The present disclosure provides downhole tools, methods for three dimensional printing hardfacing on such downhole tools, and systems for implementing such methods.

The present disclosure provides downhole tools, methods for three dimensional printing hardfacing on such downhole tools, and systems for implementing such methods.

A control system for regulating an additive manufacturing process of an additive manufacturing apparatus, the apparatus configured to add metal to a substrate by means of metal deposition. The apparatus comprises: a nozzle for output of a metal strip, the nozzle configured to be arranged at a distance from the substrate, and configured to move relative the substrate in XYZ-axes via a position actuator. The apparatus further comprises a heat source configured to melt the metal strip into a weld pool on the substrate, and an electrical power source configured to supply current via the metal strip 20 to the substrate. The control system is configured maintain process stability, during the deposition of a layer of metal, via: determining electrical conductance between the metal strip and the substrate by measuring at least one electrical property of the supplied current; determining the difference between the determined electrical conductance, and a desired electrical conductance; and, adjusting at least one of: the substrate to nozzle distance, the speed of the nozzle movement relative the substrate, the amount of supplied current, the heat provided by the heat source, and/or the rate of output of the metal strip, based on the difference between the determined conductance and the desired conductance.

A control system for regulating an additive manufacturing process of an additive manufacturing apparatus, the apparatus configured to add metal to a substrate by means of metal deposition. The apparatus comprises: a nozzle for output of a metal strip, the nozzle configured to be arranged at a distance from the substrate, and configured to move relative the substrate in XYZ-axes via a position actuator. The apparatus further comprises a heat source configured to melt the metal strip into a weld pool on the substrate, and an electrical power source configured to supply current via the metal strip 20 to the substrate. The control system is configured maintain process stability, during the deposition of a layer of metal, via: determining electrical conductance between the metal strip and the substrate by measuring at least one electrical property of the supplied current; determining the difference between the determined electrical conductance, and a desired electrical conductance; and, adjusting at least one of: the substrate to nozzle distance, the speed of the nozzle movement relative the substrate, the amount of supplied current, the heat provided by the heat source, and/or the rate of output of the metal strip, based on the difference between the determined conductance and the desired conductance.

One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam core adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core; and securing an inlet fitting and an outlet fitting to the housing, wherein a thermal management fluid path for the internal component into and out of the housing is provided by the inlet fitting and the outlet fitting.

Using three-dimensional shape data, the shape of a blade, which is an additive manufacturing product, is divided into multiple layers according to the height of a bead. Each layer of the additive manufacturing product that has been divided into multiple layers is divided by fitting regions of a set shape. By determining connecting lines for connecting the divided regions to each other and computing the extension directions of protrusions, planned lines for bead formation along said extension directions are determined. The additive manufacturing product is shaped by forming beads along planned bead formation lines.

The present disclosure provides downhole tools, methods for three dimensional printing hardfacing on such downhole tools, and systems for implementing such methods.

One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.

One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.