WO2003083148A1 - Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production - Google Patents

Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production Download PDF

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Publication number
WO2003083148A1
WO2003083148A1 PCT/GB2003/000642 GB0300642W WO03083148A1 WO 2003083148 A1 WO2003083148 A1 WO 2003083148A1 GB 0300642 W GB0300642 W GB 0300642W WO 03083148 A1 WO03083148 A1 WO 03083148A1
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WO
WIPO (PCT)
Prior art keywords
crystals
exposed
diamond
pcd
binder
Prior art date
Application number
PCT/GB2003/000642
Other languages
English (en)
Inventor
Nigel Dennis Griffin
Peter Raymond Hughes
Original Assignee
Camco International (Uk) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Camco International (Uk) Limited filed Critical Camco International (Uk) Limited
Priority to AU2003205885A priority Critical patent/AU2003205885A1/en
Priority to CA002445301A priority patent/CA2445301A1/fr
Priority to EP03702763A priority patent/EP1488019A1/fr
Publication of WO2003083148A1 publication Critical patent/WO2003083148A1/fr

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Classifications

    • 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
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C04B35/645—Pressure sintering
    • 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
    • E21B10/56—Button-type 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/40—Metallic constituents or additives not added as binding phase
    • C04B2235/405—Iron group metals
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/422—Carbon
    • C04B2235/427—Diamond
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5463—Particle size distributions
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/78—Grain sizes and shapes, product microstructures, e.g. acicular grains, equiaxed grains, platelet-structures

Definitions

  • the invention relates to superhard polycrystalline material elements for
  • the invention particularly relates to polycrystalline
  • PCD polycrystalline diamond-like
  • PCD elements are known, for the purposes of this specification, as PCD elements.
  • PCD elements are formed from a mix of materials processed under high-temperature and high-pressure into a polycrystalline
  • PCD element A well known, manufactured form of PCD element is a two-layer or multi ⁇
  • element may be in the form of a circular or part-circular tablet, or may be formed
  • PCD elements of this type may be used in almost any application where a hard wear and erosion resistant material
  • the substrate of the PCD element may be brazed to a carrier, often
  • boring bits when received in a socket of the drill bit, or when fixed to a post in a
  • PCD elements are typically called
  • PDC polycrystalline diamond cutters
  • PCD elements are most often formed by sintering diamond powder with a
  • diamond powder is used in one common process for manufacturing PCD elements.
  • the assembly is then subjected to very high temperature and pressure in
  • a less polished finish may be acceptable, in which case the machining operation may be performed with, say,
  • the working surface of the PCD during the machining operation is to cause
  • finish working surface is of very good flatness, but will still
  • microfractures very small fractures, referred to herein as microfractures, in the diamond crystals which are exposed at the working
  • crystals may also be subject to other damage during the
  • binder-catalyzing material any group NIII element, including cobalt, nickel,
  • carbonates such as powdery carbonates of Mg, Ca, Sr, and Ba are used as the
  • the present invention provides a superhard polycrystalline diamond or
  • binder-catalyzing material in a high-temperature, high-pressure (HTHP) process.
  • HTHP high-temperature, high-pressure
  • the diamond material is formed and integrally bonded to a substrate containing
  • the PCD element may be used in a wide range of applications.
  • the PCD element may find applications in downhole equipment
  • the PCD element may
  • element may be used in the machining of abrasive materials, for example
  • abrasive engineering materials such as stone, asphalt and the like.
  • PCD element comprising a body including matrix of crystals of a superhard
  • the body having a surface, a plurality of the crystals being exposed at
  • the PCD element conveniently comprises a substrate having a front
  • superhard material comprising a matrix of crystals.
  • the invention also relates to a PCD element which comprises a substrate
  • the table of superhard material comprising a matrix of
  • the table having a surface at which a plurality of the crystals are
  • portion of the surface being substantially free of microfractures.
  • the exposed parts of the exposed crystals are preferably of rounded form.
  • a PCD element comprising: sintering diamond powder with a binder-catalyst material in a high pressure
  • the step of treating the body may include performing a machining
  • the step of treating the body may include performing a machiriing operation on the
  • crystals can undergo limited plastic flow and thereby deform to generate a
  • the deformation is normally revealed by the presence of 'deformation twinning'
  • the machining operation may be an ultra-high speed grinding operation.
  • the step of treating the body may include performing a
  • thermochemical treatment on the body may involve the treatment of the working surface of the body with at least one
  • Crystals treated so as to be of rounded form are substantially free of
  • Figure 1 is a typical PCD element of the present invention.
  • Figure 2 is a micro-structural representation of part of the PCD element.
  • Figure 3 is a diagrammatic representation illustrating the crystal structure of
  • Figure 4 is a view similar to Figure 3 but illustrating the structure of a PCD in accordance with an embodiment of the invention.
  • Figure 5 is a typical PCD of the present invention shown as a cutting
  • Figure 6 is a perspective view of an insert used in machine tools utilizing
  • Figure 7 is a perspective view of a dome shaped PCD element suitable for
  • Figure 8 is a side view of a fixed cutter rotary drill bit using a PCD element
  • Figure 9 is a perspective view of a rolling cutter rotary drill bit using a PCD
  • Figure 10 is a section view of a wire drawing die having a PCD element of
  • Figure 11 is perspective view of a bearing having a PCD element of the
  • Figures 12 and 13 are front views of the mating parts of a valve having a
  • Figure 14 is a side view of an indentor having a PCD element of the present
  • Figure 15 is a partial section view of a punch having a PCD element of the
  • Figure 16 is perspective view of a measuring device having a PCD element
  • the PCD element 2 has a plurality of
  • the element 2 also has one or more
  • the element 2 is
  • a metallic substrate 6 typically tungsten carbide with a
  • cobalt binder material To be effective when used in an abrasive wear
  • the volume density of the diamond in the body 8 should be greater
  • the working surface 4 is any portion of the PCD body 8 which, in
  • the body 8 which may be exposed and/or used as a working surface.
  • any portion of any of the working surface 4 is, in and of itself, a
  • cleavage planes 61 are oriented in different directions
  • the present invention ranges from about 85% to about 99%.
  • volume density is achieved by using diamond crystals 60 with a range of particle
  • the diamond mixture may comprise 20% to 60% diamond crystals 60
  • the cleaning operation includes a finishing
  • the element 2 is treated to render the
  • the treatment comprises performing a machining operation, for
  • the surface temperature reached may be in excess of 2000°C.
  • Figure 4 is a diagrammatic view similar to Figure 3 illustrating the effect of
  • parts of the crystals 65 exposed at the working surfaces 4 are of rounded or
  • working surfaces 4 substantially free of microfractures and other surface defects
  • treatment operation could be performed on the element 2 using, for example, iron group elements or oxidizing compounds. Further, combinations of these
  • PCD element 2 of the present invention is as cutting elements 10, 50, 52 as
  • 10, 50, 52 may be a top working surface 70 and/or a peripheral working surface
  • the PCD cutting element 10 of Figure 5 is one that may be typically used in
  • the PCD cutting element 50 shown in Figure 7 may be shaped
  • This type of PCD cutting element 50 has an extended base 51 for
  • the PCD cutting element 52 of Figure 6 is adapted for use in a machining
  • the PCD cutting element 10 may be a preform cutting element 10 of a fixed
  • the PCD cutting element 10 has a body in the form of a circular
  • hard material such as cemented tungsten carbide or other metallic material.
  • the cutting element 10 is preformed and then typically bonded on a generally cylindrical carrier 34 which is also formed from cemented tungsten carbide, or
  • the PCD cutting element 10 may alternatively be attached directly to the blade.
  • the cylindrical carrier 34 is received within a correspondingly shaped
  • the carrier 34 will usually be brazed or shrink
  • the PCD cutting elements 10 may also be applied to the gauge region 36 of
  • bit 12 to provide a gauge reaming action as well as protecting the bit 12 from
  • the present invention is on a rolling cutter type drill bit 38, shown in Figure 9.
  • rolling cutter drill bit 38 typically has one or more truncated rolling cone cutters
  • cutting elements 50 may be mounted as one or more of a plurality of cutting
  • cutting elements 50 may be arranged along the leg 44 of the bit 38.
  • cutting element 50 has a body in the form of a facing table 35 of diamond or
  • this embodiment of the present invention is in the form of a domed surface 39
  • transitional layers between the facing table 35 and the substrate 37 to help more evenly distribute the stresses generated during fabrication, as is well known to
  • the rolling cutter drill bit 38 is rotated and weight is applied.
  • invention is in the form of a triangular, rectangular or other shaped material for
  • element 52 has a body in the form of a facing table 54 of diamond or diamond like material bonded to a less hard substrate 56 with working surfaces 70 and 72.
  • the cutting element 52 would then be cut into a plurality of smaller
  • the cutting element 52 may be attached to the insert
  • invention may also be used for other applications such as hollow dies, shown for
  • PCD elements 362 of the present invention may have PCD elements 362 of the present invention as
  • Punches 370 may have either or both dies 372, 374 made of
  • FIG 16 may be made of PCD elements of the present inventions.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Structural Engineering (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Earth Drilling (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

L'invention concerne un élément extra-dur à base de diamant polycristallin ou d'un matériau similaire à du diamant polycristallin, qui présente une meilleure résistance à l'usure. Dans la description de la présente invention, ces éléments sont désignés par la dénomination collective « éléments PCD ». Ces éléments sont constitués à partir d'un matériau catalyseur et liant, au cours d'un procédé haute température et haute pression (HTHP). Le matériau de diamant est formé et entièrement collé sur un substrat contenant le matériau catalyseur, au cours du procédé HTHP. Le corps en diamant ainsi formé présente une surface de travail sur laquelle sont exposées une pluralité de cristaux sensiblement exempts de microfractures. Les parties exposées de ces cristaux présentent une forme arrondie ou convexe.
PCT/GB2003/000642 2002-03-28 2003-02-13 Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production WO2003083148A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AU2003205885A AU2003205885A1 (en) 2002-03-28 2003-02-13 Polycrystalline material element with improved wear resistance and methods of manufacture thereof
CA002445301A CA2445301A1 (fr) 2002-03-28 2003-02-13 Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production
EP03702763A EP1488019A1 (fr) 2002-03-28 2003-02-13 Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US31915702P 2002-03-28 2002-03-28
US60/319,157 2002-03-28

Publications (1)

Publication Number Publication Date
WO2003083148A1 true WO2003083148A1 (fr) 2003-10-09

Family

ID=28675209

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2003/000642 WO2003083148A1 (fr) 2002-03-28 2003-02-13 Element a base d'un materiau polycristallin presentant une meilleure resistance a l'usure et ses procedes de production

Country Status (6)

Country Link
US (1) US20030183426A1 (fr)
EP (1) EP1488019A1 (fr)
AU (1) AU2003205885A1 (fr)
CA (1) CA2445301A1 (fr)
WO (1) WO2003083148A1 (fr)
ZA (1) ZA200308160B (fr)

Cited By (3)

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US7368079B2 (en) * 2003-12-09 2008-05-06 Smith International, Inc. Method for forming ultra hard sintered compacts using metallic peripheral structures in the sintering cell
US8512023B2 (en) 2011-01-12 2013-08-20 Us Synthetic Corporation Injection mold assembly including an injection mold cavity at least partially defined by a polycrystalline diamond material
US8702412B2 (en) 2011-01-12 2014-04-22 Us Synthetic Corporation Superhard components for injection molds

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Publication number Priority date Publication date Assignee Title
CA2837443C (fr) 2009-01-30 2015-09-29 Drilformance Technologies, Llc Trepan
SA110310235B1 (ar) 2009-03-31 2014-03-03 بيكر هوغيس انكوربوريتد طرق لترابط مناضد التقطيع مسبقة التشكيل بركائز عامل القطع وعامل القطع المكونة بهذه العمليات

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US20030183426A1 (en) 2003-10-02
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EP1488019A1 (fr) 2004-12-22
AU2003205885A1 (en) 2003-10-13

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