| Entries |
| Document | Title | Date |
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| 20080223621 | THERMALLY STABLE ULTRA-HARD MATERIAL COMPACT CONSTRUCTION - Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process. | 09-18-2008 |
| 20080264696 | AUTO ADAPTABLE CUTTING STRUCTURE - A cutter is configured with a diamond table made from a thin hard facing material layer of polycrystalline diamond bonded to a backing layer made from cemented tungsten carbide. The face of the diamond table includes a concavity formed with a curved shape wherein at least a portion of the face in a center of the cutter is recessed with respect to at least some portion of the face about the perimeter of the cutter. This concave curved shape is formed in the diamond table itself such that the diamond table has a varying thickness depending on the implemented concavity. Alternatively, the concave curved shape is formed in the backing layer and a substantially constant thickness diamond table layer is attached thereto. | 10-30-2008 |
| 20090025985 | Cutting element with canted interface surface and bit body incorporating the same - The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and to a bit incorporating such cutting element. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body. | 01-29-2009 |
| 20090071726 | ULTRAHARD COMPOSITE CONSTRUCTIONS - Ultrahard composite constructions comprise a plurality of first phases dispersed within a matrix second phase, wherein each can comprise an ultrahard material including PCD, PcBN, and mixtures thereof. The constructions are formed from a plurality of granules that are combined and sintered at HP/HT conditions. The granules include a core surrounded by a shell and both are formed from an ultrahard material or precursor comprising an ultrahard constituent for forming the ultrahard material. When sintered, the cores form the plurality of first phases, and the shells form at least a portion of the second phase. The ultrahard material used to form the granule core may have an amount of ultrahard constituent different from that used to form the granule shell to provide desired different properties. The ultrahard constituent in the granule core and shell can have approximately the same particle size. | 03-19-2009 |
| 20090178855 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS AND BITS INCORPORATING THE SAME - Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided. | 07-16-2009 |
| 20090218146 | Polycrystalline Abrasive Composite Cutter - A polycrystalline abrasive composite cutter, including a tool body with a top cutting surface and a flank surface. The composite cutter, joined to a substrate, constitute a shear cutter for a PDC bit, roller-cone bit insert, or other tool that can be highly useful for petroleum drilling or other applications. The body of the polycrystalline abrasive composite cutter includes a plurality of polycrystalline abrasive layers ( | 09-03-2009 |
| 20100012387 | EARTH-BORING TOOLS AND METHODS OF MAKING EARTH-BORING TOOLS INCLUDING AN IMPACT MATERIAL, AND METHODS OF DRILLING THROUGH CASING - Earth-boring tools comprise a face and a plurality of cutting elements disposed on at least a portion of the face. An impact material is positioned on at least one portion of the body and has a relative exposure equal to or greater than at least some of the cutting elements of the plurality of cutting elements. The impact material comprises a material having a lower abrasion resistance than the body. Methods of making and methods of using such earth-boring tools are also disclosed. | 01-21-2010 |
| 20100084196 | POLYCRYSTALLINE DIAMOND, POLYCRYSTALLINE DIAMOND COMPACT, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 04-08-2010 |
| 20100084197 | DIAMOND BONDED CONSTRUCTION WITH THERMALLY STABLE REGION - Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element. | 04-08-2010 |
| 20100089661 | DRILL BIT WITH CONTINUOUSLY SHARP EDGE CUTTING ELEMENTS - A method of optimizing drill bit design and an optimized drill bit for drilling a well into an earth formation comprising a bit body; a number of blades spaced around the bit body, each blade having a curved outer edge and a forward face; a first row of cutter pockets recessed into the face along the outer edge of each blade; a second group of cutter pockets recessed into the face of each blade offset from the first row; and a plurality of cutting elements, each cutting element being brazed into a different one of the cutter pockets. | 04-15-2010 |
| 20100089662 | ACTIVE GAUGE PROTECTION FOR DRILL BITS - A drill bit having a selected gauge diameter and operable to be positioned within a casing positioned within a rock formation, the casing comprising an casing inner wall having a casing inner diameter greater than the gauge diameter, wherein the positioning of the drill bit within the casing defines a drift distance corresponding to the distance between the gauge diameter and the casing inner diameter, the drill bit comprising a blade comprising a gauge cutter operable to cut an earth formation at the gauge diameter; and a protective insert coupled the drill bit such that a portion of the protective insert extends beyond the gauge diameter by a selected overgauge distance, wherein the protective insert is operable to engage the casing inner wall to substantially prevent the gauge cutter from engaging the casing inner wall as the drill bit is positioned through a selected length of the casing. | 04-15-2010 |
| 20100089663 | Nondestructive Device and Method for Evaluating Ultra-Hard Polycrystalline Constructions - A device, system and method for nondestructively obtaining qualitative and/or quantitative information relating to the material properties of a region in a diamond body comprises directing x-rays onto the body. The body can comprise sintered or unsintered diamond. The body can ultimately be in the form of a cutting element used with a subterranean drill bit. The x-rays penetrate the body and cause a target element within the desired region including the same to emit x-ray fluorescence. The emitted x-ray fluorescence is received and information relating to content, location, and/or distribution of the target element in the region within the body is determined therefrom. The measured region can extend axially or radially from a surface of the body, and the target elements are nondiamond materials that can be constituents of a substrate attached to the body, or of a container used during HPHT sintering of the body. | 04-15-2010 |
| 20100101868 | BONDING OF CUTTERS IN DIAMOND DRILL BITS - A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB | 04-29-2010 |
| 20100101869 | DIAMOND BIT STEEL BODY CUTTER POCKET PROTECTION - A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed. | 04-29-2010 |
| 20100108402 | DOWNHOLE CUTTING TOOL AND METHOD OF MAKING - A downhole cutting tool includes, a body, a first contoured cutting element in operable communication with the body, and at least one contingency contoured cutting element in operable communication with the first contoured cutting element and the body. A contour of the at least one contingency contoured cutting element substantially matches a contour of the first contoured cutting element, and the at least one contingency contoured cutting element is maintainable in reserve and positioned to substitute for the first contoured cutting element if the first contoured cutting element becomes detached. | 05-06-2010 |
| 20100108403 | SURFACE COATINGS ON CUTTING ELEMENTS - A method of forming a cutting element that includes placing at least one cutting element in an inner surface of at least one hollow tubular member such that at least a portion of the at least one cutting element is exposed; generating plasma within the hollow portion of the tubular; and depositing at least one refractory metal or sp | 05-06-2010 |
| 20100122852 | ULTRA-HARD CONSTRUCTIONS WITH ENHANCED SECOND PHASE - Ultra-hard constructions include an ultra-hard body having a first region including a polycrystalline matrix first phase and a second phase material interposed therein. The first region is substantially free of a catalyst material used to form the first phase. The body is formed by removing the catalyst material and then replacing it with the second phase material. A second region is disposed within the body and includes the polycrystalline matrix first phase and a catalyst material used to form the first phase. The second phase material has a thermal characteristic that is more closely matched to the matrix first phase than the catalyst material. The body may be joined to a substrate, and the ultra-hard body may consist entirely of the first region. The second phase material can include non-refractory metals, ceramics, silicon, silicon-containing compounds, diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof. | 05-20-2010 |
| 20100155149 | Method of Designing a Bottom Hole Assembly and a Bottom Hole Assembly - A bottom hole assembly containing a drill bit. The drill bit additionally has a plurality of primary cutter elements mounted thereto. The plurality of cutter elements comprise one or more first cutter elements and one or more second cutter elements. The second cutter element differs from the first cutter element in at least one cutter element property. The first cutter element has a diamond body containing a first region comprising an infiltrant material disposed within the interstitial regions. The first region is located remote from the working surface of the diamond body. The first cutter element also contains a second region comprising interstitial regions that are substantially free of the infiltrant material. The second region is located along at least the working surface of the diamond body. Also included are a cutter element, method of designing a bottom hole assembly as well as method of designing a drill bit. | 06-24-2010 |
| 20100181117 | METHODS OF FORMING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS, CUTTING ELEMENTS SO FORMED AND DRILL BITS SO EQUIPPED - A polycrystalline diamond compact comprising a diamond table is formed in a high pressure, high temperature process using a catalyst, the catalyst being substantially removed from the entirety of the diamond table, and the diamond table attached to a supporting substrate in a subsequent high pressure, high temperature process using a binder material differing at least in part from a material of the catalyst. The binder material is permitted to penetrate substantially completely throughout the diamond table from an interface with the substrate to and including a cutting surface, and the binder material is selectively removed from a region or regions of the diamond table by a conventional technique (e.g., acid leaching). Cutting elements so formed and drill bits equipped with such cutting elements are also disclosed. | 07-22-2010 |
| 20100187020 | BRAZING METHODS FOR PDC CUTTERS - A method for manufacturing a down hole cutting tool, wherein the cutting tool includes a cutting element support structure having at least one cutter pocket formed therein to support a cutting element comprising a substrate and an ultrahard layer, wherein the method includes inserting a base portion of the cutting element into the cutter pocket; locating a first braze alloy such that when heated the first braze alloy melts and fills a space in the cutter pocket between the cutting element and the cutting element support structure adjacent the ultrahard layer; locating a second braze alloy such that when heated the second braze alloy melts and fills a space in the cutter pocket between the cutting element and the cutting element support structure non-adjacent the ultrahard layer; and heating the first and second braze alloy such that they melt. | 07-29-2010 |
| 20100212971 | Polycrystalline Diamond Compact Including A Cemented Tungsten Carbide Substrate That Is Substantially Free Of Tungsten Carbide Grains Exhibiting Abnormal Grain Growth And Applications Therefor - Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table that is substantially free of defects formed due to abnormal grain growth of tungsten carbide grains, and methods of fabricating such PDCs. In an embodiment, a PDC comprises a cemented tungsten carbide substrate including an interfacial surface that is substantially free of tungsten carbide grains exhibiting abnormal grain growth, and a PCD table bonded to the interfacial surface of the cemented tungsten carbide substrate. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a metal-solvent catalyst disposed therein. The PCD table may be substantially free of chromium or the PCD table and the cemented tungsten carbide substrate may each include chromium. | 08-26-2010 |
| 20100219000 | IMPREGNATION BIT WITH IMPROVED CUTTING STRUCTURE AND BLADE GEOMETRY - A rotary drag bit for drilling subterranean formations and a method of forming a rotary drag bit for drilling subterranean formations comprising a bit body having a face extending from a centerline to a gage; a plurality of blades on the face generally extending radially outwardly toward the gage; and a plurality of discrete impregnated cutting posts; wherein each discrete impregnated cutting post extends outwardly from an associated one of the plurality of blades; and wherein each discrete impregnated cutting post angles generally towards a front edge of the associated blade of the discrete impregnated cutting post and generally towards the direction of rotation of the rotary drag bits. The rotary drag bit may further comprise a plurality of matrix pockets disposed on the plurality of blades, wherein the discrete impregnated cutting posts may be housed within one of the plurality of matrix pockets. | 09-02-2010 |
| 20100236837 | CUTTING TOOL INSERT AND DRILL BIT SO EQUIPPED - A polycrystalline diamond abrasive cutting element consists generally of a layer of high grade polycrystalline diamond bonded to a cemented carbide substrate. The polycrystalline diamond layer has a working surface and an outer peripheral surface and is characterized by having an annular region or a portion thereof adjacent the peripheral surface that is lean in catalysing material. A region adjacent the working surface is also lean in catalysing material such that in use, as a wear scar develops, both the leading edge and the trailing edge thereof are located in a region lean in catalysing material. | 09-23-2010 |
| 20100263938 | Impregnated Bit with Increased Binder Percentage - Control of the carbide volume in the matrix in an impregnated bit is accomplished by coating the hard particles in the matrix to space them further apart to increase the soft binder percentage in a controllable manner. The softer binder due to lower volume content of hard particles allows more rapid matrix wear in the softer formations to allow more diamond grit to cut better before getting flat spots and to be replaced faster with additional diamond grit further into the matrix as the higher content of the softer binder and the softer coating on the hard particles in the matrix promotes more effective cutting with more frequent emergence of diamond grit on the bit face as cutting progresses. | 10-21-2010 |
| 20100276210 | CUTTER POCKET DESIGN - A drilling tool including a tool body and a cutter pocket formed in the tool body, the cutter pocket including a front planar surface, a back planar surface opposite the front planar surface, a first side surface between the front and back planar surfaces, and a second side surface opposite the first side surface and between the front and back planar surfaces is disclosed herein. A method of manufacturing a drilling tool including machining a tool body having a cutter pocket in accordance with embodiments disclosed herein, disposing a cutting element in the cutter pocket, and brazing the cutting element in the cutter pocket is disclosed. | 11-04-2010 |
| 20100288564 | CUTTING ELEMENT FOR USE IN A DRILL BIT FOR DRILLING SUBTERRANEAN FORMATIONS - A cutting element for use in a drill bit for drilling subterranean formations including a substrate having a body including an upper surface extending transversely to a longitudinal axis of the body, a superabrasive layer overlying the upper surface of the substrate, wherein the superabrasive layer includes an annular shape having a central opening defined by an inner surface. The cutting element further includes an abrasive insert overlying the upper surface of the substrate and disposed within the central opening of the superabrasive layer, wherein the abrasive insert has an upper surface having a surface roughness (R | 11-18-2010 |
| 20100300765 | MODIFIED CUTTERS AND A METHOD OF DRILLING WITH MODIFIED CUTTERS - A modified cutting element that includes a base portion, an ultrahard layer disposed on said base portion, and at least one modified region disposed adjacent to a cutting face of the cutter is described. In certain applications, the ultrahard layer comprises thermally stable polycrystalline diamond. | 12-02-2010 |
| 20100320006 | POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS WITH ENGINEERED POROSITY AND METHOD FOR MANUFACTURING SUCH CUTTING ELEMENTS - A method for facilitating infiltration of an infiltrant material into a TSP material during re-bonding of the TSP material to a substrate, by enhancing the porosity of the TSP material near the interface with the substrate is provided. Cutting elements formed by such method and downhole tools including such cutting elements are also provided. | 12-23-2010 |
| 20100326740 | Bonded Assembly Having Low Residual Stress - In one aspect of the present invention, a method for forming a bonded assembly comprises providing a first and second portion of the assembly; preparing a mating surface on each portion that conforms substantially to the mating surface of the other portion; rapidly heating a bonding material while substantially heating no more than a thin surface zone adjacent each mating surface, and rapidly assembling the two portions in such a manner as to confine a fraction of the bonding material between the mating surfaces. The first portion may comprise polycrystalline diamond or thermally stable polycrystalline diamond; the second portion may comprise cobalt-cemented tungsten carbide. The assembly may comprise a tool for high-impact applications. | 12-30-2010 |
| 20110017519 | POLYCRYSTALLINE DIAMOND COMPACTS, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, polycrystalline diamond compact (“PDC”) includes a PCD table having a maximum thickness. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 01-27-2011 |
| 20110017520 | METAL-FREE SUPPORTED POLYCRYSTALLINE DIAMOND AND METHOD TO FORM - An exemplary cutting element incorporates a non-magnetic and electrically conductive substrate on which a layer of polycrystalline diamond particles is sintered to the substrate. An exemplary method of forming a cutting element comprises sintering the substrate, a layer of diamond particles and a catalyst source at a pressure greater than 20 kbar and a temperature greater than 1200° C. to form a layer of polycrystalline diamond particles bonded to the substrate. Cutting elements incorporating non-magnetic and electrically conductive substrates can be sectioned using ablation techniques, such as laser cutting. | 01-27-2011 |
| 20110024200 | CUTTING ELEMENT AND METHOD OF FORMING THEREOF - A cutting element for use in a drilling bit and/or milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further including a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer. | 02-03-2011 |
| 20110024201 | POLYCRYSTALLINE DIAMOND COMPOSITE COMPACT ELEMENTS AND TOOLS INCORPORATING SAME - A polycrystalline diamond (PCD) composite compact element | 02-03-2011 |
| 20110031029 | CUTTING ELEMENT PLACEMENT ON A FIXED CUTTER DRILL BIT TO REDUCE DIAMOND TABLE FRACTURE - A rotary drag bit includes a primary cutter row comprising at least one primary cutter mounted on a blade, at least some cutters in the primary cutter row having a portion of a cutting surface thereof covered by a portion of the blade. A backup cutter row comprising at least one cutter may also be included, and at least a portion of a cutting surface of at least some cutters in the backup cutter row is covered by a portion of the blade. Enhanced support for cutters is provided against impact loading. | 02-10-2011 |
| 20110031030 | CUTTER HAVING SHAPED WORKING SURFACE WITH VARYING EDGE CHAMFER - A cutter for a drill bit used for drilling wells in a geological formation includes an ultra hard working surface and a chamfer along an edge of the working surface, wherein the chamfer has a varied geometry along the edge. The average geometry of the chamfer varies with cutting depth. A depression in the shaped working surface is oriented with the varied chamfer and facilitates forming the varied chamfer. A non-planar interface has depressions oriented with depressions in the shaped working surface to provide support to loads on the working surface of the cutter when used. | 02-10-2011 |
| 20110031031 | CUTTING ELEMENT FOR A DRILL BIT USED IN DRILLING SUBTERRANEAN FORMATIONS - A cutting element for use in a drill bit for drilling subterranean formations includes a cutting body having a substrate including a rear surface, an upper surface, and a peripheral side surface extending between the rear surface and the upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve surrounding the peripheral side surface of the cutting body and comprising a superabrasive layer bonded to an external surface of the sleeve. | 02-10-2011 |
| 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 |
| 20110031034 | POLYCRYSTALLINE COMPACTS INCLUDING IN-SITU NUCLEATED GRAINS, EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SUCH COMPACTS AND TOOLS - Polycrystalline compacts include hard polycrystalline materials comprising in situ nucleated smaller grains of hard material interspersed and inter-bonded with larger grains of hard material. The average size of the larger grains may be at least about 250 times greater than the average size of the in situ nucleated smaller grains. Methods of forming polycrystalline compacts include nucleating and catalyzing the formation of smaller grains of hard material in the presence of larger grains of hard material, and catalyzing the formation of inter-granular bonds between the grains of hard material. For example, nucleation particles may be mixed with larger diamond grains, a carbon source, and a catalyst. The mixture may be subjected to high temperature and high pressure to form in smaller diamond grains using the nucleation particles, the carbon source, and the catalyst, and to catalyze formation of diamond-to-diamond bonds between the smaller and larger diamond grains. | 02-10-2011 |
| 20110042148 | CUTTING ELEMENTS HAVING DIFFERENT INTERSTITIAL MATERIALS IN MULTI-LAYER DIAMOND TABLES, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SAME - Methods of forming cutting elements for earth-boring tools include providing a barrier material between a first powder and a second powder each comprising diamond grains, and subjecting the powders and barrier material to high temperature and high pressure conditions to form polycrystalline diamond material. The formation of the polycrystalline diamond material is catalyzed, and catalytic material may be hindered from migrating across the layer of barrier material. Cutting elements for use in earth-boring tools include a barrier material disposed between a first layer of polycrystalline diamond material and a second layer of polycrystalline diamond material. Earth-boring tools include one or more such cutting elements for cutting an earth formation. | 02-24-2011 |
| 20110042149 | METHODS OF FORMING POLYCRYSTALLINE DIAMOND ELEMENTS, POLYCRYSTALLINE DIAMOND ELEMENTS, AND EARTH-BORING TOOLS CARRYING SUCH POLYCRYSTALLINE DIAMOND ELEMENTS - Methods of forming polycrystalline diamond elements include forming a polycrystalline diamond element. A Group VIII metal or alloy catalyst is employed to form the polycrystalline diamond compact table at a pressure of at least about 6.5 GPa or greater. The catalyst is then removed from at least a portion of the table to a depth from a working surface thereof, and may be removed from the entirety of the table. Polycrystalline diamond elements include such polycrystalline diamond compact tables. Earth-boring tools include such polycrystalline diamond elements carried thereon and employed as cutting elements. | 02-24-2011 |
| 20110056753 | Thermally Stable Ultra-Hard Material Compact Construction - Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process. | 03-10-2011 |
| 20110061942 | POLYCRYSTALLINE COMPACTS HAVING MATERIAL DISPOSED IN INTERSTITIAL SPACES THEREIN, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SUCH COMPACTS - Polycrystalline compacts include smaller and larger hard grains that are interbonded to form a polycrystalline hard material. The larger grains may be at least about 150 times larger than the smaller grains. An interstitial material comprising one or more of a boride, a carbide, a nitride, a metal carbonate, a metal bicarbonate, and a non-catalytic metal may be disposed between the grains. The compacts may be used as cutting elements for earth-boring tools such as drill bits, and may be disposed on a substrate. Methods of making polycrystalline compacts include coating smaller hard particles with a coating material, mixing the smaller particles with larger hard particles, and sintering the mixture to form a polycrystalline hard material including interbonded smaller and larger grains. The sizes of the smaller and larger particles may be selected to cause the larger grains to be at least about 150 times larger than the smaller grains. | 03-17-2011 |
| 20110061943 | IMPREGNATED ROTARY DRAG BIT WITH ENHANCED DRILL OUT CAPABILITY - A drill bit employing a plurality of abrasive, particulate-impregnated cutting structures extending upwardly from the bit face and defining a plurality of fluid passages therebetween. The cutting structures may be configured as spaced posts, or as blades with circumferentially extending grooves at radially spaced intervals. Superabrasive cutting elements in the form of thermally stable diamond are placed between the posts or in the grooves, depending on the cutting structure configuration, and at a reduced exposure. Additional cutting elements may be placed in the cone of the bit surrounding the centerline thereof. The blades may extend generally radially. Additionally, discrete protrusions may extend outwardly from at least some of the plurality of cutting structures. The discrete protrusions may be formed of thermally stable diamond. | 03-17-2011 |
| 20110061944 | POLYCRYSTALLINE DIAMOND COMPOSITE COMPACT - A polycrystalline diamond (PCD) composite compact element comprising a PCD structure bonded to a cemented carbide substrate, in which at least a peripheral region of the substrate comprises cemented carbide material having a mean free path (MFP) characteristic of at least about 0.1 microns and at most about 0.7 microns; and an elastic limit of at least about 1.9 GPa. | 03-17-2011 |
| 20110073379 | CUTTING ELEMENT AND METHOD OF FORMING THEREOF - A cutting element comprising a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface. The cutting element further includes a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate. The cutting element is also formed to include a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer. | 03-31-2011 |
| 20110083907 | POLYCRYSTALLINE DIAMOND - A PCD composite compact comprising a PCD structure bonded at an interface to a substrate comprising cemented carbide material; the PCD structure comprising a mass of directly inter-bonded diamond grains having a mean size of at most about 4 microns, and the PCD structure comprising at least about 0.05 weight percent refractory metal or carbide of a refractory metal selected from the group comprising W, Ti, V, Cr, Zr, Nb, Mo, Hf and Ta; and at least the cemented carbide material proximate the interface having a content of metallic binder material of at most about 6 weight percent. | 04-14-2011 |
| 20110083908 | Diamond Bonded Construction Comprising Multi-Sintered Polycrystalline Diamond - Diamond bonded constructions comprise a diamond body attached to a substrate, wherein the body includes a first diamond bonded volume, and a second diamond bonded volume attached thereto. The second volume may be provided in the form of a powder or a presintered mass prior to attachment, and the first volume may be provided in the form of presintered pieces when combined with the second volume. The first volume diamond volume content is greater than about 94 percent, and is the same or greater than that of the second volume. The first volume is sintered during a first HPHT process, and the second volume is sintered and/or attached to the first volume during a second HPHT process. The first HPHT pressure is greater than the second HPHT pressure. The substrate is not an infiltration substrate used to form the first diamond volume. The diamond body may be thermally stable. | 04-14-2011 |
| 20110088955 | CUTTING ELEMENT APPARATUSES, DRILL BITS INCLUDING SAME, METHODS OF CUTTING, AND METHODS OF ROTATING A CUTTING ELEMENT - A subterranean drilling system may include a drill string and a rotary drill bit coupled to the drill string. The rotary drill bit may include a bit body and a cutting element coupled to the bit body, with the cutting element being structured to rotate in response to torque applied to the cutting element. The system also may include a cam assembly coupled to the drill string, a cam follower assembly in contact with a cam surface of the cam assembly, and a torque-applying structure coupled to the cam follower assembly. The torque-applying structure may be configured to apply torque to the cutting element in response to relative rotation between the cam assembly and the cam follower assembly. | 04-21-2011 |
| 20110100724 | Fixed Cutter Bit for Directional Drilling Applications - A drill bit for drilling a borehole in earthen formations, the bit comprising: a bit body having a bit axis and a bit face including a cone region, a shoulder region, and a gage region; a first primary blade extending radially along the bit face from the cone region to the gage region; a plurality of cutter elements mounted to the first primary blade, wherein a first of the plurality of cutter elements has a planar cutting face and a second of the plurality of cutter elements has a convex cutting face; and wherein each cutting face is forward-facing. | 05-05-2011 |
| 20110114392 | DRILLING APPARATUS WITH REDUCED EXPOSURE OF CUTTERS AND METHODS OF DRILLING - A rotary drilling apparatus and method for drilling subterranean formations, including a body being provided with at least one cutter thereon exhibiting reduced, or limited, exposure to the formation, so as to control the depth-of-cut of the at least one cutter, so as to control the volume of formation material cut per rotation of the drilling apparatus, as well as to control the amount of torque experienced by the drilling apparatus and an optionally associated bottomhole assembly regardless of the effective weight-on-bit are all disclosed. The exterior of the drilling apparatus may include a plurality of blade structures carrying at least one such cutter thereon and including a sufficient amount of bearing surface area to contact the formation so as to generally distribute an additional weight applied to the drilling apparatus against the bottom of the borehole without exceeding the compressive strength of the formation rock. | 05-19-2011 |
| 20110114393 | SUPER-HARD CUTTER INSERTS AND TOOLS - A cutter insert assembly for a drill bit for boring into the earth, comprising a super-hard structure clampable to a support body by means of a clamp mechanism; the clamp mechanism comprising opposed or opposable compression members connected or connectable by a tension member capable of sustaining a clamping force between the compression members when the cutter insert assembly is in a clamped condition, in which condition the compression members exert opposing compressive forces on the super-hard structure and the support body, operable to clamp the super-hard structure to the support body, and in which condition the cutter insert assembly is self-supporting and capable of being mounted onto a drill bit body. | 05-19-2011 |
| 20110114394 | MATRIX TOOL BODIES WITH EROSION RESISTANT AND/OR WEAR RESISTANT MATRIX MATERIALS - Methods for manufacturing a matrix tool body comprising placing a first matrix material within a first region of a mold cavity proximate a surface of the mold. A second matrix material may be placed within a second region of the mold cavity positioned inwardly of the first matrix material. The first matrix material and the second matrix material comprise a plurality of hard particles. The plurality of hard particles of the second matrix material have a median particle size that is less than the median particle size of the first matrix material. The plurality of hard particles of the first matrix material and the second matrix material are infiltrated with an infiltration binder to form the tool body. Also included are tool bodies having one or more regions proximate a surface of the tool body comprising an erosion resistant matrix material and/or a wear resistant matrix material. | 05-19-2011 |
| 20110127088 | POLYCRYSTALLINE ULTRA-HARD COMPACT CONSTRUCTIONS - Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device, and improves the compact attachment strength to an end-use device when compared to conventional compacts. | 06-02-2011 |
| 20110132666 | POLYCRYSTALLINE TABLES HAVING POLYCRYSTALLINE MICROSTRUCTURES AND CUTTING ELEMENTS INCLUDING POLYCRYSTALLINE TABLES - Cutting elements comprise a substrate and an unleached polycrystalline table attached on an end of the substrate. The polycrystalline table comprises a plurality of continuously inter-bonded grains of a superhard material and a quantity of catalyst material disposed in interstitial spaces between grains of the plurality of continuously inter-bonded grains of a superhard material. A mean grain size of the plurality of continuously inter-bonded grains is at least substantially uniform throughout the polycrystalline table and the quantity of catalyst material varies across the polycrystalline table in a direction parallel to a central axis of the polycrystalline table. | 06-09-2011 |
| 20110132667 | POLYCRYSTALLINE DIAMOND STRUCTURE - A PCD structure comprising a first region, in a state of residual compressive stress, and a second region in a state of residual tensile stress adjacent the first region; the first and second regions each formed of respective PCD grades and directly bonded to each other by intergrowth of diamond grains, the PCD grades having transverse rupture strength (TRS) of at least 1,200 MPa. A third region in a state of residual compressive stress may also be provided such that the second region is disposed between the first and third regions and is bonded to the first and third regions by intergrowth of diamond grains. | 06-09-2011 |
| 20110132668 | POLYCRYSTALLINE DIAMOND CUTTING ELEMENT STRUCTURE - A cutting element may include a substrate having an interface surface; an ultrahard material layer disposed on the interface surface; and the interface surface comprising a plurality of surface features, wherein at least one of the plurality of surface features intersects a neighboring surface feature at a height that is intermediate an extremity of the at least one of the plurality of surface features and a base of the at least one of the plurality of surface features. | 06-09-2011 |
| 20110139514 | Thermally Stable Diamond Bonded Materials and Compacts - Thermally stable diamond bonded construction comprise a diamond bonded body including a thermally stable region, comprising a plurality of diamond grains bonded together by a reaction product of the diamond grains with a reactant such as Si, and a polycrystalline diamond region, comprising intercrystalline bonded diamond and a catalyst material. The body further comprises a ceramic compound formed by reaction of an Nb, Zr, Ti, or Mo getter material with a gaseous element generated during HPHT sintering of the diamond bonded body. The diamond bonded body may comprise from 0.1 to 15 percent by weight of the ceramic compound. The diamond bonded body can be formed during a single HPHT process operated at different temperatures when the reactant has a melting temperature above the catalyst material. The construction may include a metallic substrate attached to the diamond bonded body to facilitate use as a wear or cutting element. | 06-16-2011 |
| 20110162893 | HIGH-SHEAR ROLLER CONE AND PDC HYBRID BIT - A drill bit having a bit body, at least one blade extending radially from the bit body, a plurality of blade cutting elements disposed on each blade, at least one journal extending downwardly and radially outward from a longitudinal axis of the drill bit, a roller cone or roller disc mounted rotatably to each journal, and a plurality of cutting elements disposed on each roller cone or roller disc, and methods for making the drill bit are disclosed. | 07-07-2011 |
| 20110168454 | NOVEL HARDMETAL FOR USE IN OIL AND GAS DRILLING APPLICATIONS - A down hole drill bit that includes a plurality of cutting elements mounted on a cutting structure, wherein at least one of the plurality of cutting elements comprises a wear resistant material, the wear resistant material comprising coarse grains disposed in a binder matrix phase, wherein the binder matrix phase comprises nanoparticles dispersed therein is disclosed. | 07-14-2011 |
| 20110174549 | SUPERHARD INSERT AND AN EARTH BORING TOOL COMPRISING SAME - A superhard insert for a rotary earth borer tool comprises a cutter end having a peripheral cutter edge, at least part of the peripheral cutter edge being defined by a plurality of edges of a plurality of alternate hard and superhard regions. The edges of the superhard regions are arranged spaced apart from each other and are separated by edges of hard regions. The hardness of each hard region is at most 50% of the hardness of each superhard region. | 07-21-2011 |
| 20110192651 | SHAPED CUTTING ELEMENTS ON DRILL BITS AND OTHER EARTH-BORING TOOLS, AND METHODS OF FORMING SAME - Earth-boring tools include a body, one or more blades projecting outwardly from the body, and cutting elements carried by the blade. The cutting elements include at least one shearing cutting element and at least one gouging cutting element. Methods of forming an earth-boring tool include mounting a shearing cutting element comprising an at least substantially planar cutting face to a body of an earth-boring tool, and mounting a gouging cutting element comprising a non-planar cutting face to the body of the earth-boring tool. The gouging cutting element may be positioned on the body of the earth-boring tool such that the gouging cutting element will gouge formation material within a kerf cut in the formation material by the shearing cutting element, or between kerfs cut in the formation material by a plurality of shearing cutting elements. | 08-11-2011 |
| 20110192652 | COMPOSITE CUTTER SUBSTRATE TO MITIGATE RESIDUAL STRESS - A method of forming a cutting element that includes filling at least one non-planar region on an upper surface of a carbide substrate with a diamond mixture, subjecting the substrate and the diamond mixture to high pressure high temperature sintering conditions to form a reduced-CTE substrate having polycrystalline diamond that extends a depth into the reduced-CTE substrate in an interface region, and an upper surface made of a composite surface of diamond and carbide, and attaching a polycrystalline diamond body to the composite surface of the reduced-CTE substrate is disclosed. | 08-11-2011 |
| 20110214921 | Polycrystalline Diamond Abrasive Compact - A polycrystalline diamond (PCD) material and method for making the PCD material are provided. The PCD so produced comprises a skeletal diamond structure formed of intergrown diamond grains and defines interstitial regions between the diamond grains. The skeletal diamond structure contains metal carbide structures or particles that are occluded from the interstitial regions by diamond. | 09-08-2011 |
| 20110253459 | POLYCRYSTALLINE DIAMOND COMPOSITE COMPACT ELEMENT, TOOLS INCORPORATING SAME AND METHOD FOR MAKING SAME - The invention relates to a PCD composite compact element comprising a PCD structure integrally bonded at an interface to a cemented carbide substrate; the PCD structure comprising coherently bonded diamond grains having a mean size no greater than 15 microns; the cemented carbide substrate comprising carbide particles dispersed in a metallic binder, the carbide particles comprising a carbide compound of a metal; wherein the ratio of the amount of metallic binder to the amount of the metal at points in the substrate deviates from a mean value by at most 20 percent of the mean value. The invention further relates to a method for making a PDC compact element comprising a PCD structure integrally bonded to a substrate formed of cemented carbide; the method including introducing a source of excess carbon to the substrate at a bonding surface of the substrate to form a carburised substrate; contacting an aggregated mass of diamond grains with the carburised substrate; and sintering the diamond grains in the presence of a solvent/catalyst material for diamond; wherein the mean size of the diamond grains in the aggregated mass is no greater than 30 microns. | 10-20-2011 |
| 20110253460 | BLADE-TYPE DRILL BIT - The invention relates to rock destruction tools used for drilling oil and gas wells, especially for drilling slant and horizontal wells and formations having alternating layers of different hardness. The technical effect consist in improved steerability of the drilling bit and higher vibration resistance of polycrystalline diamond cutters (PDC) bit due to the use of a composite plating applied and adjustment of cutter protrusion over this plating. Blade drilling bit includes body with coupling thread, central channel, exit holes for flushing fluid and blades, equipped with polycrystalline diamond cutters PDC. Blade surface is covered with composite plating having different wear resistance depending on thickness, and tolerance of composite plating to abrasion wear increases from the outer surface to sublayers, and the size of cutter protrusion close to the centre of bit over the surface of composite plating is less than required for drilling the hardest formations in given geological section. | 10-20-2011 |
| 20110259648 | POLYCRYSTALLINE DIAMOND COMPACT AND METHOD OF MAKING SAME - A polycrystalline diamond compact includes a substrate and a polycrystalline diamond table attached to the substrate. The polycrystalline diamond table includes an upper surface and at least one peripheral surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions. The polycrystalline diamond table includes a region having silicon carbide positioned within at least some of the interstitial regions thereof. In an embodiment, the first region extends over only a selected portion of the upper surface and/or at least a portion of the at least one peripheral surface. In another embodiment, the first region substantially contours the upper surface and a chamfer. | 10-27-2011 |
| 20110259649 | DRILL BIT AND DESIGN METHOD FOR OPTIMIZING DISTRIBUTION OF INDIVIDUAL CUTTER FORCES, TORQUE, WORK, OR POWER - A design process and resulting bit structure is provided for drill bits wherein cutter geometries on the face of the bit are tailored to optimize the distribution of one or more of forces, torque, work, or power of each cutter relative to other cutters. Balanced are the forces, torque, work, or power generated by each cutter in respect to other cutters that are working within the same region of cut, so that all cutters within the same region of cut are generating sufficiently comparable forces, torque, work, or power. In this manner all of the cutters on the bit may share as closely as possible the work and loads required to penetrate the subterranean rock. The design process produces a bit structure in which each cutter is doing similar levels of work or creating similar levels of force, torque, or power relative to other cutters within the same region of cut on the bit, within specified ranges of design criteria. | 10-27-2011 |
| 20110266070 | CUTTING ELEMENTS, EARTH-BORING TOOLS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS AND TOOLS - Cutting elements include a volume of superabrasive material. The volume of superabrasive material comprises a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. An earth-boring tool may comprise a bit body and at least one cutting element attached to the bit body. Methods of forming cutting elements comprise forming a volume of superabrasive material comprising forming a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. Methods of forming earth-boring tools comprise forming a cutting element and attaching the cutting element to an earth-boring tool. | 11-03-2011 |
| 20110266071 | Rotary Drill Bits with Optimized Fluid Flow Characteristics - According to one embodiment, a rotary drill bit comprises a bit body with a bit rotational axis extending through the bit body; blades disposed outwardly from exterior portions of the bit body; and cutting elements disposed outwardly from exterior portions of each blade. At least one blade has a substantially arched configuration. Each blade comprises a leading surface and a trailing surface, where the leading surface is disposed on the side of the blade toward the direction of rotation of the rotary drill bit, and the trailing surface is disposed on the side of the blade opposite to the direction of rotation of the rotary drill bit. The rotary drill bit also comprises junk slots. Each junk slot is disposed between an adjacent leading surface and an adjacent trailing surface of associated blades. | 11-03-2011 |
| 20110278074 | POLYCRYSTALLINE DIAMOND - A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material. | 11-17-2011 |
| 20110297451 | Rotational Drill Bits and Drilling Apparatuses Including the Same - A roof-bolt drill bit. The roof-bolt drill bit may include a bit body rotatable about a central axis and at least one cutting element coupled to the bit body. The bit body may comprise a forward end, a rearward end axially opposite the forward end, and an internal passage defined within the bit body, with the internal passage extending to at least one opening defined in a side portion of the bit body. The bit body may also comprise a channel defined in a peripheral portion of the bit body, with the channel extending along a path between the rearward end of the bit body and a side portion of the bit body. | 12-08-2011 |
| 20110297452 | DETRITUS FLOW MANAGEMENT FEATURES FOR DRAG BIT CUTTERS AND BITS SO EQUIPPED - Rock detritus created by a drag bit cutter shearing subterranean formation material may flow under the cutter and attach itself to the side surface of the cutter barrel by differential pressure-induced sticking, and dilate. This attached material, confined by hydrostatic pressure, can create and strengthen a barrier between the cutter and the virgin rock being cut. The detritus barrier absorbs bit weight and reduces cutter efficiency by impairing contact of the cutter with the virgin rock formation. Increasing friction between the rock detritus and a side surface of the cutter barrel inhibits detritus flow, reduces build up, and allows hydrostatic pressure to contribute to, rather than inhibit, the cutting process. Similar beneficial results may be obtained when hydrostatic pressure drilling fluid is permitted to communicate through holes in the side surface of the cutter, or through an otherwise permeable side surface alleviating detritus sticking due to differential pressure effects. | 12-08-2011 |
| 20110297453 | POLYCRYSTALLINE DIAMOND COMPACTS AND RELATED DRILL BITS - In an embodiment, a polycrystalline diamond compact (“PDC”) comprises a cemented carbide substrate including a first cemented carbide portion and a second cemented carbide portion bonded to the first cemented carbide portion and exhibiting an erosion resistance that is greater than the first cemented carbide portion. The PDC further comprises a polycrystalline diamond (“PCD”) table bonded to the first cemented carbide portion. The PCD table includes a plurality of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween, with the plurality of bonded diamond grains defining a plurality of interstitial regions. | 12-08-2011 |
| 20110303466 | SUPERABRASIVE CUTTING ELEMENTS WITH CUTTING EDGE GEOMETRY HAVING ENHANCED DURABILITY AND CUTTING EFFICIENCY AND DRILL BITS SO EQUIPPED - A superabrasive cutting element including a diamond or other superabrasive material table having a peripheral cutting edge defined by at least one chamfer between a cutting face and a side surface of the table, an arcuate surface extending between the cutting face and an innermost chamfer of the at least one chamfer and a sharp, angular transition between an outermost chamfer of the at least one chamfer and the side surface. Methods of producing such superabrasive cutting elements and drill bits equipped with such superabrasive cutting elements are also disclosed. | 12-15-2011 |
| 20110303467 | POLYCRYSTALLINE DIAMOND ABRASIVE ELEMENTS - A polycrystalline diamond abrasive element, particularly a cutting element, comprises a table of polycrystalline diamond bonded to a substrate, particularly a cemented carbide substrate, along a non-planar interface. The non-planar interface typically has a crucifonn configuration. The polycrystalline diamond has a high wear-resistance, and has a region adjacent the working surface leanin catalysing material and a region rich in catalysing material. The region lean in catalysing material extends to a depth of 40 to 90 microns, which is much shallower than in the prior art. Notwithstanding the shallow region lean in catalysing material, the polycrystalline diamond cutters have a wear resistance, impact strength and cutter life comparable to that of prior art cutters, but requiring only 20% of the treatment times of the prior art cutters. | 12-15-2011 |
| 20110315456 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING CUTTING ELEMENTS FOR EARTH-BORING TOOLS - Cutting elements for use with earth-boring tools include a cutting table having a base surface and a substrate having a support surface. An intermediate structure and an adhesion layer extend between the base surface of the cutting table and the support surface of the substrate. Earth-boring tools include such cutting elements. Methods for fabricating cutting elements for use with earth-boring tools include forming an intermediate structure on and extending from a support surface of a substrate and adhering a cutting table comprising a superabrasive material to the support surface of the substrate. | 12-29-2011 |
| 20120012401 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A SUBSTRATE HAVING A RAISED INTERFACIAL SURFACE BONDED TO A POLYCRYSTALLINE DIAMOND TABLE, AND APPLICATIONS THEREFOR - In various embodiments, a polycrystalline diamond compact (“PDC”) comprises a substrate including an interfacial surface having a raised region. In an embodiment, a PDC comprises a substrate including an interfacial surface having a generally cylindrical raised region and a peripheral region extending about the generally cylindrical raised region. The generally cylindrical raised region extends to a height above the peripheral region of about 450 μm or less. The PDC includes a PCD table bonded to the interfacial surface of the substrate. The PCD table includes an upper surface and at least one peripheral surface, and includes a plurality of bonded diamond grains defining interstitial regions. At least a portion of the interstitial regions includes a metallic constituent therein. In another embodiment, instead of employing a generally cylindrical raised region, the interfacial surface may include a plurality of raised arms extending above the face. Each raised arm extends radially and circumferentially. | 01-19-2012 |
| 20120024609 | DRILLING APPARATUS WITH REDUCED EXPOSURE OF CUTTERS AND METHODS OF DRILLING - A rotary drilling apparatus and method for drilling subterranean formations, including a body being provided with at least one cutter thereon exhibiting reduced, or limited, exposure to the formation, so as to control the depth-of-cut of the at least one cutter, so as to control the volume of formation material cut per rotation of the drilling apparatus, as well as to control the amount of torque experienced by the drilling apparatus and an optionally associated bottomhole assembly regardless of the effective weight-on-bit are all disclosed. The exterior of the drilling apparatus may include a plurality of blade structures carrying at least one such cutter thereon and including a sufficient amount of bearing surface area to contact the formation so as to generally distribute an additional weight applied to the drilling apparatus against the bottom of the borehole without exceeding the compressive strength of the formation rock. | 02-02-2012 |
| 20120037429 | POLYCRYSTALLINE DIAMOND - The present invention relates to polycrystalline diamond (PCD) comprising diamond in granular form, the diamond grains forming a bonded skeletal mass having a network of internal surfaces, the internal surfaces defining interstices or interstitial regions within the skeletal mass, wherein part of the internal surfaces is bonded to a refractory material, part of the internal surfaces is not bonded to refractory material and part of the internal surfaces is bonded to a sintering aid material as well as to a method of making such PCD. | 02-16-2012 |
| 20120037430 | POLYCRYSTALLINE DIAMOND - The invention relates to a polycrystalline diamond (PCD) body comprising PCD material having a graphitisation onset temperature, the PCD body having a working surface and comprising a first region remote from the working surface, the first region containing a catalysing material; and a second region extending a depth from the working surface into the PCD body, the second region being substantially free of catalysing material; the depth having a thermal gradient characteristic that when the temperature at the working surface is 900 degrees centigrade, the temperature at the depth is in the range from 780 degrees centigrade to 850 degrees centigrade and to inserts, machine tools and drill bits comprising the PCD body. | 02-16-2012 |
| 20120037431 | CUTTING ELEMENTS INCLUDING NANOPARTICLES IN AT LEAST ONE PORTION THEREOF, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - Cutting elements comprise a multi-portion polycrystalline material. At least one portion of the multi-portion polycrystalline material comprises a higher volume of nanoparticles than at least another portion. Earth-boring tools comprise a body and at least one cutting element attached to the body. The at least one cutting element comprises a hard polycrystalline material. The hard polycrystalline material comprises a first portion comprising a first volume of nanoparticles. A second portion of the hard polycrystalline material comprises a second volume of nanoparticles. The first volume of nanoparticles differs from the second volume of nanoparticles. Methods of forming cutting elements for earth-boring tools comprise forming a volume of superabrasive material, including forming a first portion of the superabrasive material comprising a first volume of nanoparticles. A second portion of the superabrasive material is formed comprising a second volume of nanoparticles, the second volume differing from the first volume. | 02-16-2012 |
| 20120043138 | Rotational Drill Bits and Drilling Apparatuses Including the Same - A roof-bolt drill bit may include a bit body that is rotatable about a central axis and at least one cutting element mounted to the bit body. The at least one cutting element may include a cutting face, a cutting edge adjacent the cutting face, a back surface opposite the cutting face, and at least one coupling feature positioned adjacent the at least one cutting element. The at least one cutting element may be secured to the bit body by the at least one coupling feature. | 02-23-2012 |
| 20120055716 | HIGH QUALITY PCD COMPACT - A sintered cutting element including a superabrasive layer supported on a substrate. The superabrasive layer includes superabrasive material and secondary phase, and the substrate includes a binder phase. The sintered cutting element is formed by a high temperature high pressure sintering process in which separate source elements melt and sweep first through the superabrasive layer, and then to the substrate to form the secondary phase and binder phase. The superabrasive layer is substantially free of or free of eta-phase, Co | 03-08-2012 |
| 20120055717 | POLYCRYSTALLINE DIAMOND ELEMENT - An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or ail of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material. | 03-08-2012 |
| 20120061149 | POLYCRYSTALLINE DIAMOND ELEMENT - An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmospheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD element includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond. | 03-15-2012 |
| 20120073880 | Subterranean Cutting Tool Structure Tailored to Intended Use - A mill cutting structure is differently configured in three zones. Those zones are the center, the outer edge and in between. At the center has highly wear resistant material that has good temperature bond strength and high impact resistance. The outer periphery can have a material that is highly resistant to wear and impact. In between can be inserts such as used in the Metal Muncher® mills using sintered carbide shapes that resist tracking and create a chipping rather than a grinding action. The shapes should have high edge retention capability and shapes such as a double sided pyramid can be used. The wear patterns of prior designs are addressed to allow longer and faster milling of the fish. | 03-29-2012 |
| 20120073881 | ROLLING CUTTER - A cutting element for a drill bit that includes an outer support element having at least a bottom portion and a side portion; and an inner rotatable cutting element, a portion of which is disposed in the outer support element, wherein the inner rotatable cutting element includes a substrate and a diamond cutting face having a thickness of at least 0.050 inches disposed on an upper surface of the substrate; and wherein a distance from an upper surface of the diamond cutting face to a bearing surface between the inner rotatable cutting element and the outer support element ranges from 0 to about 0.300 inches is disclosed. | 03-29-2012 |
| 20120080239 | CUTTING ELEMENTS, EARTH-BORING TOOLS INCORPORATING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS - Cutting elements include a substrate, a thermally stable polycrystalline table comprising a superhard material secured to the substrate, and a layer of metal interposed between, and attaching the substrate and the thermally stable polycrystalline table. Methods of forming a cutting element include providing a thermally stable polycrystalline table in a mold, providing a layer of metal on the thermally stable polycrystalline table, distributing a mixture of particles comprising a plurality of hard particles and a plurality of particles comprising a matrix material on the layer of metal, and heating the mold while applying pressure to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and at least partially melt the layer of metal to flow and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween. | 04-05-2012 |
| 20120080240 | DIAMOND IMPREGNATED CUTTING STRUCTURES, EARTH-BORING DRILL BITS AND OTHER TOOLS INCLUDING DIAMOND IMPREGNATED CUTTING STRUCTURES, AND RELATED METHODS - An earth-boring tool includes a bit body, a plurality of first cutting elements, and a plurality of second cutting elements. Each of the first cutting elements includes a discontinuous phase dispersed within a continuous matrix phase. The discontinuous phase includes a plurality of particles of superabrasive material. Each of the second cutting elements includes a polycrystalline diamond compact or tungsten carbide. A method of forming an earth-boring tool includes disposing a plurality of first cutting elements on a bit body and disposing a second plurality of second cutting elements on the bit body. Another method of foaming an earth-boring tool includes forming a body having a plurality of first cutting elements and a plurality of cutting element pockets and securing each of a plurality of second cutting elements within each of the cutting element pockets. | 04-05-2012 |
| 20120085585 | COMPOSITE MATERIALS INCLUDING NANOPARTICLES, EARTH-BORING TOOLS AND COMPONENTS INCLUDING SUCH COMPOSITE MATERIALS, POLYCRYSTALLINE MATERIALS INCLUDING NANOPARTICLES, AND RELATED METHODS - A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed. | 04-12-2012 |
| 20120090900 | SPECIAL CURVE BRAZE SHEET FOR TOP LOADING CUTTER TO GET BETTER BRAZE STRENGTH - A method of brazing a top loading cutter into a cutter pocket is disclosed, wherein the method includes placing at least one braze disc between an inner wall of the cutter pocket and a portion of the top loading cutter and heating the at least one braze disc to a temperature above the melting temperature of the braze disc. | 04-19-2012 |
| 20120097457 | POLYCRYSTALLINE DIAMOND CUTTING ELEMENT - A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate. | 04-26-2012 |
| 20120097458 | DIAMOND BONDED CONSTRUCTION WITH THERMALLY STABLE REGION - Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element. | 04-26-2012 |
| 20120103697 | INSERTS, POLYCRYSTALLINE DIAMOND COMPACT CUTTING ELEMENTS, EARTH-BORING BITS COMPRISING SAME, AND METHODS OF FOMING SAME - An insert for an earth-boring tool includes a body and a coating disposed over at least a portion of the body. The coating comprises a ceramic comprising boron, aluminum, and magnesium. Polycrystalline diamond compact cutting elements may include a hard polycrystalline material, a supporting substrate, and a coating disposed over at least a portion of the hard polycrystalline material. An earth-boring drill bit may include a bit body and at least one polycrystalline diamond compact cutting element secured to the bit body. The polycrystalline diamond compact cutting element may have a coating comprising a ceramic of boron, aluminum, and magnesium, and may be disposed over at least a portion of a hard polycrystalline material. A method of forming an insert for an earth-boring tool may include forming a protective coating including a ceramic of boron, aluminum, and magnesium over a cutting element. | 05-03-2012 |
| 20120103698 | CUTTING ELEMENTS, EARTH-BORING TOOLS INCORPORATING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS - Cutting elements comprise a substrate, a polycrystalline table, and an asymmetric interface feature. The interface feature comprises a shape that is reflectively asymmetric about at least two planes defined by x, y, and z axes of a Cartesian coordinate system defined to align a z axis of the coordinate system with the central axis of the substrate and to locate a center of the coordinate system at a midpoint along an axial height of the asymmetric interface feature. Methods of forming a cutting element comprise: totaling an asymmetric interface feature at an end of a substrate; distributing a plurality of superhard particles on the substrate over the asymmetric interface feature in a mold; and bonding the superhard particles in the mold to form a polycrystalline table attached to the substrate. | 05-03-2012 |
| 20120103699 | INTERFACE DESIGN OF TSP SHEAR CUTTERS - A method of forming a cutting element is disclosed, wherein the method includes forming a substrate body, forming an intermediate layer on the substrate body, forming a diamond table, and positioning the diamond table on the intermediate layer, such that the intermediate layer is disposed between the substrate body and the diamond table. The intermediate layer has a base portion having a base height and a ring portion having a ring height H | 05-03-2012 |
| 20120103700 | CUTTING ELEMENT STRUCTURE WITH SLOPED SUPERABRASIVE LAYER - A superabrasive compact cutting element, for example, a insert utilized in shear cutter bits. The cutting elements include a layer of superabrasive materials that is provided with different shapes and positions relative to the substrate in order to enhance the abrasion resistance performance of the cutting element. The cutting element includes a top, bottom and peripheral surface. The cutting element further includes at least one superabrasive material portion comprising polycrystalline diamond (PCD) or cubic boron nitride (CBN), a substrate supporting the at least one superabrasive material portion, and an interface where the at least one superabrasive material portion and the substrate are joined. The interface slopes downwardly with a slope angle of less than about 40° and/or the cutting element has a longitudinal thickness of the at least one superabrasive material portion measured along a peripheral surface of the cutting element in a longitudinal direction greater than about 3 mm. | 05-03-2012 |
| 20120103701 | CONTOURED PCD AND PCBN SEGMENTS FOR CUTTING TOOLS CONTAINING SUCH SEGMENTS - Contoured helical solid polycrystalline PCD and PCBN superabrasive segments are provided for attachment to cutting tool substrates such as twist drill tips, reamers, burrs and endmills. Segments are provided in near to net shape for attachment to a tool substrate thereby requiring reduced finishing steps and providing increased tailorability of grade and quality of final polycrystalline segments. Cutting tools comprising cutting tool substrates having attached thereto a contoured helical solid polycrystalline PCD and PCBN superabrasive segments are also disclosed. | 05-03-2012 |
| 20120111642 | POLYCRYSTALLINE COMPACTS INCLUDING NANOPARTICULATE INCLUSIONS, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SAME - Polycrystalline compacts include non-catalytic, non-carbide-forming particles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include forming a polycrystalline material including a hard material and a plurality of particles comprising a non-catalytic, non-carbide-forming material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic, non-carbide-forming particles. | 05-10-2012 |
| 20120125695 | EARTH-BORING TOOLS INCLUDING REPLACEABLE CUTTING STRUCTURES AND RELATED METHODS - Earth-boring tools comprise a body and one or more replaceable cutting structures attached to the body at a face region of the body. Each replaceable cutting structure comprises an attachment member and a cutting portion configured to engage an underlying earth formation. Methods of forming an earth-boring tool comprise attaching one or more cutting elements to a replaceable cutting structure; positioning the replaceable cutting structure proximate a region of a body of an earth-boring tool that is susceptible to at least one of localized wear and localized impact damage; and attaching the replaceable cutting structure to the body. Methods of repairing an earth-boring tool comprise bringing a replaceable cutting structure proximate at least one portion of a body of an earth-boring tool exhibiting at least one of localized wear and localized impact damage; and attaching the replaceable cutting structure to the earth-boring tool at the at least one portion. | 05-24-2012 |
| 20120138370 | METHOD OF PARTIALLY INFILTRATING AN AT LEAST PARTIALLY LEACHED POLYCRYSTALLINE DIAMOND TABLE AND RESULTANT POLYCRYSTALLINE DIAMOND COMPACTS - In an embodiment, a method of fabricating a polycrystalline diamond compact (“PDC”) includes forming a polycrystalline diamond (“PCD”) table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (“HPHT”) process. The PCD table includes bonded diamond grains defining interstitial regions, with the metal-solvent catalyst disposed therein. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process under diamond-stable temperature-pressure conditions to partially infiltrate the at least partially leached PCD table with an infiltrant. A maximum temperature (T), a total process time (t), and a maximum pressure (P) of the second HPHT process are chosen so that β is about 2° Celsius·hours/gigapascals (“° C.·h/GPa”) to about 325° C.·h/GPa, with β represented as β=T·t/P. | 06-07-2012 |
| 20120145465 | DRILL BIT - The proposed device relates to roller drill bits with air drilling capability and can be used for drilling of rocks of high hardness. The drill bit includes a body and rock-destroying elements with cutting equipment mounted on the body one inside the other by means of bearing supports, wherein the inner element is located at an angle relatively to the axis of the drill bit, and the outer element is located in the opposite direction of the axis. The device provides for an increase of the service life, high efficiency, and interchangeability due to a special design, which envisages the cutting equipment formed as replaceable jet nozzles made of hardwearing material and provided with arm insertions, preferably made of wolframite-cobalt based alloy, wherein the bearing support of each rock-destroying element is furnished with a unit adjusting the axial play value of the rock-destroying elements. | 06-14-2012 |
| 20120152622 | In-Situ Boron Doped PDC Element - A polycrystalline diamond compact formed in an in-situ boron-doped process. The in-situ boron-doped process includes consolidating a mixture of diamond crystals and boron-containing alloy via liquid diffusion of boron into diamond crystals at a pressure greater than 5 Gpa and at a temperature greater than the melting temperature of the boron-containing alloy, typically less than about 1450° C. | 06-21-2012 |
| 20120152623 | PDC BITS WITH CUTTERS LAID OUT IN BOTH SPIRAL DIRECTIONS OF BIT ROTATION - Downhole drilling tools designed and manufactured to reduce bit axial force and torque and to enhance drilling efficiency comprising laying out some cutters in one spiral direction of rotation about a bit rotational axis and other cutters in an opposite spiral direction of rotation; evaluating forces acting on cutters during simulated engagement with a downhole formation (straight and transitional drilling); and modifying cutter layout with respect to a spiral direction of rotation. Some embodiments further comprise, prior to simulation, placing cutters in cutter groups/sets at respective locations to obtain a level of force balance. Multilevel force balanced downhole drilling tools may be designed using five respective simulations: cutter group level, neighbor cutter group level, cutter set level, group of N (N=3 or N=4) consecutive cutters level and all cutters level. Cutter layout procedures and algorithms to minimize respective bit forces and in some embodiments to obtain force balance are described. | 06-21-2012 |
| 20120152624 | PDC Bits with Mixed Cutter Blades - Downhole drilling tools designed and manufactured to minimize or reduce imbalance forces and wear by disposing cutting elements in cutter groups and cutter sets in a level of force balance and by placing impact and/or wear resistant cutters on blades subject to high impact forces and/or large loadings. Manufacturing costs may be reduced by placing inexpensive cutters on blades not subject to high impact forces and/or loadings. Some embodiments comprise designing downhole tools with combinations of thicker blades to receive high impact forces and/or loadings with thinner blades. Some embodiments comprise designing downhole drilling tools with optimized fluid-flow properties. Designing methods may comprise performing simulations on a designed tool, evaluating respective forces acting on cutters during simulated engagement with a downhole (uniform and transitional) and/or evaluating wear on cutters and bit, and/or CFD simulations to evaluate fluid-flow optimization on a tool. Various cutter layout procedures and algorithms are described. | 06-21-2012 |
| 20120152625 | BONDING STRUCTURE AND BONDING METHOD FOR CEMENTED CARBIDE ELEMENT AND DIAMOND ELEMENT, CUTTING TIP AND CUTTING ELEMENT FOR DRILLING TOOL, AND DRILLING TOOL - A cutting tip for a drilling tool includes a cemented carbide cutting base, a diamond element supported by the cutting base, and a bonding layer formed between the cutting base and the diamond element in order to bond them. The bonding layer includes diffusion layers and in which one or two or more metals selected from a group consisting of Fe, Ni, Co, Ti, Zr, W, V, Nb, Ta, Cr, Mo, and Hf diffuses into at least one of the diamond or the cement carbide. | 06-21-2012 |
| 20120160573 | Drill Bits, Cutting Elements for Drill Bits, and Drilling Apparatuses Including the Same - A roof-bolt drill bit may have a forward end, a rearward end, and a rotational axis extending between the forward end and the rearward end. A cutting element for the roof-bolt drill bit may include a cutting face and a peripheral surface extending around an outer periphery of the cutting face. The cutting element may include at least one chamfer region and a peripherally extending chamfer extending from the at least one chamfer region along the outer periphery of the cutting element, a width of the at least one chamfer region being greater than a width of the peripherally extending chamfer. | 06-28-2012 |
| 20120168232 | LOCALIZED FEATURES AND MANUFACTURING METHODS FOR INSERTS OF ROCK BITS - An insert for a drill bit and method of making an insert is disclosed herein. An insert has a grip region, a cutting extension having a cutting surface, and at least one implant embedded in the cutting extension, wherein the cutting extension comprises a first carbide material and the implant comprises a second carbide material, and wherein the second carbide material has a hardness that is greater than the first carbide material. | 07-05-2012 |
| 20120181090 | ROTARY DRILL BIT INCLUDING AT LEAST ONE SUPERABRASIVE CUTTING ELEMENT HAVING A DIAMOND-SILICON CARBIDE COMPOSITE TABLE - Embodiments relate to rotary drill bits that employ superabrasive cutting elements including a diamond-silicon carbide composite table. In an embodiment, a rotary drill bit includes a bit body configured to engage a subterranean formation. The bit body includes a plurality of blades. The rotary drill bit further includes a plurality of superabrasive cutting elements. Each of the superabrasive cutting elements is attached to a corresponding one of the cutting blades. At least one of the superabrasive cutting elements includes a substrate and a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including a matrix comprising nanometer-sized silicon carbide grains and micrometer-sized diamond grains dispersed through the matrix. | 07-19-2012 |
| 20120186884 | POLYCRYSTALLINE COMPACTS HAVING DIFFERING REGIONS THEREIN, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SUCH COMPACTS - Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming such polycrystalline compacts include removing catalyst material from interstitial spaces within a second region of a polycrystalline compact without entirely removing catalyst material from interstitial spaces within a first region of the compact. | 07-26-2012 |
| 20120186885 | POLYCRYSTALLINE COMPACTS HAVING DIFFERING REGIONS THEREIN, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SUCH COMPACTS - Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming such polycrystalline compacts include removing catalyst material from interstitial spaces within a second region of a polycrystalline compact without entirely removing catalyst material from interstitial spaces within a first region of the compact. | 07-26-2012 |
| 20120199401 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS AND BITS INCORPORATING THE SAME - Cutting elements have substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporate such cutting elements. | 08-09-2012 |
| 20120205163 | KERFING HYBRID DRILL BIT AND OTHER DOWNHOLE CUTTING TOOLS - A drill bit for drilling a borehole in earth formations may include a bit body having a bit axis and a bit face; a plurality of blades extending radially along the bit face; and a plurality of cutting elements disposed on the plurality of blades, the plurality of cutting elements comprising: at least one cutter comprising a substrate and a diamond table having a substantially planar cutting face; and at least two conical cutting elements comprising a substrate and a diamond layer having a conical cutting end, wherein in a rotated view of the plurality of cutting elements into a single plane, the at least one cutter is located a radial position from the bit axis that is intermediate the radial positions of the at least two conical cutting elements. | 08-16-2012 |
| 20120211283 | POLYCRYSTALLINE COMPACTS INCLUDING METALLIC ALLOY COMPOSITIONS IN INTERSTITIAL SPACES BETWEEN GRAINS OF HARD MATERIAL, CUTTING ELEMENTS AND EARTH BORING TOOLS INCLUDING SUCH POLYCRYSTALLINE COMPACTS, AND RELATED METHODS - Polycrystalline compacts include a polycrystalline material comprising a plurality of inter-bonded grains of hard material, and a metallic material disposed in interstitial spaces between the inter-bonded grains of hard material. At least a portion of the metallic material comprises a metal alloy that includes two or more elements. A first element of the two or more elements comprises at least one of cobalt, iron, and nickel. A second element of the two or more elements comprises at least one of dysprosium, yttrium, terbium, gadolinium, germanium, samarium, neodymium, and praseodymium. The metal alloys may comprise eutectic or near-eutectic compositions, and may have relatively low melting points. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods include the formation of such polycrystalline compacts, cutting elements, and earth-boring tools. | 08-23-2012 |
| 20120211284 | METHODS OF FORMING POLYCRYSTALLINE COMPACTS, CUTTING ELEMENTS AND EARTH-BORING TOOLS - Methods of forming a polycrystalline compact using at least one metal salt as a sintering aid. Such methods may include forming a mixture of the at least one metal salt and a plurality of grains of hard material and sintering the mixture to form a hard polycrystalline material. During sintering, the metal salt may melt or react with another compound to form a liquid that acts as a lubricant to promote rearrangement and packing of the grains of hard material. The metal salt may, thus, enable formation of hard polycrystalline material having increased density, abrasion resistance, or strength. The metal salt may also act as a getter to remove impurities (e.g., catalyst material) during sintering. The methods may also be employed to faun cutting elements and earth-boring tools. | 08-23-2012 |
| 20120228037 | SUPERABRASIVE ELEMENTS, METHODS OF MANUFACTURING, AND DRILL BITS INCLUDING SAME - Methods of manufacturing a superabrasive element and/or compact are disclosed. In one embodiment, a superabrasive volume including a tungsten carbide layer may be formed. Polycrystalline diamond elements and/or compacts are disclosed. Rotary drill bits for drilling a subterranean formation and including at least one superabrasive element and/or compact are also disclosed. | 09-13-2012 |
| 20120234608 | CUTTING ELEMENT PLACEMENT ON A FIXED CUTTER DRILL BIT TO REDUCE DIAMOND TABLE FRACTURE - A rotary drag bit includes a primary cutter row comprising at least one primary cutter mounted on a blade, at least some cutters in the primary cutter row having a portion of a cutting surface thereof covered by a portion of the blade. A backup cutter row comprising at least one cutter may also be included, and at least a portion of a cutting surface of at least some cutters in the backup cutter row is covered by a portion of the blade. Enhanced support for cutters is provided against impact loading. | 09-20-2012 |
| 20120234609 | CUTTING ELEMENT APPARATUSES, DRILL BITS INCLUDING SAME, METHODS OF CUTTING, AND METHODS OF ROTATING A CUTTING ELEMENT - A subterranean drilling system may include a drill string and a rotary drill bit coupled to the drill string. The rotary drill bit may include a bit body and a cutting element coupled to the bit body, with the cutting element being structured to rotate in response to torque applied to the cutting element. The system also may include a cam assembly coupled to the drill string, a cam follower assembly in contact with a cam surface of the cam assembly, and a torque-applying structure coupled to the cam follower assembly. The torque-applying structure may be configured to apply torque to the cutting element in response to relative rotation between the cam assembly and the cam follower assembly. | 09-20-2012 |
| 20120241223 | Cutting Insert For A Roof Drill Bit - A hard cutting insert for use with a roof drill bit includes a first webbed notch and a second webbed notch structured and arranged on the hard insert for removing or evacuating drilling debris from an upper surface of the hard insert during a drilling operation. A roof drill bit incorporating the hard cutting insert is also provided. | 09-27-2012 |
| 20120241224 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A CARBONATE-CATALYZED POLYCRYSTALLINE DIAMOND BODY AND APPLICATIONS THEREFOR - In an embodiment, a polycrystalline diamond compact (“PDC”) includes a substrate and a pre-sintered polycrystalline diamond (“PCD”) table bonded to the substrate. The pre-sintered PCD table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending between the upper surface and the back surface. The pre-sintered PCD table includes a region including at least a residual amount of at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, and a bonding region. The at least one interstitial constituent includes at least one metal carbonate and/or at least one metal oxide. The region extends inwardly from the upper surface and the at least one lateral surface. | 09-27-2012 |
| 20120241225 | COMPOSITE POLYCRYSTALLINE DIAMOND BODY - In this novel PDC cutter, diamond powders of different composition and/or different grain size, are distributed, shaped, and compacted with a novel pressing tool, in multiple stages, spatially arranged into different regions of the PDC diamond body, then HPHT sintered to form one PDC body with spatially varying hardness, toughness and thermal resistance more optimal for machining, drilling and/or cutting of hard rock and stone. | 09-27-2012 |
| 20120241226 | POLYCRYSTALLINE DIAMOND, POLYCRYSTALLINE DIAMOND COMPACTS, METHODS OF MAKING SAME, AND APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond compacts (“PDC”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 μm or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies. | 09-27-2012 |
| 20120247840 | METHODS OF FORMING EARTH BORING TOOLS AND RELATED STRUCTURES - Earth-boring tools comprise a body comprising a plurality of radially extending blades. At least one blade of the plurality of radially extending blades comprises a blade support segment integral with the body. A blade frame segment is attached to a rotationally leading portion of the blade support segment. A plurality of cutting elements is attached to the blade frame segment. Methods of forming an earth-boring tool comprise forming a body including a blade support segment of at least one blade. At least one blade frame segment is attached to a rotationally leading portion the support segment of the at least one blade. A plurality of cutting elements is secured to the at least one blade segment. | 10-04-2012 |
| 20120247841 | COATING ON PDC/TSP CUTTER FOR ACCELERATED LEACHING - A cutting element that includes a polycrystalline diamond layer having a cutting face and a diamond layer side surface, a substrate attached to the polycrystalline diamond layer, the substrate having a bottom surface and a substrate side surface, an interface between the diamond layer and the substrate, and a mask covering at least the bottom surface and the substrate side surface of the cutting element is disclosed. | 10-04-2012 |
| 20120255793 | MATRIX POWDER FOR MATRIX BODY FIXED CUTTER BITS - A drill bit is disclosed that has a bit body with a plurality of blades extending radially therefrom and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades. At least a portion of the plurality of blades has a first matrix region made of a plurality of first carbide particles separated by a first binder phase, wherein the plurality of first carbide particles have a mean free path of at least 40 microns. | 10-11-2012 |
| 20120261196 | HIGH DIAMOND FRAME STRENGTH PCD MATERIALS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having high diamond frame strength and methods for forming and evaluating such polycrystalline diamond bodies. A polycrystalline diamond body is provided, having a top surface, a cutting edge meeting the top surface, and a first region including at least a portion of the cutting edge. The first portion exhibits a diamond frame strength of about 1200 MPa or greater, or about 1300 MPa or greater. | 10-18-2012 |
| 20120267172 | METHODS FOR FORMING POLYCRYSTALLINE MATERIALS INCLUDING PROVIDING MATERIAL WITH SUPERABRASIVE GRAINS PRIOR TO HPHT PROCESSING, AND POLYCRYSTALLINE COMPACTS AND CUTTING ELEMENTS FORMED BY SUCH METHODS - Grains of superabrasive material may be infiltrated with a molten metal alloy at a relatively low temperature, and the molten metal alloy may be solidified within interstitial spaces between the grains of superabrasive material to form a solid metal alloy having the grains of superabrasive material embedded therein. The solid metal alloy with the grains of superabrasive material embedded therein may be subjected to a high pressure and high temperature process to form a polycrystalline superabrasive material. A polycrystalline superabrasive material also may be formed by depositing material on surfaces of grains of superabrasive material in a chemical vapor infiltration process to form a porous body, which then may be subjected to a high pressure and high temperature process. Polycrystalline compacts and cutting elements including such compacts may be formed using such methods. | 10-25-2012 |
| 20120267173 | DRILL BIT FOR BORING EARTH AND OTHER HARD MATERIALS - A drill bit for drilling a hole through earth and hard materials, the drill bit including a bit body having an inner bore and a cutting head at a cutting end, the cutting head including a center portion with one or more apertures extending from the cutting end to the inner bore, a perimeter portion projecting radially outward to form a plurality of blades divided by a plurality of junk slots, a cutting face, and a plurality of cutter receptacles spaced about the cutting face. A plurality of cutters with cutter tips terminating in points are in mounted into the cutter receptacles at a pitch angle relative to the cutting face, and with the plurality of cutter points together defining a projected cutting surface. | 10-25-2012 |
| 20120267174 | METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND ELEMENTS AND COMPACTS USING SP2-CARBON-CONTAINING PARTICLES - In an embodiment, a polycrystalline diamond compact includes a polycrystalline diamond table having nanocrystalline diamond present in an amount greater than zero weight percent to about 5 weight percent of the polycrystalline diamond table. The polycrystalline diamond table including a catalyst material distributed throughout at least a portion thereof. The polycrystalline diamond compact includes a substrate bonded to the polycrystalline diamond table. | 10-25-2012 |
| 20120273280 | POLYCRYSTALLINE DIAMOND COMPACT CUTTERS WITH CONIC SHAPED END - A cutting element may have a substrate; and an ultrahard material layer having a substantially planar upper surface disposed on an upper surface of the substrate; wherein at least a portion of the side surface between the upper surface of the substrate and a lower end of the substrate form at least one conic surface, wherein the at least one conic surface extends a height relative to the total height of the substrate and ultrahard material layer ranging from about 1:10 to 9:10, and wherein the substrate comprises a substantially planar lower surface. The cutting elements may also be rotatable cutting elements at least partially surrounded by outer support elements. | 11-01-2012 |
| 20120279785 | EARTH-BORING TOOLS AND METHODS OF FORMING SUCH EARTH-BORING TOOLS - Earth-boring drill bits comprise a bit body having a plurality of radially extending blades and a plurality of cutting elements attached to the plurality of radially extending blades. Only gouging cutting elements are attached to at least one blade of the plurality of radially extending blades. Only shearing cutting elements are attached to at least another blade of the plurality of radially extending blades. Only shearing cutting elements are attached to a number of blades of the plurality of radially extending blades that is different from a number of blades of the plurality of radially extending blades to which only gouging cutting elements are attached. Methods of forming an earth-boring drill bit comprise forming a bit body including a plurality of radially extending blades. Only shearing cutting elements are attached to a number of blades different from a number of blades to which only gouging cutting elements are attached. | 11-08-2012 |
| 20120292117 | WELLBORE TOOLS HAVING SUPERHYDROPHOBIC SURFACES, COMPONENTS OF SUCH TOOLS, AND RELATED METHODS - Wellbore tools include a body and a superhydrophobic surface disposed over at least a portion of the body. The superhydrophobic surface includes a patterned surface of a hydrophobic material exhibiting a higher hydrophobicity than an unpatterned surface of the hydrophobic material. A wellbore tool may include a seal, at least one sensor, and at least one flow line, each having at least one superhydrophobic surface. Methods of forming wellbore tools include forming a body, forming a hydrophobic surface over at least a portion of the body, and forming a pattern in a surface of the body, such that the patterned surface exhibits a higher hydrophobicity than an unpatterned surface of the same material. | 11-22-2012 |
| 20120292118 | ADNR COMPOSITE - A composite body has a material layer formed from aggregated diamond nanorods (ADNRs); The ADNR material layer has a first surface and a substrate. The first surface of the diamond material layer and the substrate are bonded together under high pressure and high temperature. | 11-22-2012 |
| 20120318584 | ROTARY DRILL AND METHOD FOR THE PRODUCTION THEREOF - Rotary rock bit comprising a tool body having an axial core ( | 12-20-2012 |
| 20120325563 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS FOR EARTH-BORING TOOLS - Cutting elements for use with earth-boring tools include a cutting table having at least two sections where a boundary between the at least two sections is at least partially defined by a discontinuity formed in the cutting table. Earth-boring tools including a tool body and a plurality of cutting elements carried by the tool body. The cutting elements include a cutting table secured to a substrate. The cutting table includes a plurality of adjacent sections, each having a discrete cutting edge where at least one section is configured to be selectively detached from the substrate in order to substantially expose a cutting edge of an adjacent section. Methods for fabricating cutting elements for use with an earth-boring tool including forming a cutting table comprising a plurality of adjacent sections. | 12-27-2012 |
| 20120325564 | CUTTER TOOL INSERT HAVING SENSING DEVICE - A cutting element for an earth-boring drilling tool and its method of making are provided. The cutting element may include a substrate, a superhard layer, and a sensing element. The superhard layer may be bonded to the substrate along an interface. The superhard layer may have a working surface opposite the interface and an outer peripheral surface. The outer peripheral surface may extend between the working surface and the interface. The sensing element may comprise at least a part of the superhard layer. | 12-27-2012 |
| 20130015000 | INNOVATIVE CUTTING ELEMENT AND CUTTING STRUCTURE USING SAME - A cutting tool is disclosed that includes a tool body, a plurality of cutting element support structures extending from the tool body, at least one slot formed in at least one of the cutting element support structures, a cutting element having a diamond shearing element with a plurality of surfaces, and at least one mechanical retention mechanism adjacent to the cutting element. Each cutting element support structure has a leading face, a top side, and a trailing face, and the slot has two side surfaces, each side surface terminating at the leading face and top side of the cutting element support structure. Each surface of the cutting element has two dimensional values, wherein the cutting element is positioned in the at least one slot such that a plane in which the shortest dimensional value lies intersects the slot side surfaces. | 01-17-2013 |
| 20130015001 | POLYCRYSTALLINE DIAMOND COMPACTS, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS - Embodiments of the invention relate to a polycrystalline diamond compact. In an embodiment, the polycrystalline diamond compact includes a substrate and a polycrystalline diamond table including a first polycrystalline diamond layer bonded to the substrate and at least a second polycrystalline diamond layer. At least an un-leached portion of the polycrystalline diamond table includes a plurality of diamond grains defining a plurality of interstitial regions and a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oe or more and a specific magnetic saturation of about 15 G·cm | 01-17-2013 |
| 20130043078 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A CARBONATE-CATALYZED POLYCRYSTALLINE DIAMOND TABLE AND APPLICATIONS THEREFOR - In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein. | 02-21-2013 |
| 20130048388 | DRILL BIT WITH CUTTING ELEMENTS HAVING FUNCTIONALLY ENGINEERED WEAR SURFACE - Drill bits and cutting elements having a functionally-engineered surface comprise a cermet material selected from the group consisting of refractory metal carbides, nitrides, borides, carbonitrides and mixtures thereof A functionally-engineered material is disposed over a surface portion one of the cutting elements to form a wear resistant surface thereon having a hardness that is different than that of the underlying cutting element. The wear resistant surface is provided by forming a conformable material mixture by combining one or more powders selected from the group consisting of cermets, carbides, borides, nitrides, carbonitrides, refractory metals, diamond particles, cubic boron nitride particles, Co, Fe, Ni, and combinations thereof, with an applying agent. The applied material mixture is pressurized under conditions of elevated temperature to consolidate and sinter the material mixture, thereby forming the wear resistant surface having desired properties of hardness and/or fracture toughness. | 02-28-2013 |
| 20130056284 | ELEMENT CONTAINING THERMALLY STABLE POLYCRYSTALLINE DIAMOND MATERIAL AND METHODS AND ASSEMBLIES FOR FORMATION THEREOF - The disclosure provides a super abrasive element containing a substantially catalyst-free thermally stable polycrystalline diamond (TSP) body having pores and a contact surface, a base adjacent the contact surface of the TSP body; and an infiltrant material infiltrated in the base and in the pores of the TSP body at the contact surface. The disclosure additionally provides earth-boring drill bits and other devices containing such super abrasive elements. The disclosure further provides methods and mold assemblies for forming such super abrasive elements via infiltration and hot press methods. | 03-07-2013 |
| 20130068534 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS AND RELATED METHODS - Cutting elements, earth-boring drill bits having such cutting elements and related methods are described herein. In some embodiments, a cutting element for an earth-boring tool may include a superabrasive table having a recessed surface in a cutting face thereof and a shaped feature in a substrate at the interface between the superabrasive table and the substrate, the shaped feature corresponding to the recessed surface in the cutting face of the superabrasive table. In further embodiments, a cutting element for an earth-boring tool may comprise a superabrasive table positioned on a substrate, and at least one substantially planar recessed surface in a cutting face of the superabrasive table. In yet additional embodiments, a cutting element for an earth-boring tool may comprise a superabrasive table positioned on a substrate, and at least one non-planar recessed surface in a cutting face of the superabrasive table. | 03-21-2013 |
| 20130068535 | 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 - A method of forming a cutting element for an earth-boring tool. The method includes providing diamond particles on a supporting substrate, the volume of diamond particles comprising a plurality of diamond nanoparticles. A catalyst-containing layer is provided on exposed surfaces of the volume of diamond nanoparticles and the supporting substrate. The diamond particles are processed under high temperature and high pressure conditions to form a sintered nanoparticle-enhanced polycrystalline compact. A cutting element and an earth-boring tool including a cutting element are also disclosed. | 03-21-2013 |
| 20130068536 | METHODS OF FORMING POLYCRYSTALLINE DIAMOND COMPACTS AND RESULTING POLYCRYSTALLINE DIAMOND COMPACTS AND CUTTING ELEMENTS - Methods for forming cutting elements comprising polycrystalline materials, methods for forming polycrystalline compacts for cutting elements of a drilling tool, method for forming polycrystalline diamond compacts, and resulting polycrystalline compacts and cutting elements are disclosed. Grains of a hard material are introduced to a press and subjected to a high pressure, high temperature (HPHT) process to sinter the grains. The system conditions (i.e., temperature and pressure) are then adjusted past a phase or state change point, after which, at least one of the system conditions is held during an anneal stage before the system conditions are adjusted to final levels. The resulting compacts and cutting elements may therefore include inter-granularly bonded hard material grains with a more stable microstructure (e.g., less stressed microstructure) than a polycrystalline compact and cutting element formed without an anneal stage during the HPHT process. | 03-21-2013 |
| 20130075167 | Rotary Drag Bit - A rotary drag bit has one or more fixed composite cutting structures formed from a plurality of discrete prefabricated cutters that abut each other along complementary side surfaces, the composite cutting structure being placed and oriented on the cutting face of the rotating body so that the composite cutting structure presents a cutting profile that does not expose any portion of the cutting face that is between or behind the composite cutting structure, with respect to the direction of travel of the composite cutting structure during boring, to the uncut earth formation as the body is rotated during boring. | 03-28-2013 |
| 20130081882 | METHOD OF CHARACTERIZING A MATERIAL USING THREE DIMENSIONAL RECONSTRUCTION OF SPATIALLY REFERENCED CHARACTERISTICS AND USE OF SUCH INFORMATION - A method for characterizing a three-dimensional spatial distribution of a characteristic of an ultra-hard body includes successively removing portions of the ultra-hard body to successively expose sub-portions, determining a characteristic of each of the exposed sub-portions, and reconstructing a three-dimensional spatial distribution of the characteristic of the ultra-hard body from the determined characteristic of each of the sub-portions. | 04-04-2013 |
| 20130092451 | POLYCRYSTALLINE DIAMOND COMPACTS, RELATED PRODUCTS, AND METHODS OF MANUFACTURE - Embodiments relate to polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond (“PCD”) table is infiltrated with a low viscosity cobalt-based alloy infiltrant. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (“HPHT”) process. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom to form an at least partially leached PCD table. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process effective to at least partially infiltrate the at least partially leached PCD table with a cobalt-based alloy infiltrant having a composition at or near a eutectic composition of the cobalt-based alloy infiltrant. | 04-18-2013 |
| 20130092452 | POLYCRYSTALLINE DIAMOND COMPACTS, RELATED PRODUCTS, AND METHODS OF MANUFACTURE - Embodiments relate to polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond (“PCD”) table is infiltrated with a low viscosity cobalt-based alloy infiltrant. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (“HPHT”) process. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom to form an at least partially leached PCD table. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process effective to at least partially infiltrate the at least partially leached PCD table with an alloy infiltrant comprising at least one of a cobalt-based or nickel based alloy infiltrant having a composition at or near a eutectic composition of the alloy infiltrant. | 04-18-2013 |
| 20130092453 | USE OF TUNGSTEN CARBIDE TUBE ROD TO HARD-FACE PDC MATRIX - A hardfaced infiltrated matrix downhole tool and a method for hardfacing such items. The hardfaced infiltrated matrix downhole tool includes a body, an intermediate base coat coupled to at least a portion of the surface of the body, and a hardfacing material coupled to at least a portion of the intermediate base coat. The body is composed of at least a carbide material and an infiltrating binder material. The intermediate base coat bonds to the surface of the body and to the hardfacing material. The method includes obtaining an infiltrated matrix downhole tool, applying and bonding the intermediate base coat to at least a portion of the surface of the infiltrated matrix downhole tool, and applying and bonding the hardfacing material to at least a portion of the intermediate base coat. | 04-18-2013 |
| 20130092454 | POLYCRYSTALLINE COMPACTS INCLUDING GRAINS OF HARD MATERIAL, EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SUCH COMPACTS AND TOOLS - Polycrystalline compacts include a polycrystalline superabrasive material comprising a first plurality of grains of superabrasive material having a first average grain size and a second plurality of grains of superabrasive material having a second average grain size smaller than the first average grain size. The first plurality of grains is dispersed within a substantially continuous matrix of the second plurality of grains. Earth-boring tools may include a body and at least one polycrystalline compact attached thereto. Methods of forming polycrystalline compacts may include coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, forming a green structure comprising the coated grains, and sintering the green structure. Other methods include mixing diamond grains with a catalyst and subjecting the mixture to a pressure greater than about five gigapascals (5.0 GPa) and a temperature greater than about 1,300° C. to form a polycrystalline diamond compact. | 04-18-2013 |
| 20130092455 | OBLIQUE FACE POLYCRYSTALLINE DIAMOND CUTTER AND DRILLING TOOLS SO EQUIPPED - A superabrasive cutter including a superabrasive table having a cutting face in non-perpendicular orientation with respect to a longitudinal axis of the cutter. A superabrasive cutter having a cutting face of a superabrasive table in non-parallel orientation to a back surface thereof. | 04-18-2013 |
| 20130098692 | DRILL BIT - The present invention provides a drill bit ( | 04-25-2013 |
| 20130098693 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A SUBSTRATE HAVING A RAISED INTERFACIAL SURFACE BONDED TO A LEACHED POLYCRYSTALLINE DIAMOND TABLE, AND APPLICATIONS THEREFOR - In various embodiments, a polycrystalline diamond compact (“PDC”) comprises a substrate including an interfacial surface having a raised region. The PDC comprises a polycrystalline diamond (“PCD”) table bonded to the interfacial surface of the substrate. The PCD table defines an upper surface and exhibits a thickness over the raised region. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. A first region of the PCD table adjacent to the substrate includes metal-solvent catalyst disposed interstitially between the bonded diamond grains thereof, and a leached second region of the PCD table extends inwardly from the upper surface. The interstitial regions of the leached second region are depleted of metal-solvent catalyst. The geometry of the PCD table and raised region may be selected so that residual compressive stresses therein are retained to a sufficient level after leaching to provide a damage tolerant/thermally-stable PCD table. | 04-25-2013 |
| 20130105231 | EARTH BORING CUTTING INSERTS AND EARTH BORING BITS INCLUDING THE SAME | 05-02-2013 |
| 20130140096 | CUTTING STRUCTURES, EARTH-BORING TOOLS INCLUDING SUCH CUTTING STRUCTURES, AND RELATED METHODS - Earth-boring tools comprise a body comprising at least one pocket extending into the body. A first discrete cutting element segment is secured within the at least one pocket. At least another discrete cutting element segment is secured within the at least one pocket. Methods of forming a cutting structure secured to an earth-boring tool comprise disposing at least one discrete cutting element or at least one cutting element segment within a pocket or recess formed in a blade extending longitudinally and radially over a face of a body. At least one discrete wearable element or at least another discrete cutting element segment is disposed within the pocket or recess. The at least one discrete cutting element or at least one discrete cutting element segment and the at least one discrete wearable element or at least another discrete cutting element segment are secured to the blade within the pocket or recess. | 06-06-2013 |
| 20130146368 | METHOD FOR FORMING A CUTTING ELEMENT AND DOWNHOLE TOOLS INCORPORATING THE SAME - Cutting elements include an ultrahard material body formed at high pressure and high temperature conditions in the absence of catalyzing material to provide a material microstructure comprising a matrix phase of bonded together ultrahard material particles and interstitial regions disposed throughout the matrix phase providing porosity of less than about 6 volume percent. The body may include a substrate attached thereto, and may include an infiltrant material disposed in a population of the interstitial regions. The body may have regions with different porosities, e.g., with a higher porosity region located adjacent a substrate interface and/or along a central region. The body may include more than one infiltrant, each located in different regions. The infiltrant may be introduced into the body during a separate high pressure/high temperature process. The body may include a region which extends a depth from a working surface that is substantially free of any infiltrant. | 06-13-2013 |
| 20130146369 | DIAMOND BONDED CONSTRUCTION WITH THERMALLY STABLE REGION - Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element. | 06-13-2013 |
| 20130168156 | DIAMOND ENHANCED INSERT WITH FINE AND ULTRAFINE MICROSTRUCTURE OF PCD WORKING SURFACE RESISTING CRACK FORMATION - An insert for a drill bit may include a metallic carbide body; an outer layer of polycrystalline diamond material on the uppermost end of the insert, wherein the polycrystalline diamond material comprises: a plurality of interconnected diamond grains; a plurality of additive grains; a binder material; wherein the average additive grain size is smaller than the average diamond grain size. | 07-04-2013 |
| 20130168157 | THERMALLY STABLE POLYCRYSTALLINE ULTRAHARD MATERIAL REINFORCED WITH FIBROUS MATERIALS - A polycrystalline diamond construction includes a diamond body having a thermally stable diamond matrix comprising bonded-together diamond crystals, wherein the diamond matrix includes a diamond volume content of at least 99%, and a plurality of fibers extending through the thermally stable diamond matrix. The diamond construction may be bonded to a substrate forming a shear cutter. The shear cutter may be mounted on a bit body. | 07-04-2013 |
| 20130168158 | METHOD FOR BRAZE JOINING OF CARBONATE PCD - A method for making a diamond compact includes pre-heating a diamond body which includes a carbonate catalyst to convert at least a portion of the carbonate catalyst into an oxide, assembling the diamond body and a substrate, providing a braze material between the diamond body and the substrate to form a diamond compact, heating the braze material to melt the braze material and form a braze joint between the diamond body and the substrate, and cooling the braze material after increasing the pressure. A bit having a diamond compact including a carbonate catalyst and a metal oxide mounted thereon. | 07-04-2013 |
| 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 |
| 20130213721 | SUPERHARD CUTTER - A cutter comprises a superhard construction, the cutter having a cutting edge defined by a rake face, and a flank extending therefrom. The cutter also has first and second regions, the first region abutting the second region along a boundary, the first region having a different material composition from the second region. At least the second region comprises superhard material, the material of the first region has a different coefficient of thermal expansion (CTE) from the material of the second region. The second region extends around the peripheral edge of the first region defined by the boundary to form a collar therearound, the first region and/or the second region extending to and/or forming at least a part of the rake face. | 08-22-2013 |
| 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 |
| 20130256039 | POLYCRYSTALLINE COMPACTS INCLUDING NANOPARTICULATE INCLUSIONS AND METHODS OF FORMING SUCH COMPACTS - Polycrystalline compacts include non-catalytic nanoparticles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include sintering hard particles and non-catalytic nanoparticles to faun a polycrystalline material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic nanoparticles. | 10-03-2013 |
| 20130264124 | THERMALLY STABLE MATERIALS, CUTTER ELEMENTS WITH SUCH THERMALLY STABLE MATERIALS, AND METHODS OF FORMING THE SAME - A thermally stable ultra-hard material, a cutting element incorporating such thermally stable ultra-hard material, and methods for forming the same. A thermally stable ultra-hard diamond element is combined with a second ultra-hard material volume forming an assembly. One or more surfaces of the thermally stable diamond element that face the second diamond volume are coated with a coating prior to combining the thermally stable diamond element with the second diamond volume. The assembly is sintered at high pressure and high temperature to form PCD from the second diamond volume. | 10-10-2013 |
| 20130292188 | EARTH-BORING TOOLS HAVING CUTTING ELEMENTS WITH CUTTING FACES EXHIBITING MULTIPLE COEFFICIENTS OF FRICTION, AND RELATED METHODS - An earth-boring tool having at least one cutting element with a multi-friction cutting face provides for the steering of formation cuttings as the cuttings slide across the cutting face. The multi-friction cutting element includes a diamond table bonded to a substrate of superabrasive material. The diamond table has a cutting face formed thereon with a cutting edge extending along a periphery of the cutting face. The cutting face has a first area having an average surface finish roughness less than an average surface finish roughness of a second area of the cutting face, the two areas separated by a boundary having a proximal end proximate the tool crown and a distal end remote from the tool crown. | 11-07-2013 |
| 20130299249 | SUPER-ABRASIVE MATERIAL WITH ENHANCED ATTACHMENT REGION AND METHODS FOR FORMATION AND USE THEREOF - The disclosure provides a super-abrasive body including a thermally stable polycrystalline diamond (TSP) body having a top region and an enhanced attachment region, wherein the enhanced attachment region includes tungsten carbide particles having a volume of at least 30% of the total volume of the enhanced attachment region. The disclosure further provides a super-abrasive element having the super-abrasive body attached to a substrate via an attachment material located in or around the tungsten carbide particles. The disclosure additionally provides earth-boring drill bits with such a super-abrasive element. Further, the disclosure provides methods of forming such super-abrasive bodies and elements by forming a PCD body with particle of tungsten carbide in an enhanced attachment region, then leaching the PCD body and attaching it to a substrate via an attachment material in or around the tungsten carbide particles. | 11-14-2013 |
| 20130313027 | POLYCRYSTALLINE DIAMOND COMPACT - In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table having an upper surface, an interfacial surface, and at least one side surface extending therebetween. The interfacial surface of the polycrystalline diamond table is bonded to the substrate. The polycrystalline diamond table includes bonded diamond grains defining interstitial regions. The polycrystalline diamond table includes a first region extending inwardly from at least a portion of the upper surface and at least a portion of the at least one side surface. The first region spaced from the interfacial surface. The polycrystalline diamond table includes at least a second region extending inwardly from the interfacial surface to the upper surface. The first region includes at least a first infiltrant disposed interstitially between the bonded diamond grains thereof. The second region includes at least a second infiltrant disposed interstitially between the bonded diamond grains thereof. | 11-28-2013 |
| 20130327577 | Cutting Bit With Hard Cutting Tip Centering and Braze Joint Control Feature - A cutting bit includes an elongate body having a shank portion and a head portion with an axial forward end. The head portion defines a pocket at the axial forward end thereof. The pocket includes a bottom surface and a sidewall extending from the bottom surface, wherein the sidewall of the pocket includes a plurality of projections extending outwardly from the sidewall. The cutting bit also includes a hard cutting tip attachably received in the pocket of the head portion. The plurality of projections are structured and arranged to position the hard cutting tip in the pocket and facilitate formation of a braze joint between the hard cutting tip and the pocket of the head portion. | 12-12-2013 |
| 20130333953 | CUTTING ELEMENTS RETAINED WITHIN SLEEVES - A cutter assembly may include a sleeve; and at least one cutting element having a lower spindle portion retained in the sleeve and a portion of the cutting element interfacing an axial bearing surface of the sleeve, wherein an outer diameter D of the cutting element and a radial length T of a substantially planar portion of the axial bearing surface of the sleeve have the following relationship: | 12-19-2013 |
| 20140020958 | ROTATIONAL DRILL BITS AND DRILLING APPARATUSES INCLUDING THE SAME - A roof-bolt drill bit has a bit body that is rotatable about a central axis, a coupling pocket defined in the bit body, and at least one cutting element mounted to the bit body, the at least one cutting element having a non-cylindrical periphery. The at least one cutting element includes a cutting face, a cutting edge adjacent the cutting face, a back surface opposite the cutting face, and a side surface extending between the cutting edge and the back surface, at least a portion of the side surface of the at least one cutting element being bonded to a side surface of the coupling pocket. The roof-bolt drill bit includes a coupling projection extending from the at least one cutting element, the coupling projection being bonded to a coupling recess defined in the bit body. | 01-23-2014 |
| 20140034396 | CUTTING ELEMENTS WITH RE-PROCESSED THERMALLY STABLE POLYCRYSTALLINE DIAMOND CUTTING LAYERS, BITS INCORPORATING THE SAME, AND METHODS OF MAKING THE SAME - A method of re-processing used TSP material layers to form cutting elements, bits with such cutting elements mounted on their bodies, and bits having re-processed TSP material layers attached to their bodies, as well as such cutting elements and bits are provided. The method includes providing a used TSP material cutting element having a TSP material layer and substrate, or a bit having a TSP material layer attached to the bit, removing the used TSP material layer from the cutting element or bit, cutting the used TSP material layer to a new shape, if necessary, optionally re-leaching the used TSP layer and re-using the TSP material layer to form a cutting element, or in forming a bit body. The formed cutting element may be mounted on a bit body. | 02-06-2014 |
| 20140048338 | METHODS OF FORMING AND TREATING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS, CUTTING ELEMENTS SO FORMED AND DRILL BITS EQUIPPED - A polycrystalline diamond compact comprising a diamond table is formed in a high-pressure, high-temperature process using a catalyst, the catalyst being substantially removed from the entirety of the diamond table, and the diamond table attached to a supporting substrate in a subsequent high-pressure, high-temperature process using a binder material differing at least in part from a material of the catalyst. The binder material is permitted to penetrate substantially completely throughout the diamond table from an interface with the substrate to and including a cutting surface, and the binder material is selectively removed from a region or regions of the diamond table by a conventional technique (e.g., acid leaching). Cutting elements so formed and drill bits equipped with such cutting elements are also disclosed. | 02-20-2014 |
| 20140054095 | 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 first metal carbide particles form a matrix in which the second diamond grains are dispersed, wherein the first metal carbide particles are present in the at least one transition layer in an amount ranging from about 15 to 50 volume percent. | 02-27-2014 |
| 20140060937 | POLYCRYSTALLINE DIAMOND COMPACT COATED WITH HIGH ABRASION RESISTANCE DIAMOND LAYERS - A cutting element may comprise a substrate, a first polycrystalline diamond volume, and a second diamond or diamond like volume. The first polycrystalline diamond volume may contain a catalyst material. The first polycrystalline diamond volume may be bonded to the substrate. The second diamond or diamond like volume may be formed predominantly from carbon atoms and free of catalyst materials. The second diamond or diamond like volume may be adjacent to a working surface of cutting element. The second diamond or diamond like volume may be bonded to the first polycrystalline diamond volume. | 03-06-2014 |
| 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 |
| 20140069725 | ULTRA-HARD CONSTRUCTIONS WITH EROSION RESISTANCE - Ultra-hard constructions comprise polycrystalline diamond-body having a first metallic substrate attached thereto, and having a second metallic substrate attached to the first metallic substrate. The first and second substrates each comprise a first hard particle phase, e.g., WC, and a second binder material phase, e.g., Co, wherein the hard particles in the second substrate are sized larger than those in the first substrate. The first substrate may contain a larger amount of binder material than the second substrate. Constructed in this matter, the first substrate is engineered to facilitate sintering diamond body during HPHT conditions, while the second substrate is engineered to provide an improved degree of erosion resistance when placed in an end-use application. The construction may be formed during a single HPHT process. The second substrate may comprise 80 percent or more of the combined thickness of the first and second substrates. | 03-13-2014 |
| 20140076640 | POLYCRYSTALLINE DIAMOND STRUCTURE - A PCD structure comprises a first region ( | 03-20-2014 |
| 20140097028 | POINTED DIAMOND WORKING ENDS ON A SHEAR BIT - In one aspect of the present invention, a drill string has a drill bit with a body intermediate a shank and a working face. The working face has a plurality of blades converging at a center of the working surface and diverging towards a gauge of the working face. At least one blade has a cutting element with a carbide substrate bonded to a diamond working end with a pointed geometry. The diamond working end also has a central axis which intersects an apex of the pointed geometry. The axis is oriented between a 25 and 85 degree positive rake angle. | 04-10-2014 |
| 20140110181 | METHODS FOR DESIGNING FIXED CUTTER BITS AND BITS MADE USING SUCH METHODS - Embodiments disclosed herein relate to a method for analyzing a fixed cutter drill bit, said method including selecting a cutter; selecting an earth formation; simulating drilling performance of the fixed cutter bit having at least once cutter thereon; performing finite element analysis using outputs from the simulating; and outputting stress on the at least one cutter. | 04-24-2014 |
| 20140116788 | CUTTING ELEMENTS HAVING CURVED OR ANNULAR CONFIGURATIONS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - Cutting elements for earth-boring tools include a substrate having a front end surface, an opposing back end surface, and at least one side surface extending between the front end surface and the back end surface. A volume of polycrystalline hard material is disposed on the front end surface of the substrate. The substrate and hard material may have a curved or an annular configuration defining an aperture within the cutting element. Earth boring tools include such cutting elements. Methods of forming earth-boring tools include attaching such one or more such cutting elements to a body of an earth-boring tool. | 05-01-2014 |
| 20140116789 | MULTI-LAYERED PDC CUTTERS - A cutter element for a drill bit, comprising: a substrate having a longitudinal axis; a first layer of polycrystalline diamond coupled to the substrate; and a second layer of polycrystalline diamond coupled to the first layer at a first coherent boundary; where the first layer is axially positioned between the substrate and the second layer. | 05-01-2014 |
| 20140124271 | CUTTING ELEMENTS, METHODS FOR MANUFACTURING SUCH CUTTING ELEMENTS, AND TOOLS INCORPORATING SUCH CUTTING ELEMENTS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance. | 05-08-2014 |
| 20140131117 | SINTERING OF THICK SOLID CARBONATE-BASED PCD FOR DRILLING APPLICATION - A method of making a polycrystalline diamond compact includes forming multiple layers of premised diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal, carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond. | 05-15-2014 |
| 20140131118 | METHOD OF USING SPRING LOADED BLOCKER TO RETAIN ROLLING CUTTERS OR MECHANICAL LOCK CUTTERS - A cutting element assembly may include a sleeve; an inner cutting element in the sleeve; and a blocker retained in the sleeve with at least one locking device and covering a portion of a cutting face of the inner cutting element. Cutting tools may include a tool body; a plurality of blades extending radially from the tool body, each blade comprising a leading face and a trailing face; a plurality of cutter pockets on the plurality of blades; at least one cutting element in one of the cutter pockets; and at least one blocker positioned adjacent to a cutting face of the at least one cutting element and the leading face of the blade, the blocker being retained to the cutter pocket with at least one locking device. | 05-15-2014 |
| 20140131119 | POLYCRYSTALLINE COMPACTS INCLUDING METALLIC ALLOY COMPOSITIONS IN INTERSTITIAL SPACES BETWEEN GRAINS OF HARD MATERIAL, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH POLYCRYSTALLINE COMPACTS, AND RELATED METHODS - Polycrystalline compacts include a polycrystalline material comprising a plurality of inter-bonded grains of hard material, and a metallic material disposed in interstitial spaces between the inter-bonded grains of hard material. At least a portion of the metallic material comprises a metal alloy that includes two or more elements. A first element of the two or more elements comprises at least one of cobalt, iron, and nickel. A second element of the two or more elements comprises at least one of dysprosium, yttrium, terbium, gadolinium, germanium, samarium, neodymium, and praseodymium. The metal alloys may comprise eutectic or near-eutectic compositions, and may have relatively low melting points. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods include the formation of such polycrystalline compacts, cutting elements, and earth-boring tools. | 05-15-2014 |
| 20140144712 | ERUPTION CONTROL IN THERMALLY STABLE PCD PRODUCTS BY THE ADDITION OF TRANSITION METAL CARBIDE - A method of loaning a diamond compact includes adding an additive material to a tungsten carbide substrate, the additive material including a transition metal carbide other than tungsten carbide, placing a diamond body adjacent to an interface surface of the tungsten carbide substrate, and subjecting the diamond body and the tungsten carbide substrate to a high pressure high temperature bonding process to bond the diamond body to the tungsten carbide substrate. | 05-29-2014 |
| 20140144713 | ERUPTION CONTROL IN THERMALLY STABLE PCD PRODUCTS - A method of making a polycrystalline diamond cutting element includes placing a body of polycrystalline diamond including a matrix phase of bonded together diamond grains and a plurality of empty interstitial spaces between the bonded together diamond grains adjacent a first substrate material to form an assembly and subjecting the assembly to high pressure/high temperature conditions that include an initial pressure ramping, a pressure hold, and a second pressure ramping. | 05-29-2014 |
| 20140196958 | Increased point of contact Tungsten Carbide insert for fixed rotary drill bit - A fixed rotary drill bit, especially the type rotary drill bits incorporating a plurality of spaced polycrystalline diamond compact (PDC) cutters or cutting elements on a plurality of radial blades, includes multiple tungsten carbide inserts (TCI) spaced between the PDC cutters or cutting elements, each TCI providing a mitigation to vibration for the drill bits, rapidly adapting the TCIs by wear from the intermediary formation ridges created from drilling resulting in the creation of a unique kerf in each TCI, thus increasing stability of the bit from lateral instability, making the drill bit more efficient, and promoting a continual steady state of drilling. | 07-17-2014 |
| 20140216827 | CUTTER ASSEMBLIES, DOWNHOLE TOOLS INCORPORATING SUCH CUTTER ASSEMBLIES AND METHODS OF MAKING SUCH DOWNHOLE TOOLS - Cutter assemblies include an outer support and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also disclosed is downhole tools incorporating such cutter assemblies and methods of making such downhole tools. | 08-07-2014 |
| 20140238752 | METHODS FOR PRE-SHARPENING IMPREGNATED CUTTING STRUCTURES FOR BITS, RESULTING CUTTING STRUCTURES AND DRILL BITS SO EQUIPPED - Processes for pre-sharpening cutting structures comprising particles of superabrasive material such as diamond grit, dispersed in a metal matrix material such as cemented tungsten carbide. Matrix material may be removed from a surface of a cutting structure to a desired depth to expose superabrasive particles within the matrix material adjacent the surface, and to increase exposure of partially exposed superabrasive particles at the surface. Electrodischarge machining (EDM), laser machining, electrolytic etching and chemical etching may also be employed. Pre-sharpened cutting structures are also disclosed. | 08-28-2014 |
| 20140246250 | METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND BY FUNCTIONALIZING DIAMOND NANOPARTICLES, GREEN BODIES INCLUDING FUNCTIONALIZED DIAMOND NANOPARTICLES, AND METHODS OF FORMING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS - Method of fabricating polycrystalline diamond include functionalizing surfaces of diamond nanoparticles with fluorine, combining the functionalized diamond nanoparticles with a polymer to form a mixture, and subjecting the mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles. A green body includes a plurality of diamond nanoparticles functionalized with fluorine, and a polymer material interspersed with the plurality of diamond nanoparticles. A method of forming cutting element includes functionalizing surfaces of diamond nanoparticles with fluorine, and combining the functionalized diamond nanoparticles with a polymer to form a mixture. The mixture is formed over a body, and the mixture and the body are subjected to HPHT conditions to form inter-granular bonds between the diamond nanoparticles and secure the bonded diamond nanoparticles to the body. | 09-04-2014 |
| 20140246251 | CUTTING ELEMENTS LEACHED TO DIFFERENT DEPTHS LOCATED IN DIFFERENT REGIONS OF AN EARTH-BORING TOOL AND RELATED METHODS - Earth-boring tools may comprise a body comprising a first region and a second region. The first region may be located closer to a rotational axis of the body than the second region. A first cutting element may be located in the first region and a second cutting element may be located in the second region. A first polycrystalline table of the first cutting element may be substantially free of catalyst material to a first depth and a second polycrystalline table of the second cutting element may be substantially free of catalyst material to a second, greater depth. | 09-04-2014 |
| 20140246252 | POLYCRYSTALLINE COMPACT TABLES FOR CUTTING ELEMENTS AND METHODS OF FABRICATION - Polycrystalline compact tables for cutting elements include regions of grains of super hard material. One region of grains (“first grains”) and another region of grains (“second grains”) have different properties, such as different average grain sizes, different super hard material volume densities, or both. The region of first grains and the region of second grains adjoin one another at grain interfaces that may include a curved portion in a vertical cross-section of the table. In some embodiments, discrete regions of the first grains may be vertically disposed between discrete regions of the second grains. As such, the tables have ordered grain regions of different properties that may inhibit delamination and crack propagation through the table when used in conjunction with a cutting element. Methods of forming the tables include forming the regions and subjecting the grains to a high-pressure, high-temperature process to sinter the grains. | 09-04-2014 |
| 20140251698 | POLYCRYSTALLINE COMPACTS INCLUDING DIFFERING REGIONS, AND RELATED EARTH-BORING TOOLS AND METHODS OF FORMING CUTTING ELEMENTS - Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming such polycrystalline compacts include removing catalyst material from interstitial spaces within a second region of a polycrystalline compact without entirely removing catalyst material from interstitial spaces within a first region of the compact. | 09-11-2014 |
| 20140262539 | POLYCRYSTALLINE COMPACTS INCLUDING DIAMOND NANOPARTICLES, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SAME - A polycrystalline compact comprises a plurality of diamond grains of micron size, submicron size, or both, and a plurality of diamond nanoparticles disposed in interstitial spaces between the plurality of diamond grains. A method of forming a polycrystalline compact comprises combining a plurality of micron and/or submicron-sized diamond grains and a plurality of diamond nanoparticles to form a mixture and sintering the mixture in a presence of a carburized binder to form a polycrystalline hard material comprising a plurality of inter-bonded diamond grains and diamond nanoparticles. Cutting elements comprising a polycrystalline compact and earth-boring tools bearing such compacts are also disclosed. | 09-18-2014 |
| 20140262540 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - A cutting element for an earth-boring tool includes a substrate and a volume of superabrasive material disposed over the substrate. The volume of superabrasive material may include a cutting face and a longitudinal extension extending longitudinally along a lateral side surface of the substrate. An outer peripheral surface of the longitudinal extension may define at least a portion of a lateral side surface of the cutting element and may have a surface roughness less than about 10 μin. (about 0.254 μm) RMS. Earth-boring tools may include such cutting elements. Methods may include forming such cutting elements. | 09-18-2014 |
| 20140262541 | BALLISTIC POLYCRYSTALLINE MINING TOOL AND METHOD FOR MAKING THE SAME - A cutting element for a mining or drilling tool provides a body that provides a recess for receiving a ballistic insert. The ballistic insert provides a top portion having a shape characterized by a first radius (R1) and a second radius (R2), and R1 and R2 have a tangential relationship. A sleeve may be positioned on the body to protect the body from erosion. | 09-18-2014 |
| 20140262542 | DOWNHOLE TOOLS INCLUDING TERNARY BORIDE-BASED CERMET AND METHODS OF MAKING THE SAME - Downhole tools include a component, at least a portion of which includes ternary boride cermet. A method of making a downhole tool including a ternary boride cermet includes obtaining a ternary boride cermet material and heating the ternary boride cermet material and a binder to form the downhole tool. | 09-18-2014 |
| 20140284116 | ABRASIVE WEAR-RESISTANT MATERIALS AND EARTH-BORING TOOLS COMPRISING SUCH MATERIALS - An abrasive wear-resistant material includes a matrix and sintered and cast tungsten carbide pellets. A device for use in drilling subterranean formations includes a first structure secured to a second structure with bonding material. An abrasive wear-resistant material covers the bonding material. The first structure may include a drill bit body and the second structure may include a cutting element. A method for applying an abrasive wear-resistant material to a drill bit includes providing a bit, mixing sintered and cast tungsten carbide pellets in a matrix material to provide a pre-application material, heating the pre-application material to melt the matrix material, applying the pre-application material to the bit, and solidifying the material. A method for securing a cutting element to a bit body includes providing an abrasive wear-resistant material to a surface of a drill bit that covers a brazing alloy disposed between the cutting element and the bit body. | 09-25-2014 |
| 20140299387 | CUTTING ELEMENT INCORPORATING A CUTTING BODY AND SLEEVE AND METHOD OF FORMING THEREOF - A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer. | 10-09-2014 |
| 20140367176 | POLYCRYSTALLINE DIAMOND COMPACTS WITH PARTITIONED SUBSTRATE, POLYCRYSTALLINE DIAMOND TABLE, OR BOTH - Methods for at least partially relieving stress within a polycrystalline diamond (“PCD”) table of a polycrystalline diamond compact (“PDC”) include partitioning the substrate of the PDC, the PCD table of the PDC, or both. Partitioning may be achieved through grinding, machining, laser cutting, electro-discharge machining, or combinations thereof. PDC embodiments may include at least one stress relieving partition. | 12-18-2014 |
| 20140374172 | PDC CUTTER WITH CHEMICAL ADDITION FOR ENHANCED ABRASION RESISTANCE - A superabrasive cutter and a method of making the superabrasive cutter are disclosed. The superabrasive cutter may comprise a plurality of polycrystalline superabrasive particles and about 0.01% to about 4% by weight of the superabrasive particles of a metal or metal alloy. The metal or the metal alloy may be immiscible with a catalyst for forming the polycrystalline superabrasive particles. | 12-25-2014 |
| 20150008047 | POLYCRYSTALLINE COMPACTS INCLUDING CRUSHED DIAMOND NANOPARTICLES, CUTTING ELEMENTS AND EARTH BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SAME - A polycrystalline compact comprises a plurality of diamond grains of micron size, submicron size, or both, and a plurality of crushed diamond nanoparticles disposed in interstitial spaces between the plurality of diamond grains. A method of forming a polycrystalline compact comprises combining a plurality of micron and/or submicron-sized diamond grains and a plurality of crushed diamond nanoparticles to form a mixture and sintering the mixture in a presence of a binder to form a polycrystalline hard material comprising a plurality of inter-bonded diamond grains and diamond nanoparticles. Cutting elements comprising a polycrystalline compact and earth-boring tools bearing such compacts are also disclosed. | 01-08-2015 |
| 20150014067 | CUTTER PROTECTION DURING LEACHING PROCESS - A method of forming a thermally stable cutting element may include providing a cutting element including a substrate fixed to a polycrystalline diamond cutting table; enclosing the substrate and at least a portion of the polycrystalline diamond cutting table within a protective element to form a partially enclosed cutting element; exerting a compressive squeeze on the cutting element of about 5-25%; and exposing the partially enclosed cutting element to a leaching solution so that at least part of an unenclosed portion of the polycrystalline diamond table is in contact with the leaching solution. | 01-15-2015 |
| 20150021100 | THERMALLY STABLE POLYCRYSTALLINE COMPACTS FOR REDUCED SPALLING EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND RELATED METHODS - Polycrystalline compacts include an interface between first and second volumes of a body of inter-bonded grains of hard material. The first volume is at least substantially free of interstitial material, and the second volume includes interstitial material in interstitial spaces between surfaces of the inter-bonded grains of hard material. The interface between the first and second volumes is configured, located and oriented such that cracks originating in the compact during use of the compacts and propagating along the interface generally toward a central axis of the compacts will propagate generally toward a back surface and away from a front cutting face of the compacts at an acute angle or angles. Methods of forming polycrystalline compacts involve the formation of such an interface within the compacts. | 01-22-2015 |
| 20150041224 | POLYCRYSTALLINE COMPACTS INCLUDING NANOPARTICULATE INCLUSIONS, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, AND METHODS OF FORMING SAME - A polycrystalline compact comprises a plurality of grains of hard material and a plurality of nanoparticles disposed in interstitial spaces between the plurality of grains of hard material. The nanoparticles have cores of a first material and at least one oxide material on the cores. An earth-boring tool comprises such a polycrystalline compact. A method of forming a polycrystalline compact comprises combining a plurality of hard particles with a plurality of nanoparticles to form a mixture and sintering the mixture to form a polycrystalline hard material comprising a plurality of interbonded grains of hard material. A method of forming a cutting element comprises infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of nanoparticles. | 02-12-2015 |
| 20150047912 | DRILL BIT AND CUTTERS FOR A DRILL BIT - In a fixed cutter drill bit, a hybrid cutter with a cutting edge including a substantially continuous curve interrupted by at least one arc discontinuity. In a fixed cutter drill bit, a contoured cutter with a contoured cutting face including a raised shape, wherein the raised shape has a raised shape axis which is oblique to a drill bit body axis. In a cutter for a fixed cutter drill bit, a chamfer including a side bevel and a cutting face bevel, wherein a cutting face bevel length is at least two times a side bevel length. | 02-19-2015 |
| 20150047913 | CUTTERS FOR FIXED CUTTER BITS - A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a concave cutting face perpendicular to an axis of the body is disclosed. A PDC cutter including a body formed from a substrate material, an ultrahard layer disposed on the body, and a non-planar cutting face perpendicular to an axis of the body, the cutting face including a circumferential concave portion, and an inner protrusion portion is also disclosed. | 02-19-2015 |
| 20150060150 | MASS BALANCING DRILL BIT DESIGN METHODS AND MANUFACTURING - One disclosed method includes generating a design model for a drill bit, the design model including one or more blades and channels, determining a rotational axis of the design model, dividing the design model into a plurality of unitary volume parallelepipedic elements distributed over at least a portion of the design model, determining a material density and mass of each unitary volume parallelepipedic element and using the material density and mass of each unitary volume parallelepipedic element to calculate a total mass of the design model, calculating a location of an inertia axis of the design model, determining a resulting centrifugal force of the design model upon applying a given angular velocity to the design model and using at least a portion of the total mass and the inertia axis, and modifying the design model to compensate for the resulting centrifugal force and thereby generating a modified design model. | 03-05-2015 |
| 20150107909 | EARTH-BORING TOOLS AND METHODS OF FORMING EARTH-BORING TOOLS - A fixed-cutter earth-boring tool includes a first blade substantially comprising a first material having a first elastic modulus at a temperature, and a second blade substantially comprising a second material having a second elastic modulus at the temperature. The second elastic modulus is different from the first elastic modulus. A method of forming an earth-boring tool includes forming a bit body having a plurality of blades, and providing at least one cutting element on at least one of the plurality of blades. Some fixed-cutter earth-boring drill bits include a first blade exhibiting a first deflection when subjected to a load, and a second blade exhibiting a second deflection when subjected to the load. The first deflection may be a continuous function of the load, and the second deflection may be a discontinuous function of the load. | 04-23-2015 |
| 20150114725 | NON-UNIFORM POLYCRYSTALLINE COMPOSITE AND ITS METHOD OF MANUFACTURE - A polycrystalline diamond composite including a generally circular sintered polycrystalline cutting disc and a refractory substrate operationally connected to the polycrystalline cutting disc. The polycrystalline cutting disc further includes a plurality of coarse diamond grains and a plurality of fine diamond grains. The plurality fine diamond grains are concentrated in an annulus positioned to define an outer edge of the polycrystalline cutting disc. | 04-30-2015 |
| 20150114726 | DIAMOND BONDED CONSTRUCTION WITH REATTACHED DIAMOND BODY - Diamond bonded construction comprise a diamond body attached to a support. In one embodiment, an initial substrate used to sinter the body is interposed between the body and support, and is thinned to less than 5 times the body thickness, or to less than the body thickness, prior to attachment to the support to relieve stress in the body. In another embodiment, the substrate is removed after sintering, and the body is attached to the support. The support has a material construction different from that of the initial substrate, wherein the initial substrate is selected for infiltration and the support for end use properties. The substrate and support include a hard material with a volume content that may be the same or different. Interfaces between the body, substrate, and/or support may be nonplanar. The body may be thermally stable, and may include a replacement material disposed therein. | 04-30-2015 |
| 20150122552 | Hard-Facing for Downhole Tools and Matrix Bit Bodies with Enhanced Wear Resistance and Fracture Toughness - A composite material and a methods of making and using the composite material, wherein the composite material provides improved wear resistance and fracture toughness to hard-facing and matrix materials for down hole drilling tools. | 05-07-2015 |
| 20150129321 | POLYCRYSTALLINE DIAMOND COMPACT - In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table having an upper surface, an interfacial surface, and at least one side surface extending therebetween. The interfacial surface of the polycrystalline diamond table is bonded to the substrate. The polycrystalline diamond table includes bonded diamond grains defining interstitial regions. The polycrystalline diamond table includes a first region extending inwardly from at least a portion of the upper surface and at least a portion of the at least one side surface. The first region spaced from the interfacial surface. The polycrystalline diamond table includes at least a second region extending inwardly from the interfacial surface to the upper surface. The first region includes at least a first infiltrant disposed interstitially between the bonded diamond grains thereof. The second region includes at least a second infiltrant disposed interstitially between the bonded diamond grains thereof. | 05-14-2015 |
| 20150136493 | Drill Bits Having Blind-Hole Flushing And Systems For Using Same - A drill bit for forming a hole in a formation. The drill bit has a shank and a full face crown that cooperate to define an interior space that receives water or other drilling fluid. The full face crown defines a plurality of bores that extend from a cutting face of the full face crown to the interior space. The full face crown completely circumferentially encloses the interior space of the drill bit. | 05-21-2015 |
| 20150136494 | Drill Bits Having Flushing And Systems For Using Same - A drill bit for forming a hole in a formation. The drill bit has a shank and a full face crown that cooperate to define an interior space that receives water or other drilling fluid. The full face crown defines a plurality of bores that extend from a cutting face of the full face crown to the interior space. The full face crown completely circumferentially encloses the interior space of the drill bit. A wedge shaped slot is defined therein the full face crown that extends longitudinally therein a portion of the cutting face and the circumferential outer surface of the full face crown. The slot further defines an apex that is positioned beyond the center of the cutting face of the drill bit such that the longitudinal axis of the drill bit extends through the bottom surface of the slot and into an interior void area of the slot. Further, a conduit is defined in the drill bit that is in communication with the interior space and with a portion of the defined slot. | 05-21-2015 |
| 20150136495 | POLYCRYSTALLINE DIAMOND COMPACT, AND RELATED METHODS AND APPLICATIONS - Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element. | 05-21-2015 |
| 20150299901 | Fixed Cutter Drill Bit Cutter Elements Including Hard Cutting Tables Made from CVD Synthetic Diamonds - Systems and methods of forming components from CVD single crystal diamonds that can withstand high temperatures and pressures, for example, in a mining and/or drilling environment. This may be accomplished by transforming a graphite powder by hot-filament chemical vapor deposition (HFCVD) into a CVD single diamond crystal powder, growing a plurality of CVD single diamond crystals on a planar surface of a substrate or on a dowel. In one example, if a substrate is used as the growth surface, the plurality of CVD single crystals grow in at least one layer on the substrate and at least a portion of the plurality of CVD single diamond crystals are removed from the substrate in the form of a plurality of discrete intact sheets of CVD single diamond crystals, stacked in a mold, and sintered, for example, to form a CVD single crystal diamond table. | 10-22-2015 |
| 20150345229 | METHODS OF FORMING POLYCRYSTALLINE DIAMOND AND CUTTING ELEMENTS AND TOOLS COMPRISING POLYCRYSTALLINE DIAMOND - A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm | 12-03-2015 |
| 20150354286 | CUTTER ELEMENT FOR ROCK REMOVAL APPLICATIONS - A cutter element for rock removal comprises a free standing PCD body ( | 12-10-2015 |
| 20150368981 | Cutting Element - A cutting element comprises a table of superhard material bonded to a substrate, wherein the table defines a cutting edge and has a chamfered peripheral edge, and a groove in a sidewall of the cutting element passes through the chamfered peripheral edge, so as to reduce the depth of the chamfer at the location of the groove. | 12-24-2015 |
| 20160002980 | DRILL BIT WITH FIXED CUTTER ELEMENTS - A drill bit with fixed cutter elements with a hollow upper conical pin connector connectable to the lower module of a drill string, where the upper conical pin connector has a transition to an upper cylindrical module with a central channel for supplying bore fluid from the drill string, equipped with, a lower bore holding a cylindrical socket from the lower module, connecting the upper and lower modules of the drill bit, where the central channel continues down through the lower module and branches out into nozzle channels with nozzles ending in the recesses in between the wings with fixed PDC-cutters, wherein elastic shock-absorber elements are arranged in recesses in the cylindrical wall of the bore, in the upper cylindrical module, and the elastic shock-absorbers are assembled on the bolts extending into the cylindrical socket of the lower module. | 01-07-2016 |
| 20160002981 | A CUTTER ELEMENT FOR ROCK REMOVAL APPLICATIONS - A cutter element for rock removal comprises a free standing PCD body ( | 01-07-2016 |
| 20160002982 | POLYCRYSTALLINE DIAMOND COMPACTS, RELATED PRODUCTS, AND METHODS OF MANUFACTURE - Embodiments relate to polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond (“PCD”) table is infiltrated with a low viscosity cobalt-based alloy infiltrant. | 01-07-2016 |
| 20160008955 | PDC Cutter With Chemical Addition for Enhanced Abrasion Resistance | 01-14-2016 |
| 20160017667 | EARTH-BORING TOOLS, DRILL BITS, AND DIAMOND-IMPREGNATED ROTARY DRILL BITS INCLUDING CRUSHED POLYCRYSTALLINE DIAMOND MATERIAL - A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material. | 01-21-2016 |
| 20160017668 | PRECISION POLYCRYSTALLINE DIAMOND COMPACT (PDC) POCKETS - Method of manufacturing and remanufacturing wellbore drill bits and wellbore drill bit manufactured or remanufactured by the methods are disclosed. The manufacturing method comprises providing a drill bit having at least one blade, providing at least one cutter pocket in each blade, providing a registration device in each cutter pocket, and positioning a cutting surface within each cutter pocket and in engagement with each the registration device therein. | 01-21-2016 |
| 20160024851 | CUTTING TOOL AND METHOD OF MANUFACTURE - A MAX-phase material is provided for a cutting tool and other applications. | 01-28-2016 |
| 20160031064 | METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND, AND CUTTING ELEMENTS AND EARTH-BORING TOOLS COMPRISING POLYCRYSTALLINE DIAMOND - Methods of fabricating polycrystalline diamond include functionalizing surfaces of carbon-free nanoparticles with one or more functional groups, combining the functionalized nanoparticles with diamond nanoparticles and diamond grit to form a particle mixture, and subjecting the particle mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles and the diamond grit. Cutting elements for use in an earth-boring tool includes a polycrystalline diamond material formed by such processes. Earth-boring tools include such cutting elements. | 02-04-2016 |
| 20160047170 | Cutting Element - A cutting element comprises a primary cutter including a first table of a hard material bonded to a first substrate of less hard form, the first substrate of the primary cutter having a recess formed therein in which a secondary cutter is located, the secondary cutter comprising a second table of a hard material bonded to a second substrate of less hard material, the first and second tables being spaced apart from one another by at least part of the first substrate. | 02-18-2016 |
| 20160047171 | METHOD FOR FORMING A CUTTING ELEMENT AND DOWNHOLE TOOLS INCORPORATING THE SAME - Cutting elements include an ultrahard material body formed at high pressure and high temperature conditions in the absence of catalyzing material to provide a material microstructure comprising a matrix phase of bonded together ultrahard material particles and interstitial regions disposed throughout the matrix phase providing porosity of less than about 6 volume percent. The body may include a substrate attached thereto, and may include an infiltrant material disposed in a population of the interstitial regions. The body may have regions with different porosities, e.g., with a higher porosity region located adjacent a substrate interface and/or along a central region. The body may include more than one infiltrant, each located in different regions. The infiltrant may be introduced into the body during a separate high pressure/high temperature process. The body may include a region which extends a depth from a working surface that is substantially free of any infiltrant. | 02-18-2016 |
| 20160076308 | ANODIC BONDING OF THERMALLY STABLE POLYCRYSTALLINE MATERIALS TO SUBSTRATE - Cutting elements and other hardfacing components of a drill bit or other downhole equipment are provided that include a thermally stable polycrystalline material anodically bonded to a substrate. Methods and systems for making such elements and components are also provided. | 03-17-2016 |
| 20160123086 | Anti-balling Drill Bit - The disclosure relates to polycrystalline diamond compact (PDC) drill bits utilized for drilling wellbores. | 05-05-2016 |
| 20160129555 | METHODS FOR PRE-SHARPENING IMPREGNATED CUTTING STRUCTURES FOR BITS, RESULTING CUTTING STRUCTURES AND DRILL BITS SO EQUIPPED - Processes for pre-sharpening cutting structures comprising particles of superabrasive material such as diamond grit, dispersed in a metal matrix material such as cemented tungsten carbide. Matrix material may be removed from a surface of a cutting structure to a desired depth to expose superabrasive particles within the matrix material adjacent the surface, and to increase exposure of partially exposed superabrasive particles at the surface. Electrodischarge machining (EDM), laser machining, electrolytic etching and chemical etching may also be employed. Pre-sharpened cutting structures are also disclosed. | 05-12-2016 |
| 20160136761 | METHODS AND COMPOSITIONS FOR BRAZING, AND EARTH-BORING TOOLS FORMED FROM SUCH METHODS AND COMPOSITIONS - A method includes disposing a braze material between a first body and a second body. The braze material includes a first composition and a second composition. The second composition has a melting point higher than the first composition. The method also includes heating the braze material to a brazing temperature between the melting points of the first and second materials and maintaining the braze material at the brazing temperature for a period time to transform a transient liquid phase to a solid phase, forming a bond between the first body and the second body. A braze material for securing solid bodies includes a first composition and a second composition. The first composition includes at least one element selected from the group consisting of indium, tin, zinc, and magnesium. An earth-boring tool includes a first body, a second body, and a braze material bonding the second body to the first body. | 05-19-2016 |
| 20160144482 | DIAMOND ENHANCED INSERT WITH CONTROLLED DIAMOND FRAME STRENGTH - A Diamond Enhanced Insert (DEI) includes a working layer of a polycrystalline diamond material (PCD). The PCD material includes a first phase that includes a number of particles of a first material. The PCD material also includes a second phase that is adapted as a catalyst. The PCD material has a fracture toughness greater than 12.5 MPa·√m, a flexural strength of greater than 800 MPa, and a diamond frame strength of less than 400 MPa. | 05-26-2016 |
| 20160158918 | CARBONATE-CATALYZED POLYCRYSTALLINE DIAMOND ELEMENTS, METHODS OF MANUFACTURING THE SAME, AND APPLICATIONS THEREFOR - In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein. | 06-09-2016 |
| 20160168919 | ULTRA-HARD MATERIAL CUTTING ELEMENTS AND METHODS OF MANUFACTURING THE SAME WITH A METAL-RICH INTERMEDIATE LAYER | 06-16-2016 |
| 20160194920 | CUTTING ELEMENT RETENTION FOR HIGH EXPOSURE CUTTING ELEMENTS ON EARTH-BORING TOOLS | 07-07-2016 |
| 20170232521 | POLYCRYSTALLINE DIAMOND COMPACTS HAVING PARTING COMPOUND AND METHODS OF MAKING THE SAME | 08-17-2017 |
| 20170234077 | POLYCRYSTALLINE DIAMOND COMPACTS HAVING INTERSTITIAL DIAMOND GRAINS AND METHODS OF MAKING THE SAME | 08-17-2017 |
| 20180023348 | POLYCRSTALLINE DIAMOND STRUCTURE | 01-25-2018 |
| 20190145180 | IMPREGNATED CUTTING STRUCTURES, EARTH-BORING TOOLS INCLUDING THE IMPREGNATED CUTTING STRUCTURES, AND RELATED METHODS | 05-16-2019 |
