Drilling experts frequently choose to use Rock Button Bits when working in extremely abrasive, hard rock formations. In many top hammer setups, matching top hammer button bit designs with wear-resistant materials ensures cleaner holes, fewer tool changes, and steadier penetration rates—even in challenges that grind down other bit types more.

At Taizhou Kaiqiu Drilling Tools Co., Ltd., we design our button bits so that tungsten carbide inserts and steel bit bodies work in sync under abrasive conditions. Through optimized button geometry—such as tapered or spherical buttons—and our controlled heat‑treatment processes, we strike the proper balance between hardness and toughness.

1. The Abrasion Challenge in Hard Rock

Understanding Rock Abrasivity

High-abrasivity rock types—especially those rich in silica or quartzite—are some of the more aggressive wear agents in drilling. This abrasivity accelerates wear on both tungsten carbide buttons and steel bodies. Studies show a direct relationship between rock abrasiveness and drilling tool wear: higher abrasivity correlates with quicker wear and more frequent tool breakdowns.

As the button contact surface flattens due to wear, penetration rate drops sharply. One paper notes that once the wear flat reaches one‑third of the original button diameter, penetration can decrease by up to 5%, and if wear continues to two‑thirds, the drop can reach 30% or more.

Wear Mechanisms in Tungsten‑Carbide Buttons

Wear in WC/Co buttons typically includes micro-spalling, binder erosion, cracking, and carbide pull‑out. These are driven by mechanical contact stress, thermal cycling at the bit‑rock interface, and abrasion. During drilling, even the slightest microcrack can propagate fast and provoke button failure.

2. How Button Design and Material Resist Abrasion

Tungsten Carbide: The Material Advantage

Tungsten carbide (hardness around 9.5 Mohs, Vickers hardness > 2500 HV) is dramatically harder than steel and typical rock minerals. This high hardness allows the button edges to resist wear and maintain their cutting profile for longer periods.

Meanwhile, proper material bonding ensures that the carbide doesn’t separate from the steel matrix. Our high-temperature bonding and heat treatment focus on achieving that durable bond, avoiding early delamination that many generic bit types suffer.

Button Layout and Geometry

Button bits are engineered with:

Tapered or parabolic button shapes that reduce contact friction while increasing penetration depth per impact. 

Strategic placement of gauge-row buttons to protect the bit diameter and maintain hole size as the bit wears.

Optimized spacing and size ratios between gauge and face buttons to balance cutting force distribution.

This layout reduces localized pressure on the buttons, which in turn lowers abrasive wear and helps maintain drilling efficiency.

3. Performance Advantages in Real Operations

Improved Penetration, Longer Life

Operators who switch to high-grade tungsten‑carbide button bits see:

A 10–20% increase in meters per bit in quartz-bearing hard rock compared to chipped steel bits.

A 20% longer lifespan when consistent flushing is maintained and heat generation at the cutting face is reduced.

Bit Failure Avoidance

Avoiding premature wear and button drop isn’t just about material—it’s also about usage discipline:

Graded tungsten-carbide buttons reduce binder erosion and microcrack initiation.

Monitoring wear (especially flat size) prevents the over‑use effect where penetration rate plummets by over 30% once more than two-thirds worn. 

Proper flushing cycles reduce bit-rock contact heating; high temperatures accelerate binder oxidation and tool failure. 

Choosing the right button bit is not just about material hardness—it’s a systems decision. Proper tooth layout, strategy around wear limits, maintenance discipline, and matching tools to rock type all make a difference. With Kaiqiu-designed button bits, drilling professionals get more consistent performance and higher return per drilling cycle.