US20100051351A1 - Intermetallic bonded diamond (ibd) cutting elements - Google Patents

Intermetallic bonded diamond (ibd) cutting elements Download PDF

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Publication number
US20100051351A1
US20100051351A1 US12/522,352 US52235208A US2010051351A1 US 20100051351 A1 US20100051351 A1 US 20100051351A1 US 52235208 A US52235208 A US 52235208A US 2010051351 A1 US2010051351 A1 US 2010051351A1
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United States
Prior art keywords
substrate
interface region
bonding interface
shape
cutting element
Prior art date
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Abandoned
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US12/522,352
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English (en)
Inventor
William W. King
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Halliburton Energy Services Inc
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Halliburton Energy Services Inc
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Priority to US12/522,352 priority Critical patent/US20100051351A1/en
Assigned to HALLIBURTON ENERGY SERVICES, INC. reassignment HALLIBURTON ENERGY SERVICES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KING, WILLIAM W.
Assigned to HALLIBURTON ENERGY SERVICES, INC. reassignment HALLIBURTON ENERGY SERVICES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KING, WILLIAM W.
Publication of US20100051351A1 publication Critical patent/US20100051351A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP 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
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • E21B10/55—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits with preformed cutting elements
    • 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
    • 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
    • B22F7/08—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 with one or more parts not made from powder
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2204/00—End product comprising different layers, coatings or parts of cermet
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/36—Percussion drill bits
    • E21B10/38—Percussion drill bits characterised by conduits or nozzles for drilling fluids

Definitions

  • the present invention is related to cutting elements, and more particularly, to intermetallic bonded diamond (IBD) cutting elements having various shapes and configurations.
  • IBD intermetallic bonded diamond
  • Polycrystalline Diamond Compact (PDC) cutters have become the industry standard for oil and gas drilling, especially in soft, medium soft and medium formation types, IADC codes 1,4,5, and 6 type rock. Since the early days of PDC cutter and drill bit development commencing in the mid 1970's cutter makers and bit designers have proposed complex cutter shapes that could preferentially shear adjacent portions of a target formation and/or guide movement of cuttings or sheared formation materials in a way that would enhance bit cleaning.
  • U.S. Pat. No. 4,883,132 to Tibbitts discloses conventional “flat faced” PDC cutters in conjunction with a body design that carries large void areas in the bit blades. The concept was to allow for reverse jetting of shale cuttings through the blade.
  • Intermetallic Bonded Diamond (IBD) is discussed in US Patent Application Publication 2006/0280638 published on Dec. 14, 2006 and International Publication Number WO 2006/107628 published by WIPO on Oct. 12, 2006.
  • a cutting element may include a substrate having a bonding interface region and an intermetallic bonded diamond (IBD) element bonded to the bonding interface region of the substrate.
  • the bonding interface region of the substrate may have a non-axi-symmetrical shape and/or may be symmetrical about only one plane or about zero planes.
  • the bonding interface region of the substrate may have a shape of a tube, a beveled tube, a tube with one or more internal support structures, a scoop, a plow, a concave shape, a honeycombed shape, or other irregular or complex shape.
  • One aspect of the present disclosure may include forming cutting elements and/or inserts for fixed cutter drill bit with configurations that were previously difficult and sometimes not even possible to manufacture.
  • One of the benefits of the present disclosure may include forming cutting elements with such configurations and the ability to survive repeated impact loads associated with drilling deep, high pressure and/or high temperature wellbores.
  • Forming cutting elements or inserts with an axial bore extending through each cutting element or insert may allow enhanced penetration of an adjacent formation and enhanced removal of formation materials from the bottom of a wellbore. Forming an axial bore in a cutting element or insert in accordance with teachings of the present disclosure may allow improved cooling of the cutting element or insert.
  • FIGS. 1A and 1B illustrate example tubular tungsten carbide substrates for an IBD cutter.
  • FIGS. 2A-2C illustrate an example tubular tungsten carbide IBD cutting element coupled to a blade of a cutting tool, according to one embodiment.
  • FIGS. 3A and 3B illustrate an example beveled tubular tungsten carbide IBD cutting element coupled to a blade of a cutting tool, according to one embodiment.
  • FIGS. 4A and 4B illustrate an example plow shaped IBD cutting element coupled to the substrate, according to one embodiment.
  • FIGS. 5A and 5B illustrate an example IBD cutting element for use on a Hedge Hog type impregnated bit layout, according to one embodiment.
  • cutting element and “cutting elements” may be used in this application to include various types of compacts, inserts, milled teeth and welded compacts satisfactory for use with roller cone drill bits.
  • IBD Intermetallic Bonded Diamond
  • the present disclosure embodies cutting elements that take advantage of the IBD technology to produce practical, enabled, and useful wear resistant cutters of non-symmetrical, irregular, or relatively complex geometry for drill bits and down hole tools such as coring equipment and reamers, for example.
  • a cutting element may include a substrate having a bonding interface region, and an intermetallic bonded diamond (IBD) element bonded to the bonding interface region of the substrate.
  • the bonding interface region may comprise the entire substrate or a portion of the substrate.
  • the substrate may be formed from tungsten carbide, steel, or any other suitable material(s).
  • the IBD element may be bonded to the bonding interface region of the substrate by hot isostatic pressing (HIP), or in any other suitable manner.
  • HIP hot isostatic pressing
  • an IBD cutter may be formed having a non-symmetrical, irregular, or relatively complex geometry.
  • the bonding interface region of the substrate has a non-axi-symmetrical shape.
  • the bonding interface region may be symmetrical about only one plane, or not symmetrical about any plane.
  • the bonding interface region of the substrate may include a hole extending partially or completely through the substrate.
  • the bonding interface region of the substrate may have the shape of a tube (see, e.g., FIGS. 1 and 2 ), a beveled tube (see, e.g., FIG. 3 ), a tube with one or more internal support structures, a scoop, a plow (see, e.g., FIG. 4 ), a concave shape, a honeycombed shape, or any other suitable shape.
  • the bonding interface region of the substrate has a plow shape with an included angle of less than or equal to about 100 degrees.
  • IBD when coupled with tubular, scoop shaped, plow shaped, concave, honeycomb, or other irregular or relatively complex-shaped substrates (e.g., as discussed above) may allow the bit designer unprecedented freedom in cuttings management, cutter cooling, and/or abrasives evacuation leading to enhanced drill bit performance.
  • Bits can be designed that replace traditional PDC cutters with IBD cutters of a more efficient geometry.
  • IBD cutters may also allow the bit designer to employ mixes or patterns of IBD cutters with traditional PDC cutters or with traditional tungsten carbide inserts to achieve positive effects for specific rock types. Some of these effects may include, e.g., kerfing, impact management and mitigation, cutting force management, secondary cutting, enhanced gage protection, and/or bi-modal deployments for transitional drilling.
  • IBD cutters may be deployed for hard rock drilling, IADC rock codes 3,7, and 8 by configuring the IBD cutters to replace traditional impregnated segments, impregnated posts, or impregnated discs. IBD cutters may also be used in conjunction with these traditional impregnated diamond cutting elements to achieve synergistic effects, e.g., kerfing, secondary cutting, impact management, and/or transitional drilling benefits.
  • Some fixed cutter drill bits may be manufactured with a bit body (not expressly shown) having one end operable for attachment to a drill string.
  • the drill string may apply weight to the drill bit, sometimes referred to as “weight on bit” or WOB.
  • WOB weight on bit
  • the drill string may also rotate the drill bit (revolutions per minute or RPM) relative to a bit rotational axis extending through the bit body.
  • RPM repetitions per minute
  • the drill string may also supply drilling fluid to a cavity formed within the bit body.
  • a plurality of blades may be disposed on and extend from the bit body. Exterior portions of the blades and associated cutters may form a bit face profile. For some applications the blades may cooperate with each other to form a bit face profile having an inverted, generally cone shaped configuration opposite from the one end of the bit body.
  • one or more tungsten carbide substrates maybe formed with one or more layers of IBD disposed thereon.
  • Each substrate may include a respective post sized to be received within a respective opening formed in the bit body proximate the inverted cone shaped portion of the bit face profile.
  • an opening may be formed in the bit body proximate the bit rotational axis.
  • one or more tungsten carbide (WC) blades or plates covered with IBD may be held in place by brazing the posts into respective holes formed proximate the bit rotational axis. Such blades or plates may make the layout and manufacturing of the drill bit center more efficient than current practice even with standard cylindrical PDC cutters.
  • IBD cutters may offer an attractive, cost effective replacement for dome PDC for use in roller cone bit primary cutting structures, gage row cutting structures, in shirttail protection, and/or in various other structures or applications.
  • IBD materials may be directly brazed to steel.
  • cylinders made entirely of IBD can be used as direct replacements in steel body or matrix PDC bit designs without the need for a WC substrate.
  • Such a configuration may dramatically increase the total deployed diamond carat weight for a given bit configuration compared to using conventional PDC. It may also allow for fewer blades on a bit for a given carat weight to increase drill bit penetration rate for a given weight on bit.
  • IBD may carry diamond up to 700 microns in size.
  • the coarsest grain size diamond typically used in PDC cutters is about 60 microns. Larger size diamonds generally allow for more aggressive angular cutting edges. This attribute may aid in extending typical applications for IBD drill bits to harder rock even when the cutters are deployed in configurations similar to current PDC type drill bit products.
  • IBD cutters may not suffer from the deleterious effects usually resulting from the frictional contact of diamond or PDC with ferrous materials.
  • Technical reports made by Southern Illinois University indicate that an IBD sample was run against a cast iron target for 9 hours with minimum wear or damage to the IBD.
  • the principles of the present disclosure may be used to improve the design and implementation of casing milling, casing window, and drill-out bits. It may also make possible the deployment of a combination mill out and drill ahead bit that does not suffer undue amounts of wear and short service life due to the typical damage incurred through ferrous contact during the window milling operation.
  • FIGS. 1A-5E Preferred embodiments of the invention may be better understood by reference to FIGS. 1A-5E .
  • FIGS. 1A and 1B illustrate example tubular tungsten carbide substrates for an IBD cutter.
  • FIGS. 2A-2C illustrate an example tungsten carbide tubular IBD cutting element coupled to a blade of a cutting tool, according to one embodiment.
  • FIG. 2A is a side cross-sectional view illustrating a tubular tungsten carbide (WC) substrate coupled to a steel blade.
  • An IBD element is bonded (e.g., by hot isostatic pressing) to an interface region of the substrate.
  • FIG. 2B illustrates a partial three-dimensional view of the tubular cutting element and steel blade.
  • FIG. 2C illustrates an end view of an alternative embodiment in which a support structure is positioned within the tubular cutting element, e.g., to provide structural support to the cutting element.
  • One or more such structural supports having any suitable configuration may be included to provide additional structural support to the cutting element.
  • FIGS. 3A and 3B illustrate an example beveled tubular tungsten carbide IBD cutting element coupled to a blade of a cutting tool, according to one embodiment.
  • FIG. 3A is a side cross-sectional view illustrating a beveled tubular tungsten carbide (WC) substrate coupled to a steel blade.
  • An IBD element is bonded (e.g., by hot isostatic pressing) to an interface region of the substrate.
  • FIG. 3B illustrates a partial three-dimensional view of the beveled tubular cutting element and steel blade.
  • one or more structural supports may be included to provide additional structural support to the cutting element, e.g., as discussed above regarding FIG. 2C .
  • FIGS. 4A and 4B illustrate an example plow shaped IBD cutting element coupled, according to one embodiment.
  • FIG. 4A is a cross-sectional view illustrating a plow shaped substrate having an IBD element bonded to an interface region of the substrate.
  • FIG. 4B illustrates a three-dimensional view of the plow shaped cutting element.
  • FIGS. 5A and 5B illustrate an example IBD cutting element for use on a Hedge Hog type impregnated bit layout, according to one embodiment.
  • FIG. 5A is a side view illustrating a substrate (e.g., tungsten carbide or steel post) having an IBD element bonded to an interface region of the substrate
  • FIG. 5B is an end view of the cutting element.
  • a substrate e.g., tungsten carbide or steel post
US12/522,352 2007-01-08 2008-01-07 Intermetallic bonded diamond (ibd) cutting elements Abandoned US20100051351A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/522,352 US20100051351A1 (en) 2007-01-08 2008-01-07 Intermetallic bonded diamond (ibd) cutting elements

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US88388407P 2007-01-08 2007-01-08
PCT/US2008/050395 WO2008086280A1 (fr) 2007-01-08 2008-01-07 Éléments de découpe a diamant intermétallique lié
US12/522,352 US20100051351A1 (en) 2007-01-08 2008-01-07 Intermetallic bonded diamond (ibd) cutting elements

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US20100051351A1 true US20100051351A1 (en) 2010-03-04

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US (1) US20100051351A1 (fr)
CN (1) CN101611212A (fr)
AU (1) AU2008204966A1 (fr)
CA (1) CA2674828A1 (fr)
GB (1) GB2459396A (fr)
WO (1) WO2008086280A1 (fr)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9194189B2 (en) 2011-09-19 2015-11-24 Baker Hughes Incorporated Methods of forming a cutting element for an earth-boring tool, a related cutting element, and an earth-boring tool including such a cutting element
CN105499816A (zh) * 2016-02-02 2016-04-20 中国科学院等离子体物理研究所 一种适用于聚变堆第一壁部件钨和钢连接的制造工艺

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4380471A (en) * 1981-01-05 1983-04-19 General Electric Company Polycrystalline diamond and cemented carbide substrate and synthesizing process therefor
US4593776A (en) * 1984-03-28 1986-06-10 Smith International, Inc. Rock bits having metallurgically bonded cutter inserts
US4695321A (en) * 1985-06-21 1987-09-22 New Mexico Tech Research Foundation Dynamic compaction of composite materials containing diamond
US4696354A (en) * 1986-06-30 1987-09-29 Hughes Tool Company - Usa Drilling bit with full release void areas
US6145608A (en) * 1993-11-22 2000-11-14 Baker Hughes Incorporated Superhard cutting structure having reduced surface roughness and bit for subterranean drilling so equipped
US20040159471A1 (en) * 2003-02-12 2004-08-19 Azar Michael George Novel bits and cutting structures
US6845828B2 (en) * 2000-08-04 2005-01-25 Halliburton Energy Svcs Inc. Shaped cutting-grade inserts with transitionless diamond-enhanced surface layer
US20060032677A1 (en) * 2003-02-12 2006-02-16 Smith International, Inc. Novel bits and cutting structures
US20060074616A1 (en) * 2004-03-02 2006-04-06 Halliburton Energy Services, Inc. Roller cone drill bits with optimized cutting zones, load zones, stress zones and wear zones for increased drilling life and methods
US20060280638A1 (en) * 2005-04-01 2006-12-14 Wittmer Dale E Intermetallic bonded diamond composite composition and methods of forming articles from same

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4380471A (en) * 1981-01-05 1983-04-19 General Electric Company Polycrystalline diamond and cemented carbide substrate and synthesizing process therefor
US4593776A (en) * 1984-03-28 1986-06-10 Smith International, Inc. Rock bits having metallurgically bonded cutter inserts
US4695321A (en) * 1985-06-21 1987-09-22 New Mexico Tech Research Foundation Dynamic compaction of composite materials containing diamond
US4696354A (en) * 1986-06-30 1987-09-29 Hughes Tool Company - Usa Drilling bit with full release void areas
US6145608A (en) * 1993-11-22 2000-11-14 Baker Hughes Incorporated Superhard cutting structure having reduced surface roughness and bit for subterranean drilling so equipped
US6845828B2 (en) * 2000-08-04 2005-01-25 Halliburton Energy Svcs Inc. Shaped cutting-grade inserts with transitionless diamond-enhanced surface layer
US20040159471A1 (en) * 2003-02-12 2004-08-19 Azar Michael George Novel bits and cutting structures
US20060032677A1 (en) * 2003-02-12 2006-02-16 Smith International, Inc. Novel bits and cutting structures
US20060074616A1 (en) * 2004-03-02 2006-04-06 Halliburton Energy Services, Inc. Roller cone drill bits with optimized cutting zones, load zones, stress zones and wear zones for increased drilling life and methods
US20060280638A1 (en) * 2005-04-01 2006-12-14 Wittmer Dale E Intermetallic bonded diamond composite composition and methods of forming articles from same

Also Published As

Publication number Publication date
AU2008204966A1 (en) 2008-07-17
CN101611212A (zh) 2009-12-23
GB2459396A (en) 2009-10-28
CA2674828A1 (fr) 2008-07-17
GB0912847D0 (en) 2009-08-26
WO2008086280A1 (fr) 2008-07-17

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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KING, WILLIAM W.;REEL/FRAME:020327/0578

Effective date: 20071231

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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KING, WILLIAM W.;REEL/FRAME:022923/0075

Effective date: 20071231

STCB Information on status: application discontinuation

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