CN108603255A - 超硬结构及其制造方法 - Google Patents
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Abstract
超硬结构包括:基底,所述基底包括外围表面、界面表面和在平面中延伸的纵向轴;和超硬材料层,所述超硬材料层形成在基底上并且具有露出的外表面、从其延伸的外围表面和界面表面。基底的界面表面或者超硬材料层的界面表面中的一个包括:布置成从所述界面表面凸出的一个或多个凸起,所述一个或多个凸起从基底的外围表面分隔开;和在外围侧边缘和界面表面之间延伸的外围凸缘。所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜约5度至约30度。
Description
技术领域
本文涉及超硬结构及其制造方法,更具体地但不唯一地涉及包括附接到基底的多晶金刚石(PCD)结构,并将其作为用于钻头的切削嵌件或元件来钻入地面的结构。
背景技术
多晶超硬材料(例如多晶金刚石(PCD)和多晶立方氮化硼(PCBN))可以用于多种工具,所述工具用于切割、机械加工、钻孔或破碎硬质或研磨材料,例如岩石、金属、陶瓷、复合材料和含木材料。特别是,包括PCD材料的切割元件形式的工具嵌件被广泛用于进行地面钻探以开采石油或天然气的钻头。超硬工具嵌件的工作寿命可受超硬材料的断裂限制,包括通过剥落和碎裂,或者工具嵌件的磨损。
诸如在岩石钻头中使用的切割元件或其他切割工具通常具有呈基底形式的主体,其具有界面端/表面和超硬材料,所述超硬材料形成切割层,所述切割层例如通过烧结工艺结合至基底的界面表面。基底通常由有时被称为烧结碳化钨的碳化钨-钴合金构成,并且超硬材料层典型地为多晶金刚石(PCD)、多晶立方氮化硼(PCBN)或热稳定产品TSP材料,例如热稳定多晶金刚石。
多晶金刚石(PCD)是超硬材料(也称为超硬磨料)的示例,其包括大量基本上共生的金刚石晶粒,形成了限定金刚石晶粒间间隙的骨架体(skeletal mass)。PCD材料典型地包括至少大约80%体积比的金刚石以及通常通过使金刚石晶粒的聚集体经受大于大约5GPa的超高压以及至少为大约1,200℃的温度下形成。全部或部分地填充所述间隙的材料可被称为填料或粘合剂材料。
PCD典型地在烧结助剂(例如钴)的存在下形成,烧结助剂促进金刚石晶粒的共生。用于PCD的适合的烧结助剂由于其在一定程度上溶解金刚石并催化其再沉淀的功能,通常也被称为用于金刚石的溶剂-催化剂材料。用于金刚石的溶剂-催化剂被理解为能够在金刚石热力学稳定的压力和温度条件下促进金刚石的生长或在金刚石晶粒之间直接的金刚石对金刚石的共生的材料。因此在烧结的PCD产品内的间隙中可以全部或部分地填充有剩余的溶剂-催化剂材料。最典型地,PCD常在钴-烧结碳化钨基底上形成,其提供了用于PCD的钴溶剂-催化剂源。不促进金刚石晶粒之间基本连贯共生的材料本身可与金刚石晶粒形成强的结合,但对于PCD烧结其并非适合的溶剂-催化剂。
可以用于形成适当的基底的烧结碳化钨由散布在钴基质中的碳化物颗粒通过将碳化钨颗粒/晶粒以及钴混合在一起然后加热凝固而形成。为了形成带有诸如PCD或PCBN的超硬材料层的切割元件,金刚石颗粒或晶粒或CBN晶粒被放置与难熔金属罩体(例如铌罩体)中的烧结碳化钨主体相邻并且经受高压和高温使得金刚石晶粒或CBN晶粒之间发生晶间结合,形成多晶超硬金刚石或多晶CBN层。
在一些情况下,基底可以在附接到超硬材料层之前充分固化,而在其他情况下,基底可以是生的(green),即未完全固化。在后一种情况下,基底可以在HTHP烧结工艺中充分固化。基底可以是粉末形式,并可以在用于烧结超硬材料层的烧结工艺中进行固化。
钴具有明显不同于金刚石的热膨胀系数,因此,在使用过程中一旦加热多晶金刚石材料,PCD材料所附接的基底上的钴膨胀,并且可以引起在PCD材料中形成裂纹,导致PCD层的劣化。
为了减少在基底与超硬层之间的界面产生剩余应力,已知在基底上的界面表面上形成从平面的界面表面凸出的多个同心圆环。由于基底的热膨胀系数与超硬材料层的热膨胀系数之间的差异,当切割元件经HTHP烧结后冷却时,这些层会以不同速率收缩。拉伸应力区域形成在环的上表面,而压缩应力区域形成在这些环之间的凹陷上/内。因此,在使用中当裂纹开始生长时,其可以沿着暴露于拉伸应力的圆环的整个的上表面环状生长,或者可以沿着暴露于压缩应力的凸出环之间的整个环形凹陷生长,导致切割元件过早失效。
还已知的是,切割元件基底界面包括多个分隔开的凸起,所述凸起具有从平面的界面表面凸出的相对平坦的上表面。
影响切割元件的常见问题是超硬材料层的碎裂、剥落、部分断裂和破裂。另一问题是沿着超硬材料层与基底之间的界面的破裂和裂纹沿着界面表面的扩展。这些问题可以造成超硬材料层过早失效,因而缩短切割元件的工作寿命。因此,在例如钻岩的高磨损或者高冲击力的应用中,需要具有超硬材料层和延长了工作寿命的切割元件,其中破裂、碎裂和断裂的可能性被降低或可控制。
发明内容
从第一方面看,提供了一种超硬结构,所述超硬结构包括:
基底,所述基底包括外围表面、界面表面和在平面中延伸的纵向轴;和
超硬材料层,所述超硬材料层形成在基底上并且具有露出的外表面、从其延伸的外围表面和界面表面;
其中基底的界面表面或者超硬材料层的界面表面中的一个包括:
布置成从所述界面表面凸出的一个或多个凸起;所述一个或多个凸起从基底的外围表面分隔开;和
在外围侧边缘和界面表面之间延伸的外围凸缘,所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜约5度至约30度。
从第二方面看,提供了一种包括主体的钻地钻头,所述主体上安装有作为切削元件的前述超硬结构。
附图说明
现在作为示例并参考附图来描述非限制性示例,其中:
图1是切割元件的示例的示意性横截面图,其以虚线示出了基底与超硬材料主体之间的界面基底特征;
图2是根据第一示例的图1的基底的示意性平面图;
图3是切割元件的另一示例的示意性横截面图,其以虚线示出了基底与超硬材料主体之间的界面基底特征;和
图4是图3的基底的示意性平面图。
具体实施方式
在本文描述的示例中,当凸起或凹陷被描述为形成于基底表面上时,应理解为其可以替代地形成在与基底界面表面界面结合的超硬材料层表面上,而相反的特征形成在基底上。另外,应理解为界面表面的负面或反面形成在与基底界面结合的超硬材料层上,从而使两个界面形成贴合匹配。
如本文所用,“超硬材料”是维氏硬度至少约为28GPa的材料。金刚石和立方氮化硼(cBN)材料是超硬材料的示例。
本文使用的“超硬结构”指包括多晶超硬材料的主体和与其附接的基底的结构。
本文使用的多晶金刚石(PCD)是一种包括大量金刚石晶粒的多晶超硬材料(PCS),所述金刚石晶粒大部分彼此互相结合,并且其中金刚石的含量至少约占该材料80%体积比。在PCD材料的一个示例中,金刚石晶粒之间的间隙可以至少部分地填充有包括用于金刚石的催化剂的粘合剂材料。如本文所用,“间隙”或“间隙区域”是PCD材料的金刚石晶粒之间的区域。在PCD材料的示例中,间隙或间隙区域可以基本上或部分地填充有金刚石以外的材料,或者它们可以是基本上空的。PCD材料可以包括至少一个区域,从该区域中催化剂材料已从间隙中除去,留下金刚石晶粒之间的间隙空隙。
本文使用的PCBN(多晶立方氮化硼)材料指的是包括散布在包括金属或陶瓷的基质内的立方氮化硼(cBN)晶粒的超硬材料的一种。PCBN是超硬材料的示例。
用于超硬材料的“催化剂材料”能够促进超硬材料的生长或烧结。
如本文所用,术语“基底”是指在其上形成超硬材料层的任何基底。例如,如本文所使用的“基底”可以是形成在另一个基底上的过渡层。此外,本文使用的术语"径向"、"环向"等术语不旨在将特征限制为标准圆。
在附图中示出的超硬结构1可以适合例如用作钻地钻头的切削嵌件。
在所有附图中,相同的附图标记表示相同的特征。
在如图1所示的示例中,切割元件1包括基底30,具有形成在基底30上的超硬材料层32。基底可以由诸如烧结碳化钨的硬质材料形成。超硬材料可以是例如多晶金刚石(PCD)、多晶立方氮化硼(PCBN)或热稳定产品如热稳定PCD(TSP)。可以把切割元件1安装在诸如刮刀钻头体(未示出)的钻头体中。与基底背对的超硬材料的暴露的顶表面形成切割面34,这是沿其边缘36在使用中进行切割的表面。
在基底30的一端是与超硬材料层32界面结合的界面表面38,超硬材料层32在此界面表面上与基底附接。基底30一般是圆柱形的,并且具有外围表面40、外围侧边缘41和具有一个或多个表面特征44的第一表面42。
在图1和2所示的示例中,界面表面38包括在外围侧边缘41从基底30的外围表面40延伸到第一表面42的倾斜的凸缘46。第一表面42包括基本上平面的主要部分,多个分隔开的凸起44从所述主要部分延伸,所述凸起从外围侧边缘41分隔开。凸缘46相对于垂直于切割元件1的纵向轴50延伸穿过的平面的平面以约5度至约20度的角度θ倾斜。在一些示例中,凸缘46从外围侧边缘41到第一表面42的长度在约0.1到约1mm之间,并且在一些示例中约为0.35mm。
第二示例在图3和4中示出,这示例与图1和图2中示出的示例的不同之处在于凸缘46由肩部52从外围侧表面40分隔开。在一些示例中,肩部52从外围侧边缘41到凸缘46的径向长度在约0.2到约0.8mm之间,并且在一些示例中在约0.3mm到约0.5mm之间。在这示例中,凸缘46相对于垂直于切割元件1的纵向轴50延伸的平面的平面倾斜的角度θ可以在约5度至约30度之间。在一些示例中,θ可以在大约10度到大约30度之间。
在图1至4所示的示例中,分隔开的凸起44布置在两个阵列中,所述两个阵列设置在围绕基底30的纵向轴50的基本上环形的路径中。并且,尽管示出的内部阵列的凸起更靠近外部阵列44,而不是靠近基底的纵向轴50,在其他示例中内部阵列的凸起可以更靠近纵向轴。
第二阵列中的凸起可以与第一阵列的凸起44之间的空间径向对齐。凸起和空间可以是交错的,使一个阵列中的凸起与下一个阵列中的空间重叠。这种在界面表面上三维特征的交错或非对齐的分布有助于分配压缩应力和拉伸应力,和/或减小应力场的大小,和/或通过阻断裂纹生长的连续路径而阻止裂纹的生长。
如图1至图4所示,在这些示例中,凸起44之间的界面表面42例如基本上是平面的,并且所有或大部分凸起44成形为使得凸起的全部或大部分表面不基本平行于超硬材料32的切割面34或基底的纵向轴延伸穿过的平面。
凸起44可以具有光滑的弯曲上表面或者可以具有倾斜的上表面。在一些示例中,凸起44可以在形状上稍微呈梯形或者锥形,在最靠近它们凸出来的界面表面是最宽的。
此外,这种设置被认为用来干扰材料中的"弹性"波形成,并使界面处的裂纹偏转。
在图1至4中,凸起44在各个基本上环形的阵列中/围绕各个基本上环形的阵列基本上等距分隔,各个凸起44位于具有相同尺寸的给定阵列中。但是,凸起44可以形成为任何期望的形状,如上所述,并且彼此以均匀或不均匀的方式分隔开,从而在界面表面38上改变应力场以形成基本上环形的同心的不持续环。此外,在一些示例中,凸起44之间的界面表面42是基本上非平面的。
在一些示例中,凸起44以使得它们阻断裂纹可以沿着其穿过界面表面38扩展的一个或更多个连续路径的方式定位和成形。
凸起44的布置和形状以及其间的空间可以影响切割元件1中的应力分布,并且例如通过阻止或偏转穿过凸起44之中、之上或附近的应力区域的裂纹生长,可以提高切割元件对裂纹生长的抵抗,特别是对沿着界面表面38的裂纹生长的抵抗。
如图1和3的示例所示,基底30的纵向轴50周围区域中超硬材料的深度可以是与超硬材料层32周围的超硬材料的深度基本相同的深度。这可使在使用中暴露于工作表面的超硬材料的体积和面积不会随磨损进展而显著下降,从而改善切削元件1的寿命。另外,当在轴向受力时,它有助于强化切削元件1。而且,它有助于减少或基本上消除在使用过程中形成沟槽磨损的可能性。
在一个或更多个上述示例中,肩部52、凸缘46和界面表面38的凸起44可以是整体形成的,而基底30是通过使用适当的成型模具形成的,在该模具中放置形成基底的材料的颗粒。另选地,肩部52和凸缘46和界面表面38的凸起44中的任何一个或多个可以是在基底30已经制成后制成,或者部分通过制成工艺制成,例如通过传统的机械加工工艺制成,例如EDM或激光烧蚀。可以将相似的过程应用于超硬材料层32,以产生用于与基底的界面表面形成贴合匹配的相应形状的界面表面,或者,可以通过以下方式在超硬材料层的界面中制成这种贴合匹配:将超硬材料的颗粒放置在预先形成的基底上,并使该组合经受烧结工艺,使得超硬材料层中的匹配界面在烧结期间形成。
可以通过例如常规钎焊技术或通过使用常规高压和高温技术进行烧结来将超硬材料层32附接到基底。
如果在后续加工中从超硬材料层32部分地或完全地滤除催化剂材料,或进行进一步的高压高温烧结工艺,则可进一步提高具有上述界面特征和/或缓解其内弹性应力波的切削产品(包括基底和超硬材料层)的耐用性。可以在超硬材料层32附接到基底的同时进行所述滤除,或例如通过从基底分离超硬材料层32,并滤除所分离的超硬材料层32。在后一种情况中,已进行滤除之后,可使用例如钎焊技术或通过使用高压高温技术重新烧结来将超硬材料层32重新附接到基底。
虽然已经描述和示例了一些具体示例,但是应该理解,可以做出各种改变和修改。例如,本文描述的基底已经通过示例的方式呈现。应当理解,除了碳化钨基底之外,超硬材料还可以附接到其他碳化物基底,例如由W、Ti、Mo、Nb、V、Hf、Ta和Cr的碳化物制造的基底。此外,虽然在图1至图4所示的示例中,PCD结构有锋利的边和角,但是示例可以包括具有圆的、斜切或削角的边或角的PCD结构。这种示例可以通过改善切割元件对穿过具有独特几何形状的基底或超硬材料层的界面的破裂、碎裂和断裂的抗性,来降低内部应力,并因此延长工作寿命。
Claims (17)
1.一种超硬结构,所述超硬结构包括:
基底,所述基底包括外围表面、界面表面和在平面中延伸的纵向轴;和
超硬材料层,所述超硬材料层形成在基底上并且具有露出的外表面、从其延伸的外围表面和界面表面;
其中基底的界面表面或者超硬材料层的界面表面中的一个包括:
布置成从所述界面表面凸出的一个或多个凸起;所述一个或多个凸起从基底的外围表面分隔开;和
在外围侧边缘和界面表面之间延伸的外围凸缘,所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜约5度至约30度。
2.根据权利要求1所述的超硬结构,其中外围凸缘与基底是基本上同心的。
3.根据前述权利要求中任一项所述的超硬结构,其中所述凸缘延伸至外围侧边缘。
4.根据权利要求中1或2任一项所述的超硬结构,其中所述凸缘从外围侧边缘分隔开。
5.根据权利要求4所述的超硬结构,其中所述凸缘由肩部从外围侧边缘分隔开,所述肩部在基本上垂直于基底的纵向轴延伸穿过的平面的平面上从外围侧边缘延伸约0.2至约0.8mm的径向距离。
6.根据前述权利要求中任一项所述的超硬结构,其中超硬材料层围绕基底的中心纵向轴的厚度与超硬材料层在外围表面的厚度基本上相同。
7.根据前述权利要求中任一项所述的超硬结构,其中超硬材料层包括多晶金刚石。
8.根据权利要求4所述的超硬结构,其中所述凸缘由肩部从外围侧边缘分隔开,所述肩部在基本上垂直于基底的纵向轴延伸穿过的平面的平面上从外围侧边缘延伸约0.3至约0.5mm的径向距离。
9.根据前述权利要求中任一项所述的超硬结构,其中基底的界面表面是超硬材料层的界面表面的负面或反面,使得所述两个界面表面形成贴合匹配。
10.根据前述权利要求中任一项所述的超硬结构,其中所述超硬结构是切削元件。
11.根据前述权利要求中任一项所述的超硬结构,其中所述凸起布置为使得沿着通过所述中心轴的平面具有反射对称性。
12.根据前述权利要求中任一项所述的超硬结构,所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜的角度为约5度至约20度。
13.根据权利要求1至11中任一项所述的超硬结构,所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜的角度为约5度至约15度。
14.根据权利要求1至11中任一项所述的超硬结构,所述外围凸缘相对于基本上垂直于纵向轴延伸穿过的平面的平面倾斜的角度为约5度至约10度。
15.一种包括主体的钻地钻头,所述主体上安装有作为切削元件的前述权利要求中任一项所述的超硬结构。
16.一种形成权利要求1至15中任一项所述的超硬结构的方法。
17.一种参照与在附图中说明的实施例一样的任何一个实施例的基本上如前面描述的超硬结构。
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US5971087A (en) * | 1998-05-20 | 1999-10-26 | Baker Hughes Incorporated | Reduced residual tensile stress superabrasive cutters for earth boring and drill bits so equipped |
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