Ultra-Hard Nanostructured Silicon Carbide for Deep-Hole Drilling

72485S03-I The cost for deep-well, hard rock drilling is highly dependent on the number of drill trips down the hole necessitated by bit wear, bit failure, or required maintenance. These factors are particularly critical for drilling hard rock at significant depths, where drilling costs increase exponentially with the depth of the hole. At these depths, the bits tend to wear faster in the geological formations and at the higher hole temperatures typically encountered. This project will develop nanostructured SiC as a lower cost alternative to polycrystalline diamond compact drill bit materialsfor deep-well energy extraction. The nanostructuring, or extreme grain refinement, of silicon carbide is expected to provide significant increases in hardness, strength, and toughness. In Phase I, nanostructured SiC materials will be produced and its hardness, mechanical, and tribological properties will be measured to provide an indication of the wear resistance of the material. The variant of the nanostructured SiC that possesses the most attractive properties will be tested in hard rock drilling, utilizing conditions commensurate with normal field practices. The results will be compared with polycrystalline diamond compacts. Commercial Applications and Other Benefits as described by awardee: Improvement in penetration rates and bit life, offered by the nanostructured silicon carbide drill bits for hard rock drilling, should significantly reduce the number of drill trips, the drilling time, and manpower requirements, and improve site safety, at a cost less than polycrystalline diamond compacts.