US20120241225A1 - Composite polycrystalline diamond body - Google Patents
Composite polycrystalline diamond body Download PDFInfo
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- US20120241225A1 US20120241225A1 US13/072,203 US201113072203A US2012241225A1 US 20120241225 A1 US20120241225 A1 US 20120241225A1 US 201113072203 A US201113072203 A US 201113072203A US 2012241225 A1 US2012241225 A1 US 2012241225A1
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- diamond
- pdc
- polycrystalline diamond
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- 239000010432 diamond Substances 0.000 title claims abstract description 209
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 201
- 239000002131 composite material Substances 0.000 title description 7
- 238000005520 cutting process Methods 0.000 claims abstract description 12
- 239000002245 particle Substances 0.000 claims description 39
- 239000000758 substrate Substances 0.000 claims description 16
- 230000000295 complement effect Effects 0.000 claims description 5
- 230000007423 decrease Effects 0.000 claims 2
- 239000000843 powder Substances 0.000 abstract description 35
- 239000011435 rock Substances 0.000 abstract description 15
- 239000000203 mixture Substances 0.000 abstract description 13
- 238000005553 drilling Methods 0.000 abstract description 9
- 238000003754 machining Methods 0.000 abstract description 7
- 239000004575 stone Substances 0.000 abstract description 7
- 238000003825 pressing Methods 0.000 abstract description 2
- 238000005299 abrasion Methods 0.000 description 28
- 239000003054 catalyst Substances 0.000 description 23
- 239000013078 crystal Substances 0.000 description 23
- 229910052751 metal Inorganic materials 0.000 description 23
- 239000002184 metal Substances 0.000 description 23
- 238000012360 testing method Methods 0.000 description 17
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 15
- 239000000463 material Substances 0.000 description 14
- 238000005056 compaction Methods 0.000 description 13
- 238000000034 method Methods 0.000 description 12
- 229910017052 cobalt Inorganic materials 0.000 description 10
- 239000010941 cobalt Substances 0.000 description 10
- 229910000831 Steel Inorganic materials 0.000 description 6
- 239000010438 granite Substances 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000013461 design Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 4
- 239000003082 abrasive agent Substances 0.000 description 3
- 238000009863 impact test Methods 0.000 description 3
- 238000012856 packing Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000007493 shaping process Methods 0.000 description 3
- 230000002411 adverse Effects 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000003776 cleavage reaction Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 238000000921 elemental analysis Methods 0.000 description 2
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000007017 scission Effects 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 241000519995 Stachys sylvatica Species 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical class [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 description 1
- 239000010960 cold rolled steel Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000002173 cutting fluid Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000011176 pooling Methods 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 238000010408 sweeping Methods 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- E21B10/5676—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts having a cutting face with different segments, e.g. mosaic-type inserts
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- E21B10/573—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
- E21B10/5735—Interface between the substrate and the cutting element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
- B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- the aperture of the first shell may have a diameter of 0.050 inches (12.7 mm), while the aperture of the second shell has a diameter of 0.051 inches (12.95 mm).
- the assembly of the cup, bushing and tube may be removed from the press brake or similar device.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Geology (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Crystallography & Structural Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- Physics & Mathematics (AREA)
- Geochemistry & Mineralogy (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Composite Materials (AREA)
- Earth Drilling (AREA)
- Carbon And Carbon Compounds (AREA)
Abstract
In this novel PDC cutter, diamond powders of different composition and/or different grain size, are distributed, shaped, and compacted with a novel pressing tool, in multiple stages, spatially arranged into different regions of the PDC diamond body, then HPHT sintered to form one PDC body with spatially varying hardness, toughness and thermal resistance more optimal for machining, drilling and/or cutting of hard rock and stone.
Description
- This application claims the benefit of no other prior applications.
- Exemplary embodiments are directed to a body for use in cutting, machining, drilling and similar operations, and a method of manufacture of the body. More particularly, exemplary embodiments are directed to a composite polycrystalline diamond body and method of manufacture that may be used for cutting, machining, drilling and other similar operations.
- As used in the following disclosure and claims, the term polycrystalline diamond (PCD) is intended to refer to the type of material that is made by subjecting diamond crystals to a high temperature and pressure that results in intercrystalline bonding of the individual diamond crystal. In exemplary embodiments, the intercrystalline bonding is usually facilitated by use of a specific catalyst family of transition metals, usually as molten fluid. Although catalysts greatly aid the sinter bonding of PCD, it is frequently the case that catalyst is left over in the PCD material. This is especially true for diamond granular materials that are difficult to contact with molten metals, such as fine particle size and/or highly textured diamond. The presence of residual catalyst in the PCD generally changes its quality and compels design compromise between various desirable and undesirable properties of a cutting material. PCD is not diamond; it is a composite of varying composition comprising hard diamond and soft catalyst metal.
- In many different applications, PCD has displayed advantages over the use of a single crystal diamond. Typically, a single crystal diamond has a much lower impact resistance than PCD, due to the much higher modulus of elasticity of a single crystal compared to PCD. Furthermore, the specific planes of cleavage of a single crystal may allow relatively low forces to cause fracturing of the crystal. However, PCD may alleviate the problems caused by the planes of cleavage of a single crystal because the PCD is made up of randomly oriented individual crystals.
- In some cases, PCD have been used for many years in drilling and machining. In the drilling industry the Polycrystalline Diamond Composite products are typically brazed to the drill bits is referred to as PDC. Therefore, from this point on when referring to Polycrystalline Diamond Composite used in the drilling industry, PDC is the abbreviation that will be used and it means the same thing as PCD.
- Known PDCs have drawbacks that lead to the degradation wherein the PDC is unable to cut rock or stone. One of the factors limiting the success of the PDC is that larger crystals that may be used to form the PDC, while easy to sinter completely with low residual catalyst, typically produce fewer diamond-to-diamond bonds per unit volume. Fewer diamond-to-diamond bonds per unit volume may mean a weaker PDC. However, the lower residual catalyst content improves thermal resistance of PDC. Residual catalyst metal expands far more than sintered diamond and tends to weaken the PDC. Friction heat in all machining can be very high regardless of many methods used to mitigate it. Thus, larger grain size PDC has a tendency to fracture and abrade more easily than PDC comprising a multitude of smaller crystals but is more capable of withstanding heat.
- On the contrary smaller crystals can generate more diamond-to-diamond intergranular bonds per unit volume but are more difficult to sinter completely to low residual catalyst metal content. Thus, finer grain size PCD tends to have higher hardness and strength but also higher residual catalyst content. Higher residual catalyst lowers density of diamond-to-diamond bonds, catalyst taking the space diamond would otherwise, but more importantly lowers the heat tolerance of PDC.
- The result is a range of grades of PDC representing the compromise of hardness and heat resistance achieved by coarse and fine grains, with varying residual catalyst content, which perform non-optimally. Hard PDC is more sensitive to heat; heat-tolerant PDC is soft.
- The different regions of the cutter perform different functions and optimally need not be the same material. In some embodiments, the rake may resist thermal spalling, chipping and adhesion wear, and be hard to resist abrasion of loose rock debris sliding over it. In exemplary embodiments, the flank may be very hard to grind the hard rock surface. The edge should be strong and hard. Therefore, it may be advantageous to use a multitude of smaller crystals in areas that need enhanced abrasion resistance, larger crystals in areas to enhance higher thermal resistance and/or different compositions of PDC to better handle the overall cutting function.
- PDC have been used for industrial applications including rock drilling and metal machining for many years. PDC is normally bonded to a substrate, typically sintered tungsten carbide, to make shaping of the cutter and attachment of the cutter to a tool, such as a drill, easier. PDC is very difficult to machine and attach to common drill materials, like steel or infiltrated carbide-metal. Sintered tungsten carbide is easy to machine and attach to metal drill bodies and toolholders, via for example, brazing.
- Of course one of the factors limiting the success of PDC is the strength of the bond between the polycrystalline diamond layer and the cemented tungsten carbide substrate. For example, analyses of the failure mode for drill bits used for deep hole rock drilling show that in approximately thirty-three percent of the cases, bit failure or wear is caused by delamination of the diamond from the metal carbide substrate.
- Furthermore, when cemented carbide mass is relied on to increase the impact resistance of PDC, the diamond layer is preferably relatively thin so that the diamond behaves as a supported layer, rather than monolithically. This restriction on the thickness of the diamond layer limits both the life expectancy of the composite body in use as well as the designs for PDC diamond tools.
- Yet another problem that has limited the thickness of the diamond layer in composite bodies is caused by the problem of “bridging”. Bridging refers to the phenomenon that occurs when a fine powder (especially a mono-modal powder) is pressed from multiple directions. It is observed that the individual particles in a powder being pressed tend to stack up and form arches or “bridges” that block the full amount of pressure so that the pressure often does not reach the center of the powder being pressed. This results in high porosity which requires more catalyst and thus tends to leave more residual catalyst in the sintered PDC.
- In any type of PDC, there are two countering principals that are opposed to one another. For optimal abrasion resistance, very fine crystals of the abrasive material are used. The fine abrasive materials are sintered under high pressure and result in a higher density compact with more diamond-to-diamond bonds than coarser material in the PDC. However, as a result of the high density, the abrasive mass of very fine crystals presents increased resistance to the catalyst metal or catalyst metal and carbide from sweeping through the crystal interstices as well as increased packing defects due to bridging. The increased resistance may lead to soft spots of non- or weakly bonded abrasive material in the PDC.
- However, coarser and/or larger abrasive crystals may provide larger channels and spaces in the compacted mass that may allow the catalyst metal to sweep through. Additionally, coarser and/or larger abrasive crystals may provide larger impact resistance when compared to smaller crystals, due to the higher content of catalyst metal. On the other hand, coarser materials may not provide the abrasion resistance that may be desired for a PDC material since they do not produce high diamond-to-diamond bonds per unit volume of PDC.
- While grain and packing artifacts affect the quality of the PDC sintered mass, it also affects the quality of the bond of the PDC to the substrate. That bond is made by filaments of metal intermingled between sintered tungsten carbide and the PDC body. The higher the number per unit area of metal filaments penetrating both PDC and substrate, the better the bond. This is typically optimized by fine diamond grains adjacent to the substrate. Nonetheless, the issues of pressure and compaction affect this region of PDC perhaps more so than the PDC body.
- In addition to the features mentioned above, other aspects of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments, wherein like reference numerals across the several views refer to identical or equivalent features, and wherein:
-
FIG. 1 is a perspective view of an exemplary PDC body; -
FIG. 2 is an exploded perspective view of the exemplary PDC body ofFIG. 1 ; -
FIG. 3 is a top plan view of the PDC body ofFIGS. 1-2 ; -
FIG. 4 is side elevation view of an exemplary PDC body; -
FIG. 5 is a top perspective view of an exemplary embodiment of a first portion and base portion of a PDC body; -
FIG. 6 is a perspective view of an exemplary PDC body; -
FIG. 7 is a top plan view of an exemplary PDC body; -
FIG. 8 is a side elevation view of an exemplary PDC body; -
FIG. 9 is a perspective view of an exemplary PDC body; -
FIG. 10 is a top plan view of an exemplary PDC body; -
FIG. 11 is a side elevation view of an exemplary PDC body; -
FIG. 12 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 13 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 14 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 16 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 17 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 18 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 19 is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 20 is a perspective view of an exemplary tube; -
FIG. 21 is a side elevation view of an exemplary tube; -
FIG. 22 is a top plan view of an exemplary tube; -
FIG. 23 is an exploded perspective view of an exemplary bushing within dowel pins; -
FIG. 24 is a side elevated view of an exemplary shell of a bushing -
FIG. 25 is a top plan view of an exemplary shell of a bushing; -
FIG. 26 is a front elevation view of an exemplary dowel pin; -
FIG. 27 is a top plan view of an exemplary dowel pin; -
FIG. 28 is a side elevation view of an exemplary busing; -
FIG. 29 is a side elevation view of an exemplary bushing; -
FIG. 30 is a perspective view of an assembly of an exemplary tube, bushing and cup; -
FIG. 31 is a side elevation view of an assembly of an exemplary tube, bushing and cup; -
FIG. 32 is a top plan view of an assembly of an exemplary tube, bushing and cup; -
FIG. 33 is a side elevation view of an assembly placed within a press brake; -
FIG. 34 is a side elevation view of an assembly placed within a press brake with the bushing removed; -
FIG. 35 is a side elevation view of an assembly wherein the bushing is reinserted to level the diamond particles; -
FIG. 36 is a side elevation view of the assembly after diamond particles are placed within the interior of the tube; -
FIG. 37 is a side elevation view of an assembly wherein the sleeve is inserted to compact the diamond particles; -
FIG. 38 is a cross-sectional elevation view of an assembly wherein the sleeve is inserted to compact the diamond particles; -
FIG. 39A is a top plan view of an exemplary PDC body; -
FIG. 39B is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 39C is a perspective view of an exemplary PDC body; -
FIG. 40A is an SEM picture taken of the cross section of an exemplary PDC body; -
FIG. 40B is an SEM picture taken of the cross section of an exemplary PDC body; -
FIG. 40C is an elemental analysis (Energy Dispersive X-ray Spectroscopy or EDS) of an exemplary PDC body; -
FIG. 41A is a top plan view of an exemplary PDC body; -
FIG. 41B is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 41C is a perspective view of an exemplary PDC body; -
FIG. 42 is a perspective view of an exemplary PDC body; -
FIG. 43 is an SEM picture taken of the cross section of an exemplary PDC body; -
FIG. 44A is a perspective view of an exemplary PDC body; -
FIG. 44B is a top plan view of an exemplary PDC body; -
FIG. 44C is a cross-sectional side elevation view of an exemplary PDC body; -
FIG. 45 is a perspective view of an exemplary PDC body; and -
FIG. 46 is an SEM picture taken of the cross section of an exemplary PDC body. - As seen in
FIG. 1 , an exemplary embodiment of aPDC body 5 is depicted. In this exemplary embodiment, thePDC body 5 may include afirst portion 10 and abase portion 30. In exemplary embodiments, thefirst portion 10 and thebase portion 30 may be fabricated from crystalline diamond particles. In the embodiment found inFIG. 1 , the crystalline diamond particles of at least a fraction of thefirst portion 10 are smaller than the particles found in thebase portion 30. - In the example found in
FIG. 1 , thefirst portion 10 may include an innerconcentric area 11 and an outerconcentric area 12. The innerconcentric area 11 may be comprised of diamond particles that are coarser in size compared to the diamond particles that comprise the outer concentric area. In some examples, the outerconcentric area 12 is substantially the geometry of an annular ring, wherein the thickness of the ring is substantially the same along the length of thefirst portion 10, from afirst end 10 a to asecond end 10 b. Exemplary embodiments of thefirst portion 10 include a variety of diamond particle sizes to realize the benefits of a smaller diamond particle in certain areas of the body and the benefits of a coarser diamond particle in other areas thereof. - However, in other embodiments, as depicted in the cross-sectional profile of
FIGS. 11-19 , the thickness of the ring may change along from the first end to the second end. In some examples, the thickness may taper from the first end to the second end. However, in other examples, the thickness may have a profile that is at least a portion rounded or curved along itslength 13, as depicted inFIG. 11 . The taper or rounded profile may improve the stress distribution at the fine/coarse diamond interface and may improve attachment between the coarse and fine diamond regions. - One of the factors affecting the flow of molten (liquid) cobalt is the temperature distribution within the cup. The cup will get hottest at its walls (sides) and at the top (especially close to the outside diameter where the fine diamond layer is located). Higher temperature provides more energy to the molten metal, therefore, more metal flow takes place at hotter zones, having finer diamond at these locations (which in turn presents more resistance to molten catalyst flow) will help balance the flow of the molten metal in the whole cell. The rest of the PDC body has coarser diamond which presents less resistance to the molten catalyst flow, and in turn, an overall balanced molten catalyst flow and better sinter quality throughout the PDC body.
- The thickness of the
first portion 10 from thefirst end 10 a to thesecond end 10 b may depend on the size and desired characteristics of thePDC body 5. In one example, the thickness may be approximately 0.069 inches (1.75 mm). Additionally, although any number of sizes of innerconcentric areas 11 and outerconcentric areas 12 may be used, in one example, the inner concentric area has a diameter of approximately 0.375 inches (9.53 mm) and the outerconcentric area 12 has a width of approximately 0.077 inches (1.96 mm), which produces an approximate total body diameter of 0.53 inches (13.46 mm). Furthermore, in other exemplary embodiments, any number of concentric areas may be used, and may include as many different sizes of diamond particles, as desired. An important feature is the profile of concentric area or ring may not be square. It may be radiused or tapered (ie. the area narrows the further it is from the top of the diamond table). In another example, the area may narrow when traveling from thesecond end 10 b to thefirst end 10 a, as shown in at leastFIG. 11 . Both the radius and/or taper may allow for the transformation from one diamond type and/or size to another to be more continuous and less step-wise. This may be defined as a functional gradient transformation. This was shown to have a substantial effect on the performance of exemplary PDCs. There was seen improved impact resistance with such diamond area profile compared to the square profile. - Any number of tapers and/or radiuses may be used in exemplary embodiments. A range of different tapers was tested, specifically 8° to 45° tapers off of vertical. Although this range was tested, tapers of other amounts may be used in exemplary embodiment. After processing the parts under high pressure and high temperature, the larger tapers closer to 45° produces a part with a triangular cross sectioned profile body, with almost a straight interface separating the coarse grained from the fine grained diamond. The impact resistance of such resulting product was lower for larger tapered profiles. As for the smaller tapers, the results were not significantly different from the non-tapered (square) profile. The best results were obtained when the taper was around 20°±5°, although other tapers ranges produced superior results from non-tapered profiles. When the radiused profile is used, the resulting product demonstrated comparable performance results to the exemplary taper-profiled products. In some examples, some of the typical PDC body diameters that may be used are 8 mm or 0.315″, 9 mm or 0.354″, 13 mm or 0.512″, 16 mm or 0.630″, 19 or 0.748″ and 22 mm or 0.866″.
- In exemplary embodiments, the finer diamond particles may be between the sizes of 1 to 30 micron in diameter. However, coarser diamond might be used as long as the diamond in the core and the rest of the PDC body is coarser. The coarser diamond particles are preferably between the sizes of 12 to 100 micron in diameter as long as the coarser diamond particles in one region are larger than the finer diamond in the other regions. Size refers to average or mean sizes. The closer the mean sizes are in the two regions, the easier it is to make a PDC body substantially free of defects. The farther apart the mean sizes are the more critical compaction and fill quality (density distribution) are to the formation of the PDC body. When the size ratio is more than 1½ times coarse to fine, sintering quality of the fine diamond is adversely affected. The addition (blending) of Cobalt powder to assist in the Cobalt sweep may be desired. This is further discussed in one of the examples mentioned later.
- In another example, the
first portion 10 may include one ormore segments 14 of finer diamond particles that may cross a portion of the innerconcentric circle 11. As depicted inFIGS. 9-11 , the one or more segments may cross the innerconcentric circle 11 and segment the circle in substantially similar portions. However, in other embodiments, the one ormore segments 14 may cross the inner concentric circle at any number of angles and form any number of chords across thereof. - It should be recognized that not all parts of a PDC cutter do the same job in the process of cutting rock and stone. The rake or top surface of the cutter, far from the edge is primarily responsible for moving cut debris away from the edge and flank so that the edge does not get packed with debris. The rake does not cut hard rock. Instead it must resist friction heating and tolerate friction heat, abrasion from hard rock debris (hard grits) shear flow, thermal adhesion wear, thermal cracking and thermal chipping.
- The orthogonal side or flank of the cutter, far from the edge, is primarily responsible for abrading the hard rock or stone to generate the cut surface of the hole or edge. Typically, the flank sees less friction heat than the rake, and therefore it may need to be abrasion resistant.
- The corner or edge of the cutter may need to have high bend strength to handle the high bend force of hard rock or stone pushing on it. It may also need to be abrasion resistant to compress and fracture the integral hard rock that causes cracks to propagate and proliferate and generates loose debris that is pushed over the rake surface and away (captured by cutting fluid and pumped out of the hole). To minimize the bend stress the edge is frequently chamfered on exemplary embodiments. This directs the force into the cutter body to maximize cutter bearing area and minimize the bending moment on the edge. Nonetheless, the edge must be hard to resist the abrasion of hard rock and strong to resist forces. Typically, thermal resistance is not a prime issue at the edge.
- Exemplary embodiments of the
PDC body 5 may further include thebase portion 30 that is disposed between thefirst portion 10 and asubstrate 50. The base portion hasfirst end 30 a that engages thesecond end 10 b of the first portion and asecond end 30 b that engages thesubstrate 50 at an intersectingsurface 40, as seen in at leastFIGS. 8 and 11 . In exemplary embodiments, thebase portion 30 may include coarser diamond particles of approximately the same size of the innerconcentric circle 11 of the first portion, wherein the base portion diamond particles are a continuation of the inner concentric circle diamond particles. However, in other examples, thebase portion 30 may include diamond particles that are larger or finer in size than the diamond particles included in the innerconcentric circle 11. - The
substrate 50 may include any interface shape, comprising arrangements of raised surfaces, slots, and/or roughness of any pattern random or deterministic, that can be used to support the article without delamination, cracking, or yielding. Any substrate suitable for conventional PDC cutters or in the prior art is appropriate with the novel diamond table. - In the embodiment depicted in
FIG. 1 , thePDC body 5 is substantially cylindrical in geometry. Although thePDC body 5 may be any number of geometries and sizes, anexample PDC body 5 has an approximate diameter of 0.53 inches (13.46 mm). The approximate length of these products may vary, but some examples of typical lengths are 0.315″ (8 mm), 0.512″ (13 mm), 0.630″ (16 mm), 0.748″ (19 mm). However, in some embodiments, depending upon design characteristics of the PDC body many have there are some other lengths like 1.1417″ (29 mm). - Exemplary embodiments of the PDC body dimensions are within practical limits for HPHT sintering, preferably in the range of 0.039″ to 0.2″ thick (1 to 5 mm thick), and 0.24″ to 2.56″ diameter (6 to 65 mm diameter).
- Typically, but not necessarily, finished geometric details for PDC body are within practical limits for cutters and tools. Chamfer lengths and chamfer angles, hones, radii, chip-breaking features and any other normal dimensional features of PDC and PCD tool materials are included without limit.
- Exemplary embodiments of the PDC bodies may be manufactured by any number of techniques. However, the preferred method is a powder distribution, shaping (for e.g., leveling, tapers, radii) and compacting device, as seen in at least
FIGS. 20-36 , comprising atube 100 in conjunction with abushing 110 and acup 120. The diamond powders are loaded by conventional powder conveyance methods, distributed into discrete volumes with thePDC body 5, shaped and compacted within each volume separately or in one mass, into thecup 120 using the novel press device described. Thesubstrate 50 may then be placed and/or pressed on top of and/or placed in intimate contact with, the arranged and compacted, diamond powder(s). - Compaction of diamond powder is essential to put the different regions of the PDC body in intimate contact such that catalyst metal does not accumulate to fill gaps, fissures, voids and/or holes between poorly compacted regions. The accumulation may impair bonding between the different regions of the PDC cutter.
- Since the regions of the PDC cutter have different thicknesses and shapes, comprising different diamond grain sizes and/or diamond compositions, optimal compaction requires careful consideration. This is also true about the specific region in contact with the substrate. Thus a large portion of following discussion is related to methods of distributing, shaping, and compacting the different regions of the PDC diamond table and cutter prior to HPHT sintering.
- Although any number of cups may be used, depending upon the desired geometry and size of PDC body to be manufactured, in one example, the
cup 120 may be a cylinder with afirst end 121 open and a second end 122 closed. In exemplary embodiments, thecup 120 may be manufactured from refractory metals including tantalum, molybdenum, niobium, zirconium and alloys thereof, any metal with melting point >1800 C that does not react with carbon or cobalt. - Any number of cylindrical tubes may be used, depending upon the desired geometry and size of PDC body to be manufactured. In one example, the
tube 100 may be an elongated cylinder with a length of approximately 1.5 inches (38.1 mm), an outside diameter of approximately ⅜ inches, and a wall thickness of approximately 0.01 inches (0.25 mm). Although this embodiment is substantially tubular along the entire length of the tube, other embodiments of thetube 100 may include apertures or other recessed portions to impart different cross-sectional areas in the PDC body, as desired. In this embodiment, thetube 100 is manufactured from steel or any other material capable of supporting the compaction pressure without substantial deformation. - Although any number of
bushings 110 may be used, depending upon the desired geometry and size of PDC body to be manufactured, in one example, thebushing 110 may be a two-piece plain bearing with a first andsecond shell FIGS. 23-29 , the first andsecond shells second shells second shells FIGS. 28 and 29 , the first and/orsecond shells radiused profile 118 to impart the complementary radiused and/or tapered profile of exemplary PDC bodies. The tapered and/or radiused profile may have any number of dimensions and/or sizes depending upon the desired taper and/or radius desired for the between the finer/coarser diamond interface 13. - Furthermore, exemplary embodiments of the first and
second shells chamfer 114 on at least a portion of an outside edge to help facilitate the engagement of thebushing 110 within thecup 120. In one example, as depicted inFIG. 23 , thechamfer 114 may be located at a 15 degree angle inward from the outside periphery of thebushing 110, at a length of approximately 0.011 inches (0.28 mm). - In exemplary embodiments, one or more dowel pins 113 may be used to facilitate the engagement of the one or more shells of the bushing. In one example, as depicted in
FIGS. 25 and 26 , twodowel pins 113 are used. In this example, the dowel pins are substantially cylindrical in shape, with a length of approximately 0.250 inches (6.35 mm) and an outside diameter of 0.049 inches (12.45 mm). The dowel pins may include achamfer 115 located on at least a portion of an outside edge thereof to facilitate the engagement of thedowel pin 113. - In this embodiment, the shells are manufactured from cold rolled steel or any material capable of supporting the compaction pressure without deformation. In this embodiment, the dowel pins are manufactured from common steel although in general any rigid and strong material will work.
- The
bushing 110 may include one ormore apertures 116 within the one or more shells, as depicted in at leastFIGS. 23-25 . The one ormore apertures 116 may run through the body of the one or more corresponding shells so that the apertures align and are adapted to receive anexemplary dowel pin 113. In one example, theaperture 116 of one shell may be adapted for a press fit with a dowel pin, while the corresponding aperture of the second shell may be adapted for a slip fit with the same pin. In one example, with a dowel pin having an outside diameter of 0.049 inches (12.45 mm), the aperture of the first shell may have a diameter of 0.050 inches (12.7 mm), while the aperture of the second shell has a diameter of 0.051 inches (12.95 mm). - During manufacture of an exemplary embodiment of a
PDC body 5, the first step is to assemble thebushing 110 by engaging the first andsecond shells FIG. 23 . After the bushing is assembled, the bushing may be inserted into the open end of the cup so that one end of the bushing engages the inner face of the closed end of the cup. Next, an exemplary tube may be inserted within the interior cavity of the bushing until inserted end of the tube engages at least a portion of the inner face of the closed end of the cup, as depicted inFIGS. 30-32 . - After the tube and bushing are engaged within the cup, the assembly is placed within a press brake or similar device. The assembly may be placed on a press base so that a spring loaded press plunger or similar device may be used to apply pressure on the exposed end of the tube, as seen in
FIG. 33 , wherein the bushing is used to center the tube within the cup while pressure is applied by the press plunger. Once the press plunger contacts and secures the tube against the cup, the bushing may be removed by pulling it up from around the tube and disengaging the two shells from one another, as seen inFIG. 34 . - After the bushing is removed from the tube and cup, at least a portion of the gap between the exterior wall of the tube and the interior wall of cup may be filled with diamonds. In one example, the gap between the exterior wall of the tube and the interior wall of the cup may be approximately 0.103 inches (2.62 mm) around the periphery of the tube and may be filled with diamonds of a finer size to a height in the gap of approximately 0.10 inches (2.54 mm). The bushing may be used to level the diamond placed within the gap, by reinserting the bushing and pushing against the diamonds located within the cup, as depicted in
FIG. 35 . - After the diamonds situated in the gap between the exterior wall of the tube and the interior wall of the cup have been leveled, the assembly of the cup, bushing and tube may be removed from the press brake or similar device.
- The assembly is then taken to a hydraulic press; a
sleeve 130 such as the aforementioned steel tube is slid over the original tube used in the assembly, as depicted inFIGS. 37 and 38 . Thesleeve 130 may be used to transmit pressure from the ram of a hydraulic press through the bushing and into the fine diamond powder. Once the press is engaged with the sleeve a force is applied. In one example, a 150 lb force applied by the press may generate about 1000 PSI onto the fine diamond powder, which may be enough to compact the diamond and may reduce the presence of voids in the fine diamond crystals body. It must be noted that higher compaction pressures are possible as long as the tube and the cup do not distort due to the applied pressure. A compaction pressure of 2000 PSI was tested. However, in order to protect the cup from deformation, the cup was inserted into a two piece steel cavity that had an inside diameter 0.001″ (0.025 mm) larger than the outside diameter of the cup larger. In order to protect the tube from deformation a steel rod with a diameter 0.001″ (0.025 mm) smaller than the tube inside diameter, was inserted into the tube. A 300 lb force was applied resulting in 2000 PSI. In exemplary methods, utilizing 1000 PSI seemed to be a practical pressure to apply, as this pressure did not result in significant cup or tube distortion that caused process challenges. After diamond compaction the press ram is disengaged, the sleeve is removed and the assembly is removed from the press or similar device. - Subsequently, diamond particles may be placed within the interior of the tube. In one example, the interior of the tube is filled with diamond particles that are coarser than the diamond particles placed within the gap between the tube and the cup. The coarser diamond particles may be filled within the interior of the tube to any desired height. Although, in one particular example, the interior of the tube is filled to a height of approximately 0.12 inches (3.05 mm). The coarse diamond particles may be leveled by a rod or other device once they are positioned within the tube. The coarse diamond particles may be further compacted using a rod that engages with a hydraulic press or other similar device, the pressure used to compact the coarse diamond is approximately 1000 PSI, in some exemplary embodiments. It must be noted that higher compaction pressures are possible as long as the tube does not distort due to the applied pressure on the rod. Another limitation to the pressure applied is the removal of the tube without distortion of the compacted coarse diamond. When pressure is used on the rod, it may be easier to break the tube loose from the coarse diamond while the rod is still engaged with the press ram or other similar device. In order to provide a desired amount of coarse diamonds to obtain a desired height within the tube, the amount of coarse diamonds may be measured out by weight, volume, etc. prior to positioning the diamond particles within the tube.
- After the coarse diamonds have been positioned and leveled within the
tube 100, thetube 100 andbushing 110 may be removed from thecup 120. Thecup 120 may be filled to a desired height with additional coarse or fine diamonds. Afterwards, the powders in thecup 120 may be put in contact with the substrate body, perhaps vibrated, thermally-cycled and/or hermetically-sealed and then assembled into a standard HPHT pressure cell and sintered at HPHT using well known manufacturing techniques. The resulting hard sintered body comprises a hard diamond table bonded to a substrate. The body is machined to remove cup material and create dimensions and dimensional features, as well as reveal the hard diamond table comprising a perhaps multi-layer, multi-annular volume of PDC of varying grain size and/or varying composition, comprising the diamond table. The machined PDC cutter is then fixed to a tool, such as a drill, and used to cut or drill rock or stone. - Due to the presence of the multiple layers and multiple annular regions within the PDC body of different hardness and/or toughness and/or thermal resistance, the PDC cutter lasts longer than conventional cutters comprising only one single uniform grain size and uniform composition PDC body.
- In normal PDC production, diamond powder of one size and one composition is loaded in one mass, leveled and compacted, and then HPHT sintered to form one diamond table. In this novel PDC cutter, diamond powders of different composition and/or different grain size, are distributed, shaped to include novel features and compacted with a novel pressing tool. The diamond powders of different compositions and/or grain size are fabricated in multiple stages, into different volume and shaped regions of the PDC diamond table, then HPHT sintered to form one diamond table with spatially varying hardness, toughness and thermal resistance optimized for the drilling and/or cutting of hard rock and stone.
- A number of samples with different diamond configurations were prepared and evaluated for impact and abrasion resistance. The impact and abrasion resistance tests performed on these samples are standard tests in the PDC industry.
- Description of impact test: This test evaluates the resistance of the PDC cutter to damage due to being struck by a solid object with a specific amount of energy. The impact test was performed by dropping a certain mass from specific height to produce 20 joules on energy on the impacted PDC. The PCD edge which was held at a 15° angle. Each time the mass is dropped on the PDC cutter, the cutter is examined visually and the area damaged (the area of the top surface of the PDC) after each hit is recorded, if the area damaged exceeds 25% of the total surface, the test is stopped, otherwise, the test is repeated 10 times. The total area damaged after the final hit (that would be the 10th hit if the PDC cutter does not exceed 25% area damage after any hit) is calculated and recorded as a percent of the total area of the top diamond surface. Then the average damage per drop is calculated by dividing the percentage of the area damaged divided by the number of hits performed on the PDC. This test is performed on a number of PDC cutters at least 10 pcs are tested and the average damage per hit for all pieces is reported. The measurement is reported as “percent average damage per hit” a lower value for average damage per hit is an indication of a better impact resistance cutter. In addition to the average damage per hit the average number of hits is reported, the higher the number of hits the better the cutter is on impact resistance.
- Description of abrasion test: The abrasion test evaluates the resistance of the PDC cutter to abrasion against a specific material, in this case Granite. The abrasion test consists of using the PDC cutter to machine a block of granite mounted on a vertical turning lathe. The PDC is used as the cutting tool to machine the granite block. Machining is done wet (water is flushed onto the PDC as it is engaged in the cutting action). The PDC cutter evaluated for abrasion resistance will be used to make 7 cuts of equal depth on the granite. At the end of the test, the cutter is examined and the volume of PDC that wore off is calculated, the volume of granite that was machined off using the PDC cutter is also calculated, if the wear of the PDC is too large or if the PDC part exhibits excessive breakdown, the test is stopped before all seven cuts are finished. The ratio between the Volume of Granite machined divided by the volume of the PDC machined is the G-ratio and is a measure of the abrasion resistance of the PDC cutter.
- In this example the design of the PCD layer was made with two components, a fine-grained diamond ring surrounding a coarse-grained diamond core as shown in
FIG. 39 a. The fine-grained diamond powder was compacted using 1000 PSI pressure. The coarse-grained diamond powder was leveled with a rod and compacted by hand; no device was used to apply extra pressure on the coarse grained diamond. When the diamond powder compaction was done the cross section of the coarse/fine diamond interface was rectangular, a straight vertical line and a straight horizontal line separated the diamond layers. There is no curvature or taper at the interface, and no corner radii. The product was processed under high pressure in excess of 55 kbar and temperature about 1500° C., The parts were afterwards machined to final dimensions, outside diameter of 0.529″ (13.44 mm) and a total height of 0.520″ (13.44 mm).FIG. 39 b depicts the designed PCD layer with fine-grained diamond at the edge.FIG. 40 a is an SEM picture taken of the cross section of the PDC part mentioned above, after it has been processed in HPHT and finished. It is noted that after processing in HPHT, the interface between the two diamond layers acquired some taper and a corner radius, this deformation may have occurred due to diamond powder shifting under high pressure. - This example is similar to
example # 1, the design of the PCD layer was made with two components, a fine-grained diamond ring surrounding a coarse-grained diamond core as shown inFIG. 39 c. However, the fine-grained diamond was not compacted; the coarse-grained diamond was leveled with a rod without any compaction. The cross section of the fine-grained diamond ring is a rectangle. Similar to the first example, when the diamond powder was loaded in the cup the cross section of the coarse/fine diamond interface was rectangular, a straight vertical line and a straight horizontal line separated the diamond layers. There is no curvature or taper at the interface, and no corner radii. The product was processed under high pressure and finished as the previous example.FIG. 40 b is an SEM picture taken of the cross section of the PDC part mentioned above, after it has been processed in HPHT and finished. - It is noted that after processing in HPHT, the interface between the two diamond layers was significantly changed. The diamond powders have shifted more than they did when the powders was compacted, the interface looks almost like a straight line. In addition to the interface boundary changing in shape, small metal pools are evident in the fine-grained diamond body; these appear as white spots and are circled as illustrated in
FIG. 40 b. Upon using elemental analysis (Energy Dispersive X-ray Spectroscopy or EDSFIG. 40 c), the metal pools appear to be composed of Tungsten (83%) and Cobalt (17%). The occurrence of these metal pools may have been a result of loose packing of the fine-grained diamond. - In this example the fine-grained diamond powder ring has a cross section that is tapered (the cross section width of the fine diamond increases as it gets closer to the diamond face). The cross section also has a corner radius. The fine-grained diamond was compacted using 1000 PSI pressure, the coarse-grained diamond was leveled with a rod and compacted by hand, no device was used to apply extra pressure. This part was processed in HPHT and finished as the previous example.
FIGS. 41 a and 41 b show a cross section of the designed PCD layer,FIG. 41 c is a model of the designed PDC part.FIG. 42 is a picture of the actual part.FIG. 43 is an SEM picture taken of the cross section of the PDC part mentioned above, after it has been processed in HPHT and finished. - It is noted that after processing in HPHT, the interface between the two diamond layers acquired more taper and the corner radius grew, the whole interface line boundary appears like a curved line. This deformation may have occurred due to diamond powder shifting under high pressure.
- Following on examples 1 and 2 a cross shaped groove filled with fine-grained diamond. This groove is compacted with fine-grained diamond of the same type of diamond used in the ring. The fine-grained diamond was compacted using 1000 PSI pressure, the coarse-grained diamond was leveled with a rod and compacted by hand, no device was used to apply extra pressure. The geometry of the groove is tapered and has a radius at the bottom of the groove.
FIG. 44 a shows the designed diamond arrangement in the ring and the cross.FIGS. 44 b and 44 c show a cross section of the designed PCD layer.FIG. 45 is a picture of the actual part made using the concept discussed above.FIG. 46 is an SEM picture taken of the cross section of the PDC part mentioned above, after it has been processed in HPHT and finished as the previous example. - It is noted that after processing in HPHT, the interface between the two diamond layers acquired more taper and the corner radius grew, the whole interface line boundary appears like a curved line. This deformation may have occurred due to diamond powder shifting under high pressure.
- When the coarse-grain to fine-grain diamond size ratio exceeds 1½ times, sintering of the fine-grain diamond is adversely affected, most of the molten Cobalt sweeps through the Coarse-grained diamond and a small amount sweeps through the fine-grained diamond, this condition may result in poorly sintered fine-grained PCD. When such a condition occurs, the addition of Cobalt powder that is blended with the fine-grain diamond powder may help the Cobalt sweep through the fine-grain diamond powder. Addition of Cobalt powder to the fine-grain diamond powder is done at a mix ratio of 2-5% (higher blend ratios reduce the abrasion resistance of the sintered fine-grained diamond). The particle size of Cobalt powder used is 1 micron. Such blending is followed by reduction of the diamond powder Cobalt blend in a Hydrogen rich environment done in a furnace at 850-1050° C. for a duration of 1-3 hours (depends on the firing temperature). This process is done to ensure the reduction of any Cobalt Oxides prior to sintering the diamond powder Cobalt blend. A PDC product was made using the Cobalt blended diamond crystals in the fine-grain diamond powder the fine-grain diamond size was 4 micron, the coarse-grain diamond size was 12 micron. A part similar to example 3 was made using the Cobalt blended fine-grained diamond. Diamond powders were loaded in the cup, compaction of both the fine-grain diamond powder and the coarse-grained diamond powder was done at 1000 PSI. This part was processed in HPHT and finished as the previous examples. The fine-grained diamond sintered well; there was no evidence of cracks or chips in neither the fine-grain nor the coarse-grain diamond layers.
- Impact and abrasion testing and test result summary: The finished product was then tested for impact and abrasion resistance per the tests described above, 10 pieces of each example were tested for impact and two pieces of each example were tested for abrasion resistance and the average was calculated and reported. Table 1, summarizes the impact test results of the products tested (
samples 1 through 5). Table 2 summarizes the abrasion test results of the abrasion tests performed on the products tested, - This example had neither taper nor a corner radius in the interface cross section. This product showed low impact resistance when compared to examples 3 and 4 (which were made using the same diamond grains sizes). The abrasion resistance of this example was slightly lower than that of examples 3 and 4.
- This Example had neither taper nor a corner radius in the interface cross section, and the fine-grained diamond was not compacted. The Impact resistance of this product was lower than all the examples tested; the abrasion resistance was the lowest too. Also, the fine-grained diamond layer exhibited an abundance of metal pooling.
- This Example had a taper and a corner radius on the fine diamond cross section. This example performed the best on impact resistance and had high abrasion resistance higher than examples 1 and 2 but slightly less than example 3, however, its abrasion resistance was lower than example 5 (example 5 was made with a different diamond grain in the ring layer, the fine grain diamond in the ring was the finest used amongst the examples).
- This Example was similar to example 3 with the addition of a cross shaped region that crosses the diamond surface and is made up of fine-grained diamond crystals similar to the diamond present in the ring. The impact resistance of this example was similar to example 3 and the abrasion was slightly higher than example 3 but was less than example 5 for the same reason mentioned in example 3.
- This Example was prepared similar to example 3, the main difference is that a finer diamond grain was used and it was blended with Cobalt powder at a 2% ratio, the coarse diamond used was 3 times coarser than the fine-grained diamond. This example showed the highest abrasion resistance since it used a finer diamond grain in the ring geometry than the rest of the examples. Its impact resistance was less than example 3 and 4 due to the same reason mentioned above that is finer grain diamond was used in this example, in both the ring layer and the rest of the diamond body.
- While certain exemplary embodiments are described in detail above for purposes of illustration, it would be apparent to one of skill in the art that changes may be made thereto without departing from the scope of the present invention. Therefore, the scope of the invention is not to be considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention as evidenced by the following claims:
Claims (17)
1. A cutting apparatus, comprising;
a first polycrystalline diamond portion bonded to a substrate at a substantially complementary first interface, the first polycrystalline diamond portion including a first section that is substantially cylindrical with a first diameter and a second section that is substantially cylindrical and isotonically decreases from the first diameter to a second diameter from the second end of a second section to the first end of the second section; and
a second polycrystalline diamond portion associated with the first polycrystalline diamond portion along a second substantially complementary interface that extends along the second section of the first polycrystalline diamond portion, the second polycrystalline diamond portion including diamond particles of a different size than the first portion.
2. The cutting apparatus of claim 1 , wherein the first polycrystalline diamond portion is comprised of diamond particles that are coarser in size compared to the diamond particles of the second polycrystalline diamond portion.
3. The apparatus of claim 1 , wherein the second polycrystalline diamond portion is substantially the geometry of an annular ring, wherein the thickness of the ring varies along the length of the second portion.
4. The apparatus of claim 3 , wherein the thickness of the ring varies at a substantially constant taper from the first end to the second end.
5. The apparatus of claim 4 , wherein the thickness of the ring varies at a taper of approximately 8-45 degrees off vertical.
6. The apparatus of claim 4 , wherein the thickness of the ring varies at a taper of approximately 15-25 degrees off vertical.
7. The apparatus of claim 3 , wherein the thickness of the ring varies at a substantially constant radius from the first end to the second end.
8. The apparatus of claim 1 , further comprising one or more chords of diamond particles that dissect at least a portion of a depth of the second diamond portion.
9. The apparatus of claim 8 , wherein two chords dissect at least a portion of the depth of the second section into four substantially equal sectors.
10. A cutting apparatus, comprising;
a first polycrystalline diamond portion bonded to a substrate at a substantially complementary first interface, the first polycrystalline diamond portion including a first section that is substantially cylindrical with a first diameter and a second section that is substantially cylindrical and isotonically decreases from the first diameter to a second diameter from the second end of a second section to the first end of the second section; and
a second polycrystalline diamond portion associated with the first polycrystalline diamond portion along a second substantially complementary interface that extends along the second section of the first polycrystalline diamond portion, the second polycrystalline diamond portion including diamond particles of a different size than the first portion; and
wherein the first polycrystalline diamond portion is comprised of diamond particles that are coarser in size compared to the diamond particles of the second polycrystalline diamond portion.
11. The apparatus of claim 10 , wherein the second polycrystalline diamond portion is substantially the geometry of an annular ring, wherein the thickness of the ring varies along the length of the second portion.
12. The apparatus of claim 11 , wherein the thickness of the ring varies at a substantially constant taper from the first end to the second end.
13. The apparatus of claim 12 , wherein the thickness of the ring varies at a taper of approximately 8-45 degrees off vertical.
14. The apparatus of claim 13 , wherein the thickness of the ring varies at a taper of approximately 15-25 degrees off vertical.
15. The apparatus of claim 11 , wherein the thickness of the ring varies at a substantially constant radius from the first end to the second end.
16. The apparatus of claim 10 , further comprising one or more chords of diamond particles that dissect at least a portion of a depth of the second diamond portion.
17. The apparatus of claim 16 , wherein two chords dissect at least a portion of the depth of the second section into four substantially equal sectors.
Priority Applications (3)
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US13/072,203 US20120241225A1 (en) | 2011-03-25 | 2011-03-25 | Composite polycrystalline diamond body |
US14/248,717 US10214967B2 (en) | 2011-03-25 | 2014-04-09 | Composite polycrystalline diamond body |
US14/504,882 US20150114725A1 (en) | 2011-03-25 | 2014-10-02 | Non-uniform polycrystalline composite and its method of manufacture |
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US13/072,203 US20120241225A1 (en) | 2011-03-25 | 2011-03-25 | Composite polycrystalline diamond body |
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US14/248,717 Continuation US10214967B2 (en) | 2011-03-25 | 2014-04-09 | Composite polycrystalline diamond body |
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US20120241225A1 true US20120241225A1 (en) | 2012-09-27 |
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US13/072,203 Abandoned US20120241225A1 (en) | 2011-03-25 | 2011-03-25 | Composite polycrystalline diamond body |
US14/248,717 Expired - Fee Related US10214967B2 (en) | 2011-03-25 | 2014-04-09 | Composite polycrystalline diamond body |
US14/504,882 Abandoned US20150114725A1 (en) | 2011-03-25 | 2014-10-02 | Non-uniform polycrystalline composite and its method of manufacture |
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US14/248,717 Expired - Fee Related US10214967B2 (en) | 2011-03-25 | 2014-04-09 | Composite polycrystalline diamond body |
US14/504,882 Abandoned US20150114725A1 (en) | 2011-03-25 | 2014-10-02 | Non-uniform polycrystalline composite and its method of manufacture |
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GB2514894A (en) * | 2013-03-31 | 2014-12-10 | Element Six Abrasives Sa | Superhard constructions & methods of making same |
WO2017161075A1 (en) * | 2016-03-16 | 2017-09-21 | Diamond Innovations, Inc. | Polycrystalline diamond bodies having annular regions with differing characteristics |
GB2559481A (en) * | 2016-12-31 | 2018-08-08 | Element Six Ltd | Superhard constructions and methods of making same |
US10105826B2 (en) | 2016-03-16 | 2018-10-23 | Diamond Innovations, Inc. | Methods of making polycrystalline diamond bodies having annular regions with differing characteristics |
GB2569896A (en) * | 2017-12-31 | 2019-07-03 | Element Six Uk Ltd | Polycrystalline diamond constructions |
CN114833341A (en) * | 2022-05-07 | 2022-08-02 | 成都惠灵丰金刚石钻头有限公司 | Sintering process of diamond bearing |
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US10704335B2 (en) | 2016-03-16 | 2020-07-07 | Diamond Innovations, Inc. | Polycrystalline diamond bodies having annular regions with differing characteristics |
WO2017161075A1 (en) * | 2016-03-16 | 2017-09-21 | Diamond Innovations, Inc. | Polycrystalline diamond bodies having annular regions with differing characteristics |
US10105826B2 (en) | 2016-03-16 | 2018-10-23 | Diamond Innovations, Inc. | Methods of making polycrystalline diamond bodies having annular regions with differing characteristics |
KR20180123537A (en) * | 2016-03-16 | 2018-11-16 | 다이아몬드 이노베이션즈, 인크. | Polycrystalline diamond bodies with annular zones having different characteristics |
CN108884707A (en) * | 2016-03-16 | 2018-11-23 | 戴蒙得创新股份有限公司 | Polycrystalline diamond body comprising the annular region with different characteristics |
US10683706B2 (en) | 2016-03-16 | 2020-06-16 | Diamond Innovations, Inc. | Polycrystalline diamond bodies having annular regions with differing characteristics |
KR102450565B1 (en) * | 2016-03-16 | 2022-10-04 | 다이아몬드 이노베이션즈, 인크. | Polycrystalline diamond bodies having annular zones with different characteristics |
US11649682B1 (en) * | 2016-08-26 | 2023-05-16 | Us Synthetic Corporation | Multi-part superabrasive compacts, rotary drill bits including multi-part superabrasive compacts, and related methods |
GB2559481A (en) * | 2016-12-31 | 2018-08-08 | Element Six Ltd | Superhard constructions and methods of making same |
GB2559481B (en) * | 2016-12-31 | 2020-06-24 | Element Six Ltd | Superhard constructions and methods of making same |
GB2569896A (en) * | 2017-12-31 | 2019-07-03 | Element Six Uk Ltd | Polycrystalline diamond constructions |
CN114833341A (en) * | 2022-05-07 | 2022-08-02 | 成都惠灵丰金刚石钻头有限公司 | Sintering process of diamond bearing |
Also Published As
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US10214967B2 (en) | 2019-02-26 |
US20150114725A1 (en) | 2015-04-30 |
US20140237906A1 (en) | 2014-08-28 |
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