CN105798312A - 一种石油钻头用金刚石复合片烧结工艺 - Google Patents
一种石油钻头用金刚石复合片烧结工艺 Download PDFInfo
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Abstract
本发明公开了一种石油钻头用金刚石复合片烧结工艺，具体涉及一种生产高耐热性、高耐磨性石油钻头用金刚石复合片的生产工艺。要解决的技术问题是传统的石油钻头用金刚石复合片耐热性差、耐磨性低，易出现整体脱层现象。本发明包括以下步骤：①将硬质合金衬底I和金刚石微粉层装在屏蔽杯中形成组装件I，金刚石微粉层中添加有结合剂；②将组装件在比正常合成压力低5‑12%的环境下烧结合成金刚石复合片；③将硬质合金衬底I去掉，对金刚石层进行脱结合剂处理；④将金刚石层和硬质合金衬底II重新装于屏蔽杯中形成组装块II，按正常合成压力进行二次烧结。采用这样技术方案的本发明增加了二次烧结合成，大幅提高了产品的耐热性、耐磨性。
Description
技术领域
本发明涉及金刚石复合片领域，具体涉及一种用于高耐热性、高耐磨性石油钻头用金刚石复合片的生产工艺。
背景技术
目前，传统的石油钻头用金刚石复合片主要采用两种方法制成：
方法（一）：如图1所示的内组装方法。烧结过程中通过硬质合金衬底I1中的钴及金刚石微粉层2中添加的结合剂共同扫越合成金刚石层，加上相邻金刚石颗粒的碳原子在1600℃、6GPa以上压力状态下形成的共价键，从而形成复合型的超硬材料烧结体。但是在烧结条件下，硬质合金衬底中的钴呈熔融状态，由于表面张力的作用，将由高浓度向低浓度流动，从而会有部分钴均匀渗透至金刚石层中，而金刚石微粉层2中添加的结合剂中也有一定量的钴，因此该技术生产的金刚石复合片产品的金刚石层中会有含量超过6%的钴分布，使得金刚石复合片在使用过程中产生诸多问题：（1）作为金刚石向石墨转化的触媒，影响产品的耐热性；（2）工作状态下数倍于金刚石的热膨胀系数导致金刚石层微裂纹的产生，使金刚石层发生非正常破损；（3）结合剂填充于金刚石颗粒中间影响碳原子间共价键的形成；（3）影响金刚石的致密度，降低产品的耐磨性。
方法（二）：对方法（一）产品的金刚石层3经脱结合剂处理后，采用多种方式通过焊料层4高温钎焊至硬质合金层1衬底上(如图2所示)。该钎焊产品能显著提高产品的耐热性，但易出现整体脱层现象。
发明内容
本发明要解决的技术问题是传统的石油钻头用金刚石复合片耐热性差、耐磨性低，易出现整体脱层现象，提供一种高耐热性、高耐磨性的石油钻头用金刚石复合片烧结工艺。
为实现上述目的，本发明采用下述技术方案：一种石油钻头用金刚石复合片烧结工艺，它包括以下步骤：①将硬质合金衬底I和金刚石微粉层装在屏蔽杯中形成组装件I，金刚石微粉层中添加有结合剂；②将步骤①形成的组装件在比正常合成压力低5-12%的环境下烧结合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I去掉，对金刚石层进行脱结合剂处理；④将脱结合剂处理后的金刚石层和硬质合金衬底II重新装于屏蔽杯中形成组装块II，将组装块II按正常合成压力进行二次烧结合成。
还包括以下步骤：对步骤③去掉硬质合金衬底I后的金刚石层进行初加工，将金刚石层加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层后再进行脱结合剂处理；将步骤④二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
还包括以下步骤：将步骤③脱结合剂处理后的金刚石层清洗干净、高温烘干后再进行步骤④的组装；所述的高温烘干温度为120℃～200℃，烘干时间为3个小时以上
所述的步骤②和步骤④中烧结合成金刚石复合片时的温度为1600℃以上。
所述正常合成压力为6GPa以上。
所述脱结合剂处理为采用强酸浸泡法或电化学的方法进行处理。
所述强酸为王水。
采用上述技术方案的本发明在现有技术的基础上增加了二次烧结合成，使产品性能大幅提高；通过增加金刚石颗粒间C﹣C键合程度及降低金刚石层的含钴量来提高产品的耐热性和耐磨性，检测结果表明：同类产品的耐磨性提高20%以上，该工艺产品加热700℃，20分钟后，样品的耐磨性没有明显变化。
附图说明
图1是传统方法（一）金刚石复合片烧结时及本发明第一次烧结时的内组装结构示意图；
图2是传统方法（二）金刚石层高温钎焊至硬质合金层衬底结构示意图；
图3是本发明第二次烧结时的内组装结构示意图。
具体实施方式
如图1和图3所示，本发明包括以下步骤：①将硬质合金衬底I1和金刚石微粉层2装在屏蔽杯5中形成组装件I6，金刚石微粉层2中添加有结合剂；②将步骤①形成的组装件6在比正常合成压力低5-12%的环境下烧结合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I1去掉，对金刚石层3进行脱结合剂处理，本发明采用线切割的方式将硬质合金衬底I1作废料被去除；④将脱结合剂处理后的金刚石层3和硬质合金衬底II8重新装于屏蔽杯5中形成组装块II7，将组装块II7按正常合成压力进行二次烧结合成。本发明采用的结合剂为高纯钴粉，结合剂的用量为每100份金刚石微粉添加结合剂1-5份；步骤②烧结时的压力比正常合成压力低不足5%时，会使本次烧结压力接近正常合成压力，脱结合剂处理时效果不佳，比正常合成压力低超过12%时，金刚石层难以成型。金刚石层中的钴有两个来源：作为结合剂人为添加及硬质合金中的钴渗透，超过6%的钴分布的金刚石层是现有金刚石复合片耐热性低、耐磨性差的主要原因，而脱结合剂主要是脱除结合剂中的钴，步骤②在比正常合成压力低5-12%的环境下扫越合成金刚石复合片，使得脱结合剂处理效果更好，有效降低金刚石层的钴含量，使金刚石层中的钴含量降低至5%以下。二次烧结扫越所采用的金刚石层为脱钴金刚石层，并使金刚石颗粒间的共价键数量有所提高，该技术对产品性能提高有关键性作用。
还包括以下步骤：对步骤③去掉硬质合金衬底I1后的金刚石层3进行初加工，将金刚石层3加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层3后再进行脱结合剂处理；将步骤④二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
还包括以下步骤：将步骤③脱结合剂处理后的金刚石层3清洗干净、高温烘干后再进行步骤④的组装；所述的高温烘干温度为120℃～200℃，烘干时间为3个小时以上
所述的步骤②和步骤④中烧结合成金刚石复合片时的温度为1600℃以上。
所述正常合成压力为6GPa以上。
所述脱结合剂处理为采用强酸浸泡法或电化学的方法进行处理。
所述强酸为王水。
下面为本发明的具体实施例：
实施例1：
一种石油钻头用金刚石复合片烧结工艺,包括以下步骤：将硬质合金衬底I1和金刚石微粉层2装在屏蔽杯5中形成组装件I6，金刚石微粉层2中添加有结合剂；组装完成后将组装块I6用常规方法置于由碳管、盐管、白云石管、叶腊石块等组成的合成块中；②将步骤①形成的组装块6在比正常合成压力6GPa低5%，温度1580℃的的环境下扫越合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I1去掉，对去掉硬质合金衬底I1后的金刚石层3进行初加工，将金刚石层3加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层3后,将金刚石层3直接浸入王水进行脱结合剂处理，将脱结合剂处理后的金刚石复合片清洗干净，150℃烘干3个小时；④将烘干后的金刚石层3和硬质合金衬底II8重新装于屏蔽杯5中形成组装块II7，将组装块II7按正常合成压力6GPa，温度1580℃进行二次烧结合成，将二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
实施例2：
一种石油钻头用金刚石复合片烧结工艺,包括以下步骤：将硬质合金衬底I1和金刚石微粉层2装在屏蔽杯5中形成组装件I6，金刚石微粉层2中添加有结合剂；组装完成后将组装块I6用常规方法置于由碳管、盐管、白云石管、叶腊石块等组成的合成块中；②将步骤①形成的组装块6在比正常合成压力6.5GPa低5%，温度1650℃的的环境下扫越合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I1去掉，对去掉硬质合金衬底I1后的金刚石层3进行初加工，将金刚石层3加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层3后,将金刚石层3直接浸入王水进行脱结合剂处理，将脱结合剂处理后的金刚石复合片清洗干净，200℃烘干3个小时；④将烘干后的金刚石层3和硬质合金衬底II8重新装于屏蔽杯5中形成组装块II7，将组装块II7按正常合成压力6.5GPa，温度1650℃进行二次烧结合成，将二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
实施例3：
一种石油钻头用金刚石复合片烧结工艺,包括以下步骤：将硬质合金衬底I1和金刚石微粉层2装在屏蔽杯5中形成组装件I6，金刚石微粉层2中添加有结合剂；组装完成后将组装块I6用常规方法置于由碳管、盐管、白云石管、叶腊石块等组成的合成块中；②将步骤①形成的组装块6在比正常合成压力7GPa低10%，温度1650℃的的环境下扫越合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I1去掉，对去掉硬质合金衬底I1后的金刚石层3进行初加工，将金刚石层3加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层3后,将金刚石层3直接浸入王水进行脱结合剂处理，将脱结合剂处理后的金刚石复合片清洗干净，180℃烘干4个小时；④将烘干后的金刚石层3和硬质合金衬底II8重新装于屏蔽杯5中形成组装块II7，将组装块II7按正常合成压力7GPa，温度1700℃进行二次烧结合成，将二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
Claims (7)
1.一种石油钻头用金刚石复合片烧结工艺，其特征在于：它包括以下步骤：①将硬质合金衬底I（1）和金刚石微粉层（2）装在屏蔽杯（5）中形成组装件I（6），金刚石微粉层（2）中添加有结合剂；②将步骤①形成的组装件（6）在比正常合成压力低5-12%的环境下烧结合成金刚石复合片；③将步骤②合成的金刚石复合片的硬质合金衬底I（1）去掉，对金刚石层（3）进行脱结合剂处理；④将脱结合剂处理后的金刚石层（3）和硬质合金衬底II（8）重新装于屏蔽杯（5）中形成组装块II（7），将组装块II（7）按正常合成压力进行二次烧结合成。
2.根据权利要求1所述的石油钻头用金刚石复合片烧结工艺，其特征在于：还包括以下步骤：对步骤③去掉硬质合金衬底I（1）后的金刚石层（3）进行初加工，将金刚石层（3）加工至厚度与成品相同，外径尺寸比成品大0.3-0.4mm的金刚石层（3）后再进行脱结合剂处理；将步骤④二次烧结合成的金刚石复合片进行再次加工至成品尺寸。
3.根据权利要求1所述的石油钻头用金刚石复合片烧结工艺，其特征在于：还包括以下步骤：将步骤③脱结合剂处理后的金刚石层（3）清洗干净、高温烘干后再进行步骤④的组装；所述的高温烘干温度为120℃～200℃，烘干时间为3个小时以上。
4.根据权利要求1所述的石油钻头用金刚石复合片烧结工艺，其特征在于：所述的步骤②和步骤④中烧结合成金刚石复合片时的温度为1600℃以上。
5.根据权利要求1所述的石油钻头用金刚石复合片烧结工艺，其特征在于：所述正常合成压力为6-7GPa。
6.根据权利要求1所述的石油钻头用金刚石复合片烧结工艺，其特征在于：所述脱结合剂处理为采用强酸浸泡法或电化学的方法进行处理。
7.根据权利要求6所述的石油钻头用金刚石复合片烧结工艺，其特征在于：所述强酸为王水。
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