Patent application number | Description | Published |
20110031032 | DIAMOND TRANSITION LAYER CONSTRUCTION WITH IMPROVED THICKNESS RATIO - An insert for a drill bit may include a metallic carbide body; an outer layer of polycrystalline diamond material on the outermost end of the insert, the polycrystalline diamond material comprising a plurality of interconnected first diamond grains and a first binder material in interstitial regions between the interconnected first diamond grains; and at least two transition layers between the metallic carbide body and the outer layer, the at least two transition layers comprising: an outermost transition layer comprising a composite of second diamond grains, first metal carbide or carbonitride particles, and a second binder material; and an innermost transition layer comprising a composite of third diamond grains, second metal carbide or carbonitride particles, and a third binder material wherein a thickness of the outer layer is lesser than that of each of the at least two transition layers. | 02-10-2011 |
20110031033 | HIGHLY WEAR RESISTANT DIAMOND INSERT WITH IMPROVED TRANSITION STRUCTURE - An insert for a drill bit may include a metallic carbide body; an outer layer of polycrystalline diamond material on the outermost end of the insert, the polycrystalline diamond material comprising a plurality of interconnected first diamond grains and a first binder material in interstitial regions between the interconnected first diamond grains; and at least one transition layer between the metallic carbide body and the outer layer, the at least one transition layer comprising a composite of second diamond grains, first metal carbide particles, and a second binder material, wherein the second diamond grains have a larger grain size than the first diamond grains. | 02-10-2011 |
20110031037 | POLYCRYSTALLINE DIAMOND MATERIAL WITH HIGH TOUGHNESS AND HIGH WEAR RESISTANCE - A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 80% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 50% by weight of the plurality of metallic phases is disclosed. | 02-10-2011 |
20110042147 | FUNCTIONALLY GRADED POLYCRYSTALLINE DIAMOND INSERT - PCD inserts comprise a PCD body having multiple FG-PCD regions with decreasing diamond content moving from a body outer surface to a metallic substrate. The diamond content changes in gradient fashion by changing metal binder content. A region adjacent the outer surface comprises 5 to 20 percent by weight metal binder, and a region remote from the surface comprises 15 to 40 percent by weight metal binder. One or more transition regions are interposed between the PCD body and substrate. The transition region comprises PCD, binder metal, and a carbide, comprises a metal binder content less than that present in the PCD body region positioned next to it. | 02-24-2011 |
20110239767 | Acoustic Emission Toughness Testing Having Smaller Noise Ratio - A method, system and apparatus for testing properties of a hard component. The apparatus includes a holder, a component, an indenter, a sensor holder, and an acoustic sensor. The holder includes a first end and a second end opposite the first end. The first end defines a first cavity extending towards the second end. The component is positioned in the first cavity. The indenter is positioned adjacent to a portion of the component and applies a load onto the component. The sensor holder includes an upper portion, a lower portion, and a second cavity therein. The upper portion is coupled to the second end. The sensor is positioned within the second cavity. In some embodiments, the apparatus includes a rod coupled to the lower portion. The rod has a lower acoustic impedance than the sensor holder, thereby allowing sound waves to pass through the sensor holder and not be reflected back into the sensor. | 10-06-2011 |
20110286304 | Downhole Acoustic Emission Formation Sampling - A method, system and apparatus for testing properties of a rock formation surrounding a wellbore in situ. The apparatus includes a tool body, one or more indenters, and one or more acoustic sensors. The body includes an outer surface that defines one or more cavities therein. Each cavity extends into the body. Each indenter is positioned within a corresponding cavity and is positionable into an operating position and a non-operating position. The acoustic sensor is positioned within the cavity and adjacent to the indenter. The indenter is positioned at least partially beyond the outer surface when in the operating position. The acoustic sensor senses one or more acoustic events occurring when the indenter is in the operating position. The apparatus is inserted into the wellbore. Once inserted, the indenter applies a load onto the rock formation causing cracking and the sensor receives the generated acoustic transmissions. The transmissions are analyzed. | 11-24-2011 |
20130001100 | Ultrasound Assisted Electrochemical Catalyst Removal For Superhard Materials - A catalyst removal apparatus and method for removing catalyst from a polycrystalline cutter. The cutter includes a substrate and a cutting table. The apparatus includes a tank forming a cavity therein, an electrolyte fluid occupying the cavity, the cutter, a covering surrounding at least a portion of the cutter's sidewall and extending from at least the substrate's top surface towards the bottom surface, a cathode submersed within the fluid, and a power source. The cutting table is submersed within the fluid and positioned near the cathode, thereby forming a gap therebetween. The power source is coupled to the cutter and the cathode and electrolyzes the fluid to react with the catalyst in the cutting table to produce a salt. The salt dissolves in the fluid and is removed from the cutter. Optionally, a transducer is sonically coupled to the cutter and emits vibrations to remove salt from the cutting table. | 01-03-2013 |
20130067824 | ATTACHMENT OF THERMALLY STABLE POLYCRYSTALLINE TO A SUBSTRATE AND COMPACTS CONSTRUCTED - A method and apparatus for fabricating a cutter. The method includes obtaining a compact including a cutting surface, a bonding interface, and a sidewall extending from the perimeter of the cutting surface to the perimeter of the bonding interface. The method includes obtaining a substrate including a bonding surface, a mounting surface, and a substrate sidewall extending from the perimeter of the bonding surface to the perimeter of the mounting surface. At least a portion of the bonding interface is positioned adjacent at least a portion of the bonding surface. At least one of the substrate and the compact is rotated to produce a rotational differential therebetween. The temperature is increased on at least the bonding surface to a first temperature. The compact is coupled to the substrate to form the cutter. The apparatus includes a first holder coupled to the compact and a second holder coupled to the substrate. | 03-21-2013 |
20130067985 | THERMAL-MECHANICAL WEAR TESTING FOR PDC SHEAR CUTTERS - A method and apparatus for testing the abrasive wear resistance of PDC cutters or other superhard materials. The method includes obtaining a first cutter having a first substrate and a first cutting table coupled thereto and obtaining a second cutter having a second substrate and a second cutting table coupled thereto. The method also includes positioning a surface of the first cutting table in contact with a surface of the second cutting table. The method also includes rotating at least one of the first cutters and the second cutters where at least a portion of the first and/or second cutting tables is removed. The method includes determining the amount of first and/or second cutting table removed. The apparatus includes a first holder coupled to the first cutter and a second holder coupled to the second cutter, where at least one holder rotates circumferentially. | 03-21-2013 |
20130166214 | Acoustic Emission Toughness Testing For PDC, PCBN, Or Other Hard Or Superhard Material Inserts - An acoustic emissions testing device includes a test cutter including a first surface, an acoustic sensor, an indenter coupled to the first surface, and a load. The load is exerted on the indenter, which transfers the load to the first surface. The acoustic sensor is communicably coupled to the test cutter and detects one or more acoustic events occurring therein. An acoustic emissions testing system includes a data recorder coupled to the testing device. The data recorder records the data from testing device. Based upon the data received, the toughness of the test cutter is objectively determined and can be ranked comparatively to the toughness of other test cutters. The load is ramped up to a peak load, held for a period of time, and then ramped down. Cutters from the same cutter type as the test cutters have similar toughness. | 06-27-2013 |
20130213433 | Method to Improve the Performance of a Leached Cutter - A cleaned component having a polycrystalline structure, a method and apparatus for cleaning a leached component to form the cleaned component, and a method for determining the effectiveness of cleaning the leached component. The cleaned component includes a leached layer that has at least a portion of by-product materials removed. The by-product materials were deposited into the leached layer during a leaching process that formed the leached layer. The apparatus and method for cleaning includes a tank, a cleaning fluid placed within the tank, and at least a portion of the leached layer immersed into the cleaning fluid. Optionally, a transducer emits ultrasonic waves into the leached layer. The method for determining the effectiveness of cleaning includes cleaning the leached component to form the cleaned component, measuring one or more capacitance values of the cleaned component, repeating the cleaning and the measuring until achieving a stable lower limit capacitance value. | 08-22-2013 |
20130213720 | Method And Apparatus To Improve The Performance Of A Leached Cutter - A cleaned component having a polycrystalline structure, a method and apparatus for cleaning a leached component to form the cleaned component, and a method for determining the effectiveness of cleaning the leached component. The cleaned component includes a leached layer that has at least a portion of by-product materials removed. The by-product materials were deposited into the leached layer during a leaching process that formed the leached layer. The apparatus and method for cleaning includes a tank, a cleaning fluid placed within the tank, and at least a portion of the leached layer immersed into the cleaning fluid. Optionally, a transducer emits ultrasonic waves into the leached layer. The method for determining the effectiveness of cleaning includes cleaning the leached component to form the cleaned component, measuring one or more capacitance values of the cleaned component, repeating the cleaning and the measuring until achieving a stable lower limit capacitance value. | 08-22-2013 |
20130214768 | Use of Eddy Currents to Analyze Polycrystalline Diamond - A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using eddy current measurements. The apparatus includes an eddy current measuring device having at least one terminal, a leached component comprising a polycrystalline structure, a first wire, and a probe. The leached component includes a cutting surface and an opposing second surface. A portion of the polycrystalline structure extending inwardly from the cutting surface has at least a portion of a catalyst material removed from therein. The first wire electrically couples the terminal to the probe, which is placed in contact with the cutting surface. The eddy current is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure. | 08-22-2013 |
20130214769 | Use of Capacitance And Eddy Currents to Analyze Polycrystalline Diamond - A method for non-destructively characterizing one or more regions within a polycrystalline structure using capacitance and eddy current measurements. The eddy current measurements include at least one of an impedance amplitude and a phase shift angle. The capacitance is measured one or more times and compared to a first calibration curve to determine an estimated leaching depth within the polycrystalline structure. A first data scattering range is ascertained from the capacitance measurements to determine a relative porosity or the leaching quality within the polycrystalline structure. The eddy current is measured one or more times and compared to a second calibration curve to determine an estimated leaching depth within the polycrystalline structure. A second data scattering range is ascertained from the eddy current measurements to determine a relative porosity or the leaching quality within the polycrystalline structure. Results from both measurements are used to ascertain a quality of the polycrystalline structure. | 08-22-2013 |
20130214799 | Use of Capacitance to Analyze Polycrystalline Diamond - A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using capacitance measurements. The apparatus includes a capacitance measuring device having a positive and negative terminal, a leached component comprising a polycrystalline structure, a first wire, and a second wire. The leached component includes a first surface and an opposing second surface. The first wire electrically couples the positive terminal to one of the surfaces of the leached component and the second wire electrically couples the negative terminal to the other surface of the leached component. The capacitance is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure. | 08-22-2013 |
20130247478 | Method to Improve the Leaching Process - A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth. | 09-26-2013 |
20130248258 | Leached Cutter And Method For Improving The Leaching Process - A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth. | 09-26-2013 |
20130263521 | HIGH TEMPERATURE HIGH HEATING RATE TREATMENT OF PDC CUTTERS - A post manufacture method and apparatus for reducing residual stresses present within a component. The component includes a substrate, a polycrystalline structure coupled thereto, and residual stresses present therein. The method includes obtaining a component from a component category, determining a critical temperature and a critical time period for the component category at which the component becomes structurally impaired, determining a heat treatment temperature and a heat treatment time period based upon the critical temperature and the critical time period, and heating one or more remaining components from the component category to the heat treatment temperature for the heat treatment time period. The apparatus includes a heater defining a heating chamber and a molten bath positioned within the heating chamber. The components are placed within the pre-heated molten bath and isolated from oxygen during heating to the heat treatment temperature for the heat treatment time period. | 10-10-2013 |
20140060938 | POLYCRYSTALLINE DIAMOND MATERIAL WITH HIGH TOUGHNESS AND HIGH WEAR RESISTANCE - A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 85% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 35% by weight of the plurality of metallic phases is disclosed. | 03-06-2014 |