CN108941577A - 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
本发明涉及一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:S1原料预组装;S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在高压烧结合成室中烧结4‑6min,去掉硬质合金基体I得到金刚石复合片粗成品待用;S3粗成品加工;S4金刚石复合片二次烧结:将金刚石复合片粗成品采用强酸浸泡法脱结合剂,清水清洗2‑3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1400‑1450℃、压力为5.6GPa的高压烧结合成室中烧结6‑8min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。本发明具有提升产品性能、提高产品的耐热性和耐磨性的优点。
Description
技术领域
本发明涉及金刚石复合片技术领域,具体涉及一种石油钻头用金刚石复合片烧结工艺。
背景技术
金刚石复合片是采用金刚石微粉与硬质合金基片在超高压高温条件下烧结而成,既具有金刚石的高硬度、高耐磨性与导热性,又具有硬质合金的强度与抗冲击韧性,是制造切削刀具、钻井钻头及其他耐磨工具的理想材料。
金刚石复合片,又称金刚石与硬质合金复合材料,其是由0.5-1.0mm厚的金刚石与几毫米厚的WC/Co(碳化钨/钴)硬质合金衬底在高温高压下烧结而成的。这种材料具有金刚石的硬度与耐磨性,又由于硬质合金衬底的存在而具有优越的耐冲击性,是一种优良的复合材料。它被广泛地应用于制造石油钻头、地质钻头和切削工具。
金刚石复合片中金刚石的晶粒尺寸对产品性能有着重要的影响,其晶粒越小,其冲击韧性越好,同时可以兼具硬度、耐磨性,特别适合对材料的精密/超精密加工。例如晶粒尺寸小于1μm、显微结构均匀的金刚石聚晶在做切削工具或拉丝模时具有优异的性能。
在现有技术金刚石复合片烧结工艺中,钴作为金刚石向石墨转化的触媒,影响产品的耐热性;也容易出现整体脱层现象。
发明内容
本发明的目的在于克服现有技术的不足,提供一种石油钻头用金刚石复合片烧结工艺。
本发明的目的是通过以下技术方案来实现的:
一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:
S1原料预组装:将喷涂有结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1400-1450℃、压力为5.0GPa的高压烧结合成室中烧结4-6min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.2-0.3mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用强酸浸泡法脱结合剂,清水清洗2-3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1400-1450℃、压力为5.6GPa的高压烧结合成室中烧结6-8min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
金刚石复合片烧结工艺中采用两次烧结,使产品性能大幅提高;通过增加金刚石颗粒间碳碳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35%以上,复合片的磨损程度减少约35%以上。
金刚石复合片一次烧结的温度和压力控制在1400-1450℃、5.0GPa,处于金刚石稳定区,烧结时间短,金刚石表面不会石墨化;二次烧结过程中提高烧结压力,使产品性能大幅提高。
进一步地,所述S1步骤中结合剂的喷涂厚度为0.01-0.02mm。
进一步地,所述结合剂中钴含量为20-30%。
进一步地,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
进一步地,所述碳化钨/钴硬质合金基体中钴含量为10-15%。
结合剂中钴含量为20-30%,碳化钨/钴硬质合金基体中钴含量为10-15%,在结合剂中添加部分钴,避免钴只能从碳化钨/钴硬质合金基体中扩散出来从而造成产品性能化不均匀。
进一步地,所述S4步骤中强酸为王水。
进一步地,所述S4步骤中高温炉的烘干温度为140-160℃,烘干时间为3h以上。
本发明的有益效果是:
1.金刚石复合片烧结工艺中采用两次烧结,使产品性能大幅提高;通过增加金刚石颗粒间碳碳键合程度及降低金刚石层的含钴量来提高产品的耐磨性,检测结果表明:同类产品的耐磨性提高35%以上,复合片的磨损程度减少约35%以上;
2.金刚石复合片一次烧结的温度和压力控制在1400-1450℃、5.0GPa,处于金刚石稳定区,烧结时间短,金刚石表面不会石墨化;二次烧结过程中提高烧结压力,使产品性能大幅提高;
3.结合剂中钴含量为20-30%,碳化钨/钴硬质合金基体中钴含量为10-15%,在结合剂中添加部分钴,避免钴只能从碳化钨/钴硬质合金基体中扩散出来从而造成产品性能化不均匀。
具体实施方式
下面结合具体实施例进一步详细描述本发明的技术方案,但本发明的保护范围不局限于以下所述。
实施例1
一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:
S1原料预组装:将喷涂有0.01mm的结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1400℃、压力为5.0GPa的高压烧结合成室中烧结4min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.2mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用王水浸泡法脱结合剂,清水清洗2次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1400℃、压力为5.6GPa的高压烧结合成室中烧结6min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
具体地,所述结合剂中钴含量为20%。
具体地,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
具体地,所述碳化钨/钴硬质合金基体中钴含量为10%。
具体地,所述S4步骤中高温炉的烘干温度为140℃,烘干时间为3h以上。
将实施例1制备得到的金刚石复合片用于PDC钻头上,使用后进行跟踪,跟踪样本数为6,未发现掉齿、崩刃等非正常磨损现象,复合片的磨损明显减少,磨损面积约减少35%以上。
实施例2
一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:
S1原料预组装:将喷涂有0.02mm的结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1420℃、压力为5.0GPa的高压烧结合成室中烧结6min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.3mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用王水浸泡法脱结合剂,清水清洗3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1420℃、压力为5.6GPa的高压烧结合成室中烧结8min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
具体地,所述结合剂中钴含量为25%。
具体地,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
具体地,所述碳化钨/钴硬质合金基体中钴含量为12%。
具体地,所述S4步骤中高温炉的烘干温度为150℃,烘干时间为3h以上。
将实施例2制备得到的金刚石复合片用于PDC钻头上,使用后进行跟踪,跟踪样本数为6,未发现掉齿、崩刃等非正常磨损现象,复合片的磨损明显减少,磨损面积约减少40%以上。
实施例3
一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:
S1原料预组装:将喷涂有0.02mm的结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1450℃、压力为5.0GPa的高压烧结合成室中烧结5min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.3mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用王水浸泡法脱结合剂,清水清洗3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1450℃、压力为5.6GPa的高压烧结合成室中烧结7min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
具体地,所述结合剂中钴含量为30%。
具体地,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
具体地,所述碳化钨/钴硬质合金基体中钴含量为15%。
具体地,所述S4步骤中高温炉的烘干温度为160℃,烘干时间为3h以上。
将实施例3制备得到的金刚石复合片用于PDC钻头上,使用后进行跟踪,跟踪样本数为4,未发现掉齿、崩刃等非正常磨损现象,复合片的磨损明显减少,磨损面积约减少38%以上。
实施例4
一种石油钻头用金刚石复合片烧结工艺,包括如下步骤:
S1原料预组装:将喷涂有0.02mm的结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1450℃、压力为5.0GPa的高压烧结合成室中烧结4min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.2mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用王水浸泡法脱结合剂,清水清洗3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1450℃、压力为5.6GPa的高压烧结合成室中烧结6min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
具体地,所述结合剂中钴含量为25%。
具体地,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
具体地,所述碳化钨/钴硬质合金基体中钴含量为15%。
具体地,所述S4步骤中高温炉的烘干温度为150℃,烘干时间为3h以上。
将实施例4制备得到的金刚石复合片用于PDC钻头上,使用后进行跟踪,跟踪样本数为4,未发现掉齿、崩刃等非正常磨损现象,复合片的磨损明显减少,磨损面积约减少40%以上。
以上所述仅是本发明的优选实施方式,应当理解本发明并非局限于本文所披露的形式,不应看作是对其他实施例的排除,而可用于各种其他组合、修改和环境,并能够在本文所述构想范围内,通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围,则都应在本发明所附权利要求的保护范围内。
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,包括如下步骤:
S1原料预组装:将喷涂有结合剂的金刚石粉料与硬质合金基体I装在屏蔽杯中形成组装件,待用;
S2金刚石复合片一次烧结:将S1步骤中的组装件送入高压烧结合成室中,在温度为1400-1450℃、压力为5.0GPa的高压烧结合成室中烧结4-6min,去掉硬质合金基体I得到金刚石复合片粗成品待用;
S3粗成品加工:将金刚石复合片粗成品通过陶瓷砂轮粗磨,再通过树脂砂轮精磨使其厚度与成品要求相同,外径尺寸比成品要求大0.2-0.3mm;
S4金刚石复合片二次烧结:将金刚石复合片粗成品采用强酸浸泡法脱结合剂,清水清洗2-3次后,在高温炉中高温烘干,再与硬质合金基体II装在屏蔽杯中形成组装件送入高压烧结合成室中,在温度为1400-1450℃、压力为5.6GPa的高压烧结合成室中烧结6-8min,将金刚石复合片二次烧结得到成品之后再次加工至成品要求尺寸。
2.根据权利要求1所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述S1步骤中结合剂的喷涂厚度为0.01-0.02mm。
3.根据权利要求1或2所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述结合剂中钴含量为20-30%。
4.根据权利要求1所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述S2步骤中硬质合金基体I和硬质合金基体II均为碳化钨/钴硬质合金基体。
5.根据权利要求4所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述碳化钨/钴硬质合金基体中钴含量为10-15%。
6.根据权利要求1所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述S4步骤中强酸为王水。
7.根据权利要求1所述的一种石油钻头用金刚石复合片烧结工艺,其特征在于,所述S4步骤中高温炉的烘干温度为140-160℃,烘干时间为3h以上。
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