on each tooth to provide hard cutting edges as the bit cutter is rotated about said axis, (f) at least one of said core and layers being provided by application of powder metal in a suitable binder, the binder subsequently volatilized and the powder metal consolidated in a granular bed via which pressure is transmitted to said metal powder.
Claim 2
Independent Claim
167 words
The method of producing a roller bit cutter, that includes the steps (a) providing a tough, metallic, generally conical and fracture resistant core having a hollow interior, the core defining an axis, (b) providing an annular, metallic, radial bearing layer carried by said core at the interior thereof to support the core for rotation, said bearing layer extending about said axis, (c) providing a wear resistant outer metallic layer on the exterior of the core, (d) the core including metallic teeth integral with the core and protruding outwardly therefrom, at least some of said teeth spaced about said axis, (e) and providing an impact and wear resistant layer on each tooth to provide hard cutting edges as the bit cutter is rotated about said axis, (f) at least one of said core and layers being provided by application of powder metal in a suitable binder, the binder subsequently volatilized and the powder metal consolidated in a granular bed via which pressure is transmitted to said metal powder.
Claim 3
Dependent Claim
29 words
The method of claim 1, including (a) providing an impact and wear resistant metallic inner layer on the core at the interior thereof, to provide an axial thrust bearing.
Claim 4
Dependent Claim
18 words
The method of claim 1 wherein said outer layer is applied to cover the core between said teeth.
Claim 5
Dependent Claim
16 words
The combination of claim 1 wherein said layer on each tooth consists essentially of tungsten carbide.
Claim 6
Dependent Claim
60 words
The method of claim 1 wherein said one of the core and layers is initially provided in preform state wherein the powder metal is mixed with said binder, and wherein the preform after said volatilization is embedded in said granular bed via which said pressure is applied to the preform to consolidate the metal powder to form an integral body.
Claim 7
Independent Claim
20 words
The method of one of claims 1-4 wherein at least one of said layers consists essentially of consolidated powder metal.
Claim 8
Independent Claim
20 words
The method of one of claims 1-4 wherein at least two of said layers consist essentially of consolidated powder metal.
Claim 9
Independent Claim
25 words
The method of claims 1-4 wherein at least three of said layers consist essentially of consolidated powder metal, and said core consists essentially of steel.
Claim 10
Independent Claim
18 words
The method of one of claims 1-4 wherein all of said layers consist essentially of consolidated powder metal.
Claim 11
Dependent Claim
25 words
The method of claim 1 wherein said core consists essentially of steel alloyed with elements that include carbon, manganese, silicon, nickel, chromium, molybdenum, and copper.
Claim 12
Dependent Claim
43 words
The method of claim 10 wherein said elements have the following weight percents: ______________________________________
carbon 0.1 to 0.65
manganese 0.25 to 2.0
silicon 0.15 to 2.2
nickel 0.01 to 3.75
chromium 0.01 to 1.2
molybdenum 0.01 to 0.40
copper 0 to 0.3
______________________________________
Claim 13
Dependent Claim
14 words
The method of claim 1 wherein said core consists essentially of cast alloy steel.
Claim 14
Dependent Claim
14 words
The method of claim 11 wherein said core consists of ultra high strength steel.
Claim 15
Dependent Claim
26 words
The method of claim 13 wherein said steel is selected from the group consisting of D-6A, H-11, 9Ni-4Co, 18-Ni maraging, 300-M, 4134, 4330 V and 4340.
Claim 16
Dependent Claim
42 words
The method of claim 1 wherein said core consists of consolidated ferrous powder metal steel having the following composition, indicated percentages being by weight: ______________________________________
iron 79 to 98%
copper
0 to 20%
carbon
0.4 to 1.0%
nickel
0 to 4.0%
______________________________________
Claim 17
Dependent Claim
51 words
The method of claim 1 wherein said core consists of age hardenable and martensitic stainless steel alloyed with elements that include the following with indicated weight percents: ______________________________________
chromium 0 to 20%
aluminum 0 to 2.5%
titanium 0 to 1.5%
copper 0 to 4.0%
columbium plus 0 to 0.5%
tantalum
______________________________________
Claim 18
Independent Claim
46 words
The method of any one of claims 1 or 10-16 wherein the core has mechanical properties in excess of the following lower limits: ______________________________________
130 ksi ultimate tensile strength
80 ksi yield strength
5% tensile elongation
15% reduction in area
10 ft-lb (izod) impact strength
______________________________________
Claim 19
Dependent Claim
21 words
The method of claim 1 wherein said outer layer consists of a composite mixture of refractory particles in a binder metal.
Claim 20
Dependent Claim
28 words
The method of claim 18 wherein said refractory particles have micro hardness in excess of 1,000 kg/mm 2 , and a melting point in excess of 1,600° C.
Claim 21
Dependent Claim
32 words
The method of claim 18 wherein said refractory particles are selected from the group consisting of Ti, W, Al, Vm, Zr, Mo, Ta, Nb, Hf, and carbides, oxides, nitrides, and borides thereof.
Claim 22
Dependent Claim
17 words
The method of claim 1 wherein said outer layer consists of tool steel initially in powder form.
Claim 23
Dependent Claim
42 words
The method of claim 5 wherein said core together with said layer or layers are simultaneously consolidated by said pressure application via said granular matrix in a die, said core and said layer or layers having been preliminarily embedded in said matrix.
Claim 24
Independent Claim
228 words
The method of producing a roller bit cutter, includes the steps: (a) providing a tough, metallic, generally conical and fracture resistant core member having a hollow interior, the core defining an axis, (b) providing an annular, metallic, radial bearing layer carried by said core at the interior thereof to support the core for rotation, said bearing layer extending about said axis, (c) providing a wear resistant outer metallic layer on the exterior of the core, (d) the core including metallic teeth integral with the core and protruding outwardly therefrom, at least some of said teeth spaced about said axis, (e) and providing an impact and wear resistant layer on each tooth to provide hard cutting edges as the bit cutter rotates about said axis, (f) initially assembling the above core and layers as members of a green preform, at ordinary room temperatures, by using an organic binder with and without a volatile solvent when necessary, (g) burning out the binder (and solvent) at elevated temperature, (h) immersing the heated preform assembly in a granular bed of refractory material within a metal die, and (i) applying a pressure to the granular bed, which transmits the pressure to the preform assembly, until the members of the preform assembly are substantially consolidated and bonded to each other to form a single body means with sufficient mechanical integrity to be functionally useful.
Claim 25
Independent Claim
228 words
The method of producing a roller bit cutter, includes the steps: (a) providing a tough, metallic, generally conical and fracture resistant core member having a hollow interior, the core defining an axis, (b) providing an annular, metallic, radial bearing layer carried by said core at the interior thereof to support the core for rotation, said bearing layer extending about said axis, (c) providing a wear resistant outer metallic layer on the exterior of the core, (d) the core including metallic teeth integral with the core and protruding outwardly therefrom, at least some of said teeth spaced about said axis, (e) and providing an impact and wear resistant layer on each tooth to provide hard cutting edges as the bit cutter rotates about said axis, (f) initially assembling the above core and layers as members of a green preform, at ordinary room temperatures, by using an organic binder with and without a volatile solvent when necessary, (g) burning out the binder (and solvent) at elevated temperature, (h) immersing the heated preform assembly in a granular bed of refractory material within a metal die, and (i) applying a pressure to the granular bed, which transmits the pressure to the preform assembly, until the members of the preform assembly are substantially consolidated and bonded to each other to form a single body means with sufficient mechanical integrity to be functionally useful.
Claim 26
Dependent Claim
29 words
The method of claim 23, including (j) providing an impact and wear resistant metallic inner layer on the core at the interior thereof, to provide an axial thrust bearing.
Claim 27
Dependent Claim
28 words
The method of claim 23 wherein said outer layer is applied to cover the core between said teeth as a power metal and a liquid fugitive binder mixture.
Claim 28
Dependent Claim
30 words
The method of claim 25 wherein said outer layer is applied on the core exterior includes a powder metal mixed with a powder organic binder and a liquid volatile solvent.
Claim 29
Dependent Claim
28 words
The method of claim 23 wherein the core is a metal powder cold compressed and/or sintered to a density less than the theoretical density of the said metal.
Claim 30
Dependent Claim
18 words
The method of claim 23 wherein the core is in the form of a wrought or cast metal.
Claim 31
Dependent Claim
21 words
The method of claim 23 wherein the radial bearing layer is applied as a metal powder mixed with an organic binder.
Claim 32
Dependent Claim
44 words
The method of claim 23 wherein the radial bearing layer is applied as a wrought sintered or cast alloy insert in the process of assembling the green preform with or without any other metallic layer applied between the bearing metal layer and the core.
Claim 33
Dependent Claim
26 words
The method of claim 23 wherein the radial bearing layer is applied as a bearing alloy after the hot consolidation step (i) by a fusion process.
Claim 34
Dependent Claim
30 words
The method of claim 24 where the said thrust bearing is applied as a wrought, sintered or cast alloy insert or inserts in the process of assembling the green preform.
Claim 35
Dependent Claim
30 words
The method of claim 23 wherein at least one of the layers is metal powder compacted to a density lower than its theoretical density prior to the consolidation step (i).
Claim 36
Dependent Claim
30 words
The method of claim 23 wherein at least two of the layers are metal powder compacted to a density lower than their theoretical density prior to the consolidation step (i).
Claim 37
Dependent Claim
29 words
The method of claim 23 wherein at least three of the layers are compacted to a density lower than their respective theoretical densities prior to the consolidation step (i).
Claim 38
Dependent Claim
44 words
The method of claim 23 wherein some or all of the said layers or portions of thereof are assembled together by using a separate layer of metallic powder in between, and consolidated to incorporate such interface layers as part of the consolidated body means.
Claim 39
Dependent Claim
29 words
The method of claim 23 wherein the said impact and wear resistant layer on each tooth is applied as a mixture of metallic powders and a fugitive organic binder.
Claim 40
Dependent Claim
39 words
The method of claim 23 wherein the said impact and wear resistant layer on each tooth is applied as one or more solid inserts with or without utilizing a bonding metal powder between the tooth core and the insert.
Claim 41
Dependent Claim
21 words
The method of claim 23 wherein said outer layer consists of a composite mixture of refractory particles in a binder metal.
Claim 42
Dependent Claim
14 words
The method of claim 38 wherein the said insert is cobalt cemented tungsten carbide.
Claim 43
Dependent Claim
24 words
The method of claim 37 wherein the said layer on each tooth consists of a mixture of a binding metal and refractory hard particles.
Claim 44
Dependent Claim
33 words
The method of claim 41 wherein said refractory particles are selected from the group consisting of Ti, W, Al, V, Zr, Cr, Mo, Ta, Nb, Hf, and carbides, oxides, nitrides, and borides thereof.
Claim 45
Dependent Claim
24 words
The method of claim 41 wherein said binding metal is selected from the alloy systems based on Fe, Ni, Co, Cu, Mo and W.
References Cited (Backward Citations)
US3310870A
Cited
US3235316A
Cited
US3453849A
Cited
US3356496A
Cited
US3689259A
Cited
US3721307A
Cited
US3984158A
Cited
US3995917A
Cited
US4108692A
Cited
US4074922A
Cited
US4173457A
Cited
US4368788A
Cited
US4372404A
Cited
US4365679A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-06-02 | 1989-12-02 | 1990-06-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-06-02 | 1993-12-02 | 1994-06-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-06-02 | 1997-12-02 | 1998-06-03 | $7700.00 | Window Closed / Lapsed |