Method of fabrication of rock bit inserts of tungsten carbide (WC) and cobalt (Co) with cutting surface wear pad of relative hardness and body portion of relative toughness sintered as an integral composite

Claim 1

A method for enhancing the wear resistance of inserts in the gage row of a cone in a roller cone rock bit comprising the steps of: mixing a first mixture of tungsten carbide powder having a grain size from three to four microns and cobalt powder in the range of nine to eleven percent of the mixture; mixing a second mixture of tungsten carbide powder having a grain size from five to six microns and cobalt powder in the range of fifteen to sixteen percent of the mixture; pressing a portion of the first mixture into a wear pad die cavity at a pressure of about fifteen tons per square inch for forming an unsintered wear pad; positioning the pressed, unsintered wear pad into an insert body die cavity having a wear pad cavity complementary to the wear pad; pressing a portion of the second mixture into the balance of said body die cavity at a pressure of about fifteen tons per square inch, for forming the body of said insert; sintering said pressed insert in a furnace for about one hundred minutes at a temperature of about fourteen hundred degrees centrigrade for forming an insert for the gage row of a rock bit with a relatively harder wear resistant pad for contacting formation adjacent the gage of a bore hole and a relatively tougher body; and pressing the body of such inserts into an interference fit in the gage row of a cone of a rock bit in a location wherein the wear pad is adjacent the gage of the rock bit.

Claim 2

A method for enhancing the wear resistance of inserts in the gage row of a cone in a roller cone rock bit comprising the steps of: mixing a first mixture of tungsten carbide powder having a grain size from three to four microns and cobalt powder in the range of nine to eleven percent of the mixture; mixing a second mixture of tungsten carbide powder having a grain size from five to six microns and cobalt powder in the range of fifteen to sixteen percent of the mixture; pressing a portion of the first mixture into a wear pad die cavity at a pressure of about fifteen tons per square inch for forming an unsintered wear pad; positioning the pressed, unsintered wear pad into an insert body die cavity having a wear pad cavity complementary to the wear pad; pressing a portion of the second mixture into the balance of said body die cavity at a pressure of about fifteen tons per square inch, for forming the body of said insert; sintering said pressed insert in a furnace for about one hundred minutes at a temperature of about fourteen hundred degrees centrigrade for forming an insert for the gage row of a rock bit with a relatively harder wear resistant pad for contacting formation adjacent the gage of a bore hole and a relatively tougher body; and pressing the body of such inserts into an interference fit in the gage row of a cone of a rock bit in a location wherein the wear pad is adjacent the gage of the rock bit.