A chromium-free, distributed hardfacing disposable on a surface of a wellsite component is disclosed. The hardfacing includes a metal filler (e.g., nickel) and particles distributed about the filler. The particles include pellets made of tungsten carbide and pieces made of angular molybdenum carbide. The pieces are smaller than the pellets for distribution in the filler between the pellets whereby a uniform distribution of particles is provided about the filler.

The present invention relates to a method of producing a composite rod from a braze material and a sheet of material comprising cermet. The method comprises scoring a surface of the sheet to produce at least one line of localised stress and subsequently causing the sheet to break along the line or localised stress, thereby to produce a plurality of cermet chunks. The cermet chunks can be combined with the braze material to produce the composite rod. In a particular embodiment, the sheet of material may be a used cermet cutting tip.

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

A brazing tape or preform includes a layer of a brazing material, and a plurality of ceramic members affixed to the layer. The plurality of ceramic members are configured to be removable by a ceramic solvent. The plurality of ceramic members are comprised of a plurality of water-soluble ceramic members. The ceramic solvent used to remove the ceramic members is water. The brazing material is selected from the group comprising, nickel, nickel alloys, cobalt, cobalt alloys, iron, iron alloys, and combinations thereof. The ceramic members comprise, about 60% to about 70% by weight of alumina (Al2O3), about 15% to about 25% by weight of zircon (ZrSiO4) flour, about 5% to about 15% by weight of sodium hydrogen phosphate (Na2HPO4), and about 5% by weight of sugar. The brazing tape may be configured as a flexible tape, and the brazing preform may be configured as a pre-sintered preform.

The microstructure of braze joints in polycrystalline diamond compact (PDC) cutters may be tailored to increase the shear strength of the braze joint, for example, by increasing the amount of a dispersed particulate microstructure therein. A method for forming a dispersed particulate microstructure may include brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 5 C. above a solidus temperature of the braze alloy and 200 C. above a liquidus temperature of the braze alloy; and forming a braze joint between the polycrystalline diamond table and the hard composite substrate that comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 m to 2.0 m and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

A method for joining engine components includes positioning a first plurality of thermal protection structures across a thermal protection space between a first thermal protection surface and a second thermal protection surface. The first and second engine components are locally joined by forming a first plurality of transient liquid phase (TLP) or partial transient liquid phase (PTLP) bonds along corresponding ones of the first plurality of thermal protection structures between the first thermal protection surface and the second thermal protection surface. The second thermal protection surface is formed from a second surface material different from a first surface material of the first thermal protection surface.

Composite structures having a reinforced material interjoined with a substrate, wherein the reinforced material comprises a compound selected from the group consisting of titanium monoboride, titanium diboride, and combinations thereof.

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

A method of forming micro channels in a thermal barrier coating includes placing a brazing tape on a substrate. The brazing tape has a first side and a second side with a plurality of ceramic members attached thereto. The first side is placed in contact with the substrate. A brazing step brazes the brazing tape to the substrate. An applying step applies a bond coat to the second side of the brazing tape. Another applying step applies a thermal barrier coating (TBC) onto the bond coat. A removing step removes the plurality of ceramic members by exposing the plurality of ceramic members to a ceramic solvent. A plurality of micro channels are formed in the thermal barrier coating by voids left from the plurality of ceramic members.

A system for producing chemicals, such as, ethylene or gasoline, at high temperature (above 1100 degrees C.) having a feedstock source. The system includes a chemical conversion portion connected with the feedstock source to receive feedstock and convert the feedstock to ethylene or gasoline. The conversion portion includes a coil array and a furnace that heats the feedstock to temperatures in excess of 1100 C. or 1200 C. or even 1250 C. or even 1300 C. or even 1400 C. A method for producing chemicals, such as ethylene or gasoline, at high temperature.