Stabilizer blade

Claim 2

Method for applying hard tungsten carbide particles to the surface of a metal substrate, comprising: applying a soft, elastic metal powder to the surface of said substrate; coating large tungsten carbide particles having a maximum dimension at least within the range of more than 1/4 of an inch and less than 1 inch with said soft elastic metal powder; placing said coated large tungsten carbide particles on the surface of the substrate coated with the soft, elastic metal powder; dispersing additional soft elastic metal powder over the tungsten carbide particles, and fusing said powder to form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate; and applying and fusing a hard matrix over said large tungsten carbide particles containing mixture, the hard matrix containing smaller tungsten carbide particles having a maximum dimension at least within the range of more than 1/32 of an inch and less than 1/4 of an inch.

Claim 3

The method of claim 1, wherein said soft, elastic metal powder has a Rockwell Hardness in the range of Rc 10-20.

Claim 4

The method of claim 2 wherein said soft, elastic metal powder is comprised of silicon, boron, and 90-97% of nickel by weight.

Claim 5

The method of claim 1, wherein said hard matrix has a Rockwell Hardness in the range of Rc 40-60.

Claim 6

The method of claim 4 wherein said hard matrix is comprised of 10-20% chromium, 0-10% cobalt, iron, carbon, silicon and boron being present, not exceeding 10% by weight, and at least 60% nickel by weight.

Claim 7

The method of claim 5 wherein the ratio by weight of hard matrix to smaller carbide particles is in the range from 1:2 to 2:1.

Claim 8

The method of claim 6 wherein the ratio by weight of metal matrix to smaller carbide particles is 1:1.

Claim 9

The method of claim 7 wherein the step of applying additional powder over the carbide particles and fusing said powder to form a homogeneous mixture is achieved with an acetylene/oxygen torch which sprays the powder at 1950°-2100° F. to fluidize said powder as it is sprayed and fuse the powder to the substrate and large carbide particles upon contact with them.

Claim 10

The method of claim 8 wherein the step of applying and fusing a hard matrix over said carbide particle containing mixture is achieved by spraying the hard matrix material in molten form from an oxygen/acetylene torch at about 1950°-2100° F.

Claim 11

The method of claim 8 wherein the step of applying and fusing a hard matrix over said large carbide particle containing mixture is achieved by first forming a hard rod comprised of the material which is to form the hard matrix and then melting the rod over said large carbide particle containing mixture.

Claim 12

Method of applying hard tungsten carbide particles to the surface of a metal substrate comprising: applying a soft, elastic metal powder to the surface of said substrate, said powder having a Rockwell Hardness in the range of Rc 10-20 and being comprised of silicon, boron, and 90-97% nickel by weight of the matrix; coating large tungsten carbide particles having maximum dimensions at least within the range of more than 1/4 of an inch and less than 1 inch with said soft elastic metal powder; placing said coated large tungsten carbide particles on the surface of the substrate coated with the soft, elastic metal powder; spraying additional, soft elastic metal powder over the tungsten carbide particles with a torch which sprays the powder in fluidized form over the tungsten carbide particles to fuse said soft metal powder to the substrate and large tungsten carbide particles and form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate; and applying and fusing a hard matrix over said large tungsten carbide particle containing mixture, the hard matrix containing smaller tungsten carbide particles having maximum dimensions at least within the range of more than 1/32 of an inch and less than 1/4 of an inch and said hard matrix in fluidized form through and acetylene/oxygen sprayer at about 1950°-2100° F., said hard matrix being comprised of 10-20% chromium, 0-10% cobalt, at least 60% nickel and iron, carbon, silicone and boron being present, not exceeding 10% by weight, the ratio by weight of metal matrix to smaller carbide particles being in the range from 1:2 to 2:1.

Claim 13

Method of applying hard tungsten carbide particles to the surface of a metal substrate comprising: applying a soft, elastic metal powder to the surface of said substrate, said powder having a Rockwell Hardness in the range of Rc 10-20 and being comprised of silicon, boron, and 90-97% nickel by weight of the matrix; coating large tungsten carbide particles having maximum dimensions at least within the range of more than 1/4 of an inch and less than 1 inch with said soft elastic metal powder; placing said coated large tungsten carbide particles on the surface of the substrate coated with the soft, elastic metal powder; spraying additional, soft elastic metal powder over the tungsten carbide particles with a torch which sprays the powder in fluidized form over the tungsten carbide particles to fuse said soft metal powder to the substrate and large tungsten carbide particles and form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate; and applying and fusing a hard matrix over said large tungsten carbide particle containing mixture, the hard matrix containing smaller tungsten carbide particles having maximum dimensions at least within the range of more than 1/32 of an inch and less than 1/4 of an inch and said hard matrix in fluidized form through and acetylene/oxygen sprayer at about 1950°-2100° F., said hard matrix being comprised of 10-20% chromium, 0-10% cobalt, at least 60% nickel and iron, carbon, silicone and boron being present, not exceeding 10% by weight, the ratio by weight of metal matrix to smaller carbide particles being in the range from 1:2 to 2:1.

Claim 14

The method of claim 11 wherein the ratio by weight of metal matrix to smaller carbide particles is 1:1.

Claim 15

Method of applying hard tungsten carbide particles to the surface of a metal substrate, comprising: applying a soft, elastic metal powder to the surface of said substrate, said powder having a Rockwell Hardness in the range of Rc 10-20 and being comprised of silicon, boron, and 90-97% nickel by weight of the matrix; coating large tungsten carbide particles having diameters within the range of more than 1/4 of an inch and 1 inch with said soft elastic metal powder; placing said large tungsten carbide particles on the surface of the substrate which has been coated with the soft, elastic metal powder; spraying additional, soft elastic metal powder over the large carbide particles with an acetylene/oxygen torch which sprays the powder in fluidized form over the tungsten carbide particles at 1950°-2100° F. to form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate; applying and fusing a hard matrix having a Rockwell Hardness of Rc 40-60 over said large tungsten carbide particle containing mixture by forming a hard rod comprised of the material which is to form the hard matrix and then melting the rod over said large tungsten carbide particle containing mixture.

Claim 16

Method of applying hard tungsten carbide particles to the surface of a metal substrate, comprising: applying a soft, elastic metal powder to the surface of said substrate, said powder having a Rockwell Hardness in the range of Rc 10-20 and being comprised of silicon, boron, and 90-97% nickel by weight of the matrix; coating large tungsten carbide particles having diameters within the range of more than 1/4 of an inch and 1 inch with said soft elastic metal powder; placing said large tungsten carbide particles on the surface of the substrate which has been coated with the soft, elastic metal powder; spraying additional, soft elastic metal powder over the large carbide particles with an acetylene/oxygen torch which sprays the powder in fluidized form over the tungsten carbide particles at 1950°-2100° F. to form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate; applying and fusing a hard matrix having a Rockwell Hardness of Rc 40-60 over said large tungsten carbide particle containing mixture by forming a hard rod comprised of the material which is to form the hard matrix and then melting the rod over said large tungsten carbide particle containing mixture.

Claim 17

Method for applying hard tungsten carbide particles to a metal substrate, comprising: providing a substrate; applying and fusing a soft matrix to said substrate, said soft matrix (being characterized by) having a Rockwell Hardness in the range of Rc 10-20 and having dispersed in said soft matrix a plurality of large tungsten carbide having maximum dimensions at least within the range of more than about 1/4 inch and 1 inch; and applying and fusing a hard matrix in substantially covering relationship to said soft matrix, the hard matrix having a Rockwell Hardness in the range of Rc 40-60 and having dispersed in said hard matrix a plurality of small tungsten carbide particles having maximum dimensions at least within the range of 1/32 inch and less than 1/4 inch.

Claim 18

Method for applying hard tungsten carbide particles to a metal substrate, comprising: providing a substrate; applying and fusing a soft matrix to said substrate, said soft matrix (being characterized by) having a Rockwell Hardness in the range of Rc 10-20 and having dispersed in said soft matrix a plurality of large tungsten carbide having maximum dimensions at least within the range of more than about 1/4 inch and 1 inch; and applying and fusing a hard matrix in substantially covering relationship to said soft matrix, the hard matrix having a Rockwell Hardness in the range of Rc 40-60 and having dispersed in said hard matrix a plurality of small tungsten carbide particles having maximum dimensions at least within the range of 1/32 inch and less than 1/4 inch.

Claim 19

A stabilizer blade for use in drilling comprising: a substrate; a soft matrix fused to said substrate, said soft matrix substantially encapsulating large particles of tungsten carbide, said large particles having a maximum dimension at least within the range of more than 1/4 inch to one inch; a hard matrix fused in substantially covering relationship to said soft matrix, said hard matrix having a plurality of small tungsten carbide particles dispersed therein, said small particles having a maximum dimension at least within the range of 1/32 inch and less than 1/4 inch.

Claim 20

A stabilizer blade for use in drilling comprising: a substrate; a soft matrix fused to said substrate, said soft matrix substantially encapsulating large particles of tungsten carbide, said large particles having a maximum dimension at least within the range of more than 1/4 inch to one inch; a hard matrix fused in substantially covering relationship to said soft matrix, said hard matrix having a plurality of small tungsten carbide particles dispersed therein, said small particles having a maximum dimension at least within the range of 1/32 inch and less than 1/4 inch.

Claim 21

The stabilizer blade of claim 15 wherein said soft matrix has a Rockwell Hardness in the range of Rc 10-20.

Claim 22

The stabilizer blade of claim 16 wherein said soft matrix is comprised of silicon, boron, and 90-97% nickel by weight.

Claim 23

The stabilizer blade of claim 15 wherein said hard matrix has a Rockwell Hardness in the range of Rc 40-60.

Claim 24

The stabilizer blade of claim 18 wherein said hard matrix is comprised of 10-20% chromium, 0-10% cobalt, at least 60% nickel, and less than 10% iron, carbon, silicon and boron by weight of matrix.

Claim 25

The stabilizer blade of claim 19 wherein the ratio by weight of metal matrix to smaller carbide particles is in the range from 1:2 to 2:1.

Claim 26

The stabilizer blade of claim 20 wherein the ratio by weight of metal matrix to smaller carbide particles is 1:1.

Claim 27

A stabilizer blade for use in drilling, comprising: a substrate; a soft matrix of silicon, boron, and 90-97% nickel by weight of matrix fused to said substrate, said soft matrix substantially encapsulating large particles of tungsten carbide, said large particles having a maximum dimension at least within the range of more than 1/4 inch to one inch; a hard matrix comprised of 10-20% chromium, 0-10% cobalt, at least 60% nickel, and iron, carbon, silicon and boron, being present, not exceeding 10% by weight, said hard matrix fused in substantially covering relationship to said soft matrix, said hard matrix further having a plurality of small tungsten carbide particles dispersed therein, said small particles having a maximum dimension at least within the range of 1/32 inch to less than 1/4 inch, the ratio by weight of hard matrix to smaller carbide particles being 1:1.

Claim 28

A stabilizer blade for use in drilling, comprising: a substrate; a soft matrix of silicon, boron, and 90-97% nickel by weight of matrix fused to said substrate, said soft matrix substantially encapsulating large particles of tungsten carbide, said large particles having a maximum dimension at least within the range of more than 1/4 inch to one inch; a hard matrix comprised of 10-20% chromium, 0-10% cobalt, at least 60% nickel, and iron, carbon, silicon and boron, being present, not exceeding 10% by weight, said hard matrix fused in substantially covering relationship to said soft matrix, said hard matrix further having a plurality of small tungsten carbide particles dispersed therein, said small particles having a maximum dimension at least within the range of 1/32 inch to less than 1/4 inch, the ratio by weight of hard matrix to smaller carbide particles being 1:1.