Patent application number | Description | Published |
20100264198 | THERMALLY STABLE POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS - Thermally stable polycrystalline constructions comprise a body having a polycrystalline ultra-hard phase and a plurality of empty voids. A population of the voids can be filled with a reaction product. The body is substantially free of a catalyst material. The construction comprises a first support member attached to the body by a first braze material. A second support member is attached to the body and the first support member by a second braze material. The construction may include a third support member attached to the body that is integral or separate from one of the other support members. The braze materials used to attached the support members can be the same or different, as can be the materials used to form the different support members. | 10-21-2010 |
20100300767 | Diamond Bonded Construction with Improved Braze Joint - Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material. | 12-02-2010 |
20110056753 | Thermally Stable Ultra-Hard Material Compact Construction - Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process. | 03-10-2011 |
20110127088 | POLYCRYSTALLINE ULTRA-HARD COMPACT CONSTRUCTIONS - Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device, and improves the compact attachment strength to an end-use device when compared to conventional compacts. | 06-02-2011 |
20110139514 | Thermally Stable Diamond Bonded Materials and Compacts - Thermally stable diamond bonded construction comprise a diamond bonded body including a thermally stable region, comprising a plurality of diamond grains bonded together by a reaction product of the diamond grains with a reactant such as Si, and a polycrystalline diamond region, comprising intercrystalline bonded diamond and a catalyst material. The body further comprises a ceramic compound formed by reaction of an Nb, Zr, Ti, or Mo getter material with a gaseous element generated during HPHT sintering of the diamond bonded body. The diamond bonded body may comprise from 0.1 to 15 percent by weight of the ceramic compound. The diamond bonded body can be formed during a single HPHT process operated at different temperatures when the reactant has a melting temperature above the catalyst material. The construction may include a metallic substrate attached to the diamond bonded body to facilitate use as a wear or cutting element. | 06-16-2011 |
20120125696 | Polycrystalline Diamond Constructions Having Optimized Material Composition - Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing. | 05-24-2012 |
20120227332 | DEEP LEACH PRESSURE VESSEL FOR SHEAR CUTTERS - A system for producing thermally stable cutting elements may include a heat source, a pressure vessel, at least one polycrystalline diamond body attached to a carbide substrate, and a leaching agent is disclosed, wherein the heat source includes a container comprising at least one receiving mechanism and at least one retention mechanism, and wherein the carbide substrate is disposed in the at least one receiving mechanism of the pressure vessel, and wherein the leaching agent is disposed in the pressure vessel, and wherein the leaching agent removes the catalyzing material from the interstitial spaces interposed between the diamond particles of the at least one polycrystalline diamond body, and wherein the at least one retention mechanism of the pressure vessel seals at least a portion of the carbide substrate into the at least one receiving mechanism and prevents the leaching agent from contacting at least a portion of the carbide substrate. | 09-13-2012 |
20120261196 | HIGH DIAMOND FRAME STRENGTH PCD MATERIALS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having high diamond frame strength and methods for forming and evaluating such polycrystalline diamond bodies. A polycrystalline diamond body is provided, having a top surface, a cutting edge meeting the top surface, and a first region including at least a portion of the cutting edge. The first portion exhibits a diamond frame strength of about 1200 MPa or greater, or about 1300 MPa or greater. | 10-18-2012 |
20130133531 | HIGH PRESSURE CARBIDE COMPONENT WITH SURFACES INCORPORATING GRADIENT STRUCTURES - An anvil including a hard phase and a metal matrix in which the hard phase is dispersed, a concentration of the metal matrix phase varying according to a concentration gradient, is disclosed. The anvil may be used in a high pressure press. Methods of making an anvil including forming a hard phase dispersed in a metal matrix phase, a concentration of the metal matrix phase varying according to a concentration gradient, are also disclosed. | 05-30-2013 |
20130133957 | SHEAR CUTTER WITH IMPROVED WEAR RESISTANCE OF WC-CO SUBSTRATE - A cutting element having a substrate, an abrasive layer mounted to the substrate at an interface, and a longitudinal axis extending through the abrasive layer and the substrate is disclosed, wherein the substrate has a binder material, a plurality of metal carbide grains bonded together by an amount of the binder material, and at least one binder gradient, and wherein the amount of binder material decreases along at least one direction to form the at least one binder gradient. | 05-30-2013 |
20130152480 | METHODS FOR MANUFACTURING POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS AND POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS - Polycrystalline ultra-hard constructions are made by subjecting a sintered ultra-hard body, substantially free of a sintering catalyst material, to a further HPHT process. The process is controlled to initially melt and infiltrating a filler material into the sintered ultra-hard body to form a filler region having interstitial regions filled with the filler material. The filler region extends a partial depth into the sintered ultra-hard body and is formed at a temperature below the melting temperature of an infiltrant material. Next, the process is controlled to melt and infiltrate the infiltrant material into the sintered ultra-hard body to form an infiltrant region that extends a partial depth into the sintered ultra-hard body. A portion of the filler region and/or the infiltrant region may be removed to form a thermally stable region. | 06-20-2013 |
20130168158 | METHOD FOR BRAZE JOINING OF CARBONATE PCD - A method for making a diamond compact includes pre-heating a diamond body which includes a carbonate catalyst to convert at least a portion of the carbonate catalyst into an oxide, assembling the diamond body and a substrate, providing a braze material between the diamond body and the substrate to form a diamond compact, heating the braze material to melt the braze material and form a braze joint between the diamond body and the substrate, and cooling the braze material after increasing the pressure. A bit having a diamond compact including a carbonate catalyst and a metal oxide mounted thereon. | 07-04-2013 |
20130264124 | THERMALLY STABLE MATERIALS, CUTTER ELEMENTS WITH SUCH THERMALLY STABLE MATERIALS, AND METHODS OF FORMING THE SAME - A thermally stable ultra-hard material, a cutting element incorporating such thermally stable ultra-hard material, and methods for forming the same. A thermally stable ultra-hard diamond element is combined with a second ultra-hard material volume forming an assembly. One or more surfaces of the thermally stable diamond element that face the second diamond volume are coated with a coating prior to combining the thermally stable diamond element with the second diamond volume. The assembly is sintered at high pressure and high temperature to form PCD from the second diamond volume. | 10-10-2013 |
20130266678 | THERMAL INSULATION LAYER AND PRESSURE TRANSFER MEDIUM FOR HIGH PRESSURE HIGH TEMPERATURE CELL - A thermal insulation layer for an HPHT cell, the thermal insulation layer including CsCl, CsBr, CsI, or a combination thereof, and the thermal insulation layer being electrically insulating; the thermal insulation layer including a thermal insulation sleeve and/or a thermal insulation button for an HPHT cell; a pressure transfer medium for an HPHT cell, the pressure transfer medium including CsBr, CsI or a combination thereof; and a pressure transfer medium for an HPHT cell, the pressure transfer medium including CsCl and additive, with the proviso that the additive does not include ZrO | 10-10-2013 |
20140007512 | TECHNIQUES AND MATERIALS FOR THE ACCELERATED REMOVAL OF CATALYST MATERIAL FROM DIAMOND BODIES - A method for making a thermally stable cutting element may include forming an acid mixture containing two different acid species by combining an acid solution and at least one acid-forming compound, wherein the at least one acid-forming compound is provided in solid form, and wherein the at least one acid-forming compound produces an acid that is different than the acid solution; treating at least a portion of a sintered diamond body by placing the sintered diamond body in the acid mixture, wherein the sintered diamond body comprises: a matrix phase of bonded-together diamond grains; a plurality of interstitial regions dispersed within the matrix phase; and a metal material disposed within a plurality of the interstitial regions; wherein the treating removes the metal material from at least a portion of the plurality of interstitial regions; and removing the sintered diamond body from the acid mixture after a predetermined length of time, wherein at least a portion of the diamond body removed from the acid mixture is substantially free of the metal material and is a thermally stable diamond body. | 01-09-2014 |
20140013671 | CUTTING ELEMENTS, METHODS FOR MANUFACTURING SUCH CUTTING ELEMENTS, AND TOOLS INCORPORATING SUCH CUTTING ELEMENTS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance. | 01-16-2014 |
20140069725 | ULTRA-HARD CONSTRUCTIONS WITH EROSION RESISTANCE - Ultra-hard constructions comprise polycrystalline diamond-body having a first metallic substrate attached thereto, and having a second metallic substrate attached to the first metallic substrate. The first and second substrates each comprise a first hard particle phase, e.g., WC, and a second binder material phase, e.g., Co, wherein the hard particles in the second substrate are sized larger than those in the first substrate. The first substrate may contain a larger amount of binder material than the second substrate. Constructed in this matter, the first substrate is engineered to facilitate sintering diamond body during HPHT conditions, while the second substrate is engineered to provide an improved degree of erosion resistance when placed in an end-use application. The construction may be formed during a single HPHT process. The second substrate may comprise 80 percent or more of the combined thickness of the first and second substrates. | 03-13-2014 |
20140069727 | ULTRA-HARD CONSTRUCTIONS WITH IMPROVED ATTACHMENT STRENGTH - Ultra-hard constructions comprise a sintered diamond-bonded body comprising a matrix of bonded-together diamond grains and a plurality of interstitial regions substantially free of a catalyst material. A metal material comprising a carbide constituent is disposed on a substrate interface surface of the diamond body. A substrate is attached to the diamond-bonded body through a braze joint interposed between the metal material and the substrate. The braze joint is formed from a non-active braze material that reacts with the substrate and metal material. The braze joint is formed at the melting temperature of the non-active braze material in the absence of high-pressure conditions. In an example embodiment, the non-active braze material reacts with the carbide constituent in the metal material. Example materials useful for forming the non-active braze material include those selected from Cu, Ni, Mn, Au, Pd, and combinations and alloys thereof. | 03-13-2014 |
20140097159 | SYSTEM AND METHOD FOR BRAZING TSP MATERIALS TO SUBSTRATES - Methods and systems of attaching a thermally stable polycrystalline diamond (TSP) material layer to a substrate. The methods include placing a braze material between the TSP material layer and the substrate, pressing at least one of the TSP material layer and substrate against the other of the TSP material layer and the substrate, heating the braze material to a temperature of at least 800° C., and cooling the braze forming a bond attaching the TSP material layer to the substrate. | 04-10-2014 |
20140109491 | THERMALLY STABLE DIAMOND BONDED MATERIALS AND COMPACTS - Thermally stable diamond bonded construction comprise a diamond bonded body including a thermally stable region, comprising a plurality of diamond grains bonded together by a reaction product of the diamond grains with a reactant such as Si, and a polycrystalline diamond region, comprising intercrystalline bonded diamond and a catalyst material. The body further comprises a ceramic compound formed by reaction of an Nb, Zr, Ti, or Mo getter material with a gaseous element generated during HPHT sintering of the diamond bonded body. The diamond bonded body may comprise from 0.1 to 15 percent by weight of the ceramic compound. The diamond bonded body can be formed during a single HPHT process operated at different temperatures when the reactant has a melting temperature above the catalyst material. The construction may include a metallic substrate attached to the diamond bonded body to facilitate use as a wear or cutting element. | 04-24-2014 |
20140124271 | CUTTING ELEMENTS, METHODS FOR MANUFACTURING SUCH CUTTING ELEMENTS, AND TOOLS INCORPORATING SUCH CUTTING ELEMENTS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance. | 05-08-2014 |
20140130418 | METHOD OF MAKING CARBONATE PCD AND SINTERING CARBONATE PCD ON CARBIDE SUBSTRATE - A method of forming a polycrystalline diamond body includes mixing a sintering agent with diamond powder to form a premixed layer, the sintering agent including at least one alkaline eat mewl carbonate; forming an infiltration layer adjacent to the premixed layer, the infiltration layer including an infiltrant material including at least one alkaline earth metal carbonate; and subjecting the premixed layer and the infiltration layer to high pressure high temperature conditions. | 05-15-2014 |
20140131117 | SINTERING OF THICK SOLID CARBONATE-BASED PCD FOR DRILLING APPLICATION - A method of making a polycrystalline diamond compact includes forming multiple layers of premised diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal, carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond. | 05-15-2014 |
20140215927 | POLYCRYSTALLINE DIAMOND CONSTRUCTIONS HAVING OPTIMIZED MATERIAL COMPOSITION - Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing. | 08-07-2014 |
20140250798 | THERMALLY STABLE POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS - Thermally stable polycrystalline constructions include a body having a polycrystalline ultra-hard phase and a plurality of empty voids. The construction includes a backside support member over at least a portion of the backside surface of the body and a sidewall support member over at least a portion of the sidewall surface of the body extending an axial distance along at least a portion of the body and at least partially covering a circumferential surface of the body. The construction has a compressive stress exerted on the body. | 09-11-2014 |
20150060151 | CUTTING ELEMENTS WITH WEAR RESISTANT DIAMOND SURFACE - Cutting elements include polycrystalline diamond which may be attached to a substrate. The polycrystalline diamond may have a ratio of cubic to hexagonal cobalt crystalline structures of greater than about 1.2. The polycrystalline diamond may have a high level surface compressive stress of greater than about 500 MPa. | 03-05-2015 |
20150068817 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND AND METHODS OF MAKING THE SAME - A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material. | 03-12-2015 |