Class / Patent application number | Description | Number of patent applications / Date published |
175434000 | Diamond | 53 |
20080202821 | Multi-Layer Encapsulation of Diamond Grit for Use in Earth-Boring Bits - A method of constructing an earth-boring, diamond-impregnated drill bit has a first step of coating diamond grit with tungsten to create tungsten-coated diamond particles. These coated particles are then encapsulated in a layer of carbide powder held by an organic green binder material. The encapsulated granules are then mixed along with a matrix material and placed in a mold. The matrix material includes a matrix binder and abrasive particles. The mixture is heated in the mold at atmospheric pressure to cause the matrix binder to melt and infiltrate the encapsulated granules and abrasive particles. | 08-28-2008 |
20080223623 | POLYCRYSTALLINE DIAMOND CONSTRUCTIONS HAVING IMPROVED THERMAL STABILITY - Polycrystalline diamond constructions include a diamond body comprising a matrix phase of bonded together diamond crystals formed at high pressure/high temperature conditions with a catalyst material. The sintered body is treated remove the catalyst material disposed within interstitial regions, rendering it substantially free of the catalyst material used to initially sinter the body. Accelerating techniques can be used to remove the catalyst material. The body includes an infiltrant material disposed within interstitial regions in a first region of the construction. The body includes a second region adjacent the working surface and that is substantially free of the infiltrant material. The infiltrant material can be a Group VIII material not used to initially sinter the diamond body. A metallic substrate is attached to the diamond body, and can be the same or different from a substrate used as a source of the catalyst material used to initially sinter the diamond body. | 09-18-2008 |
20080230280 | POLYCRYSTALLINE DIAMOND HAVING IMPROVED THERMAL STABILITY - PCD constructions include a PCD body comprising a polycrystalline matrix region, a first region that includes a replacement material positioned remote from a body surface, and a second region that is substantially free of the replacement material and that extends a depth from the body surface. The PCD construction can further include a substrate that is attached to the body. The PCD body is formed by removing a solvent catalyst material used to form the body, replacing the removed solvent catalyst material with a replacement material, and then removing the replacement material from a region of the body to thereby form the second region. The replacement material can be introduced into the PCD body during a HPHT process, and the substrate may or may not be the source of the noncatalyzing material. | 09-25-2008 |
20080302579 | POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS HAVING IMPROVED THERMAL RESISTANCE - Polycrystalline diamond constructions of this invention have a polycrystalline diamond body and a substrate attached thereto, wherein the diamond body has a material microstructure comprising a plurality of bonded-together diamond crystals forming a polycrystalline matrix phase, and second phase formed from different types of materials or sintering aids designed to reduce or eliminate the amount of free Group VIII elements therein. The use of such materials and the reduction and/or elimination of free Group VIII elements, in addition to graphitization, facilitates the sintering the construction at high pressure/high temperature conditions, e.g., greater than about 65 Kbar, to produce a construction having a high degree of thermal stability and/or thermal resistance when compared to conventional PCD materials. Polycrystalline diamond constructions of this invention are preferably configured as cutting elements that are disposed on drill bits used for drilling subterranean earthen formations. | 12-11-2008 |
20090000828 | Roof Bolt Bit - In one aspect of the present invention, a roof bolt drill bit for use in underground mines comprises a bit body with a shank adapted for attachment to a driving mechanism. A working face disposed opposite the shank comprises a plurality of polycrystalline diamond cutting elements. Carbide bolsters are disposed intermediate the plurality of cutting elements and the bit body. | 01-01-2009 |
20090071727 | ULTRA-HARD COMPOSITE CONSTRUCTIONS COMPRISING HIGH-DENSITY DIAMOND SURFACE - Ultra-hard composite constructions comprise an ultra-hard body having a plurality of diamond crystals bonded to one another by a carbide reaction product. A reactant material is selected from materials that are strong carbide formers to form a carbide reaction product with diamond at HPHT conditions. The body includes a high-density diamond region positioned along a surface portion of the body and that is substantially exclusively diamond, and that has a diamond volume content of 95 to 99 percent or more. The high-density diamond region can form a working surface of the composite construction. A substrate can be attached to the body, thereby forming a compact, and can include metallic materials, ceramic materials, carbides, nitrides, cermets, and mixtures thereof. An intermediate layer can be interposed between the body and the substrate depending on the substrate and/or method of attaching the same. | 03-19-2009 |
20090090562 | CUTTING ELEMENT HAVING STRESS REDUCED INTERFACE - Cutting elements include an ultra-hard body, e.g., comprising diamond, that is attached to substrate, e.g., comprising a cermet. An interface exists between the body and the substrate, and an angle of departure as measured between the interface and a free edge of the cutting element within one or both of the body and substrate, is less than about 90 degrees to provide a desired stress reduction along the interface. The angle of departure can be from about 3 to 87 degrees. The desired reduced angle of departure is provided by a surface feature disposed along an outer side surface of the cutting element adjacent a free edge of the interface. The surface feature can in the form of a groove disposed circumferentially around the body and/or substrate outer side surface, that is configured to provide the desired reduced angle of departure within the body and/or substrate. | 04-09-2009 |
20090090563 | DIAMOND-BONDED CONSTRCUTIONS WITH IMPROVED THERMAL AND MECHANICAL PROPERTIES - Diamond-bonded constructions include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix phase of bonded-together diamond crystals, and interstitial regions comprising a reaction product. The reaction product is formed by reaction between the diamond crystals and a reactive material. The reactant is a carbide former and the reaction product is a carbide. The diamond-bonded body includes a further diamond region extending from the thermally stable region that comprises the matrix phase and a Group VIII metal disposed within interstitial regions of the matrix phase. The thermally stable region is substantially free of a catalyst material used to initially form the diamond-bonded body. The diamond-bonded body may include a material layer formed from the reaction product that is disposed on a surface of the diamond-bonded body thermally stable region. | 04-09-2009 |
20090114454 | Thermally-Stable Polycrystalline Diamond Materials and Compacts - Thermally-stable polycrystalline diamond materials of this invention comprise a first phase including a plurality of bonded together diamond crystals, and a second phase including a reaction product formed between a binder/catalyst material and a material reactive with the binder/catalyst material. The reaction product is disposed within interstitial regions of the polycrystalline diamond material that exists between the bonded diamond crystals. The first and second phases are formed during a single high pressure/high temperature process condition. The reaction product has a coefficient of thermal expansion that is relatively closer to that of the bonded together diamond crystals than that of the binder/catalyst material, thereby providing an improved degree of thermal stability to the polycrystalline diamond material. | 05-07-2009 |
20090133938 | Thermally Stable Pointed Diamond with Increased Impact Resistance - In one aspect of the present invention, an insert comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate. The diamond body comprises a substantially conical shape with conical side wall terminating at an apex. The diamond body comprises a first region with a metallic catalyst dispersed through interstices between the diamond grains and a second region proximate the apex with the characteristic of higher thermal stability than the first region. | 05-28-2009 |
20090260895 | Polycrystalline diamond materials, methods of fabricating same, and applications using same - Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to a HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a method includes subjecting a mixture to heat and pressure sufficient to form a PCD material. The mixture comprises a plurality of diamond particles exhibiting a diamond particle size distribution characterized, in part, by a parameter θ that is less than about 1.0, where | 10-22-2009 |
20090283336 | DIAMOND IMPREGNATED BITS AND METHOD OF USING AND MANUFACTURING THE SAME - A drill bit that includes a body having a lower end face for engaging a rock formation, the end face having a plurality of raised ribs extending from the face of the bit body and separated by a plurality of channels therebetween; and at least one of the plurality of ribs having a cutting portion of the at least one rib comprising a first diamond impregnated matrix material and at least a portion of a gage surface region thereof comprising a second diamond impregnated matrix material, the gage surface region backed by a third matrix material is disclosed. | 11-19-2009 |
20100012390 | Method and apparatus for selectively leaching portions of PDC cutters already mounted in drill bits - A polycrystalline diamond compact (PDC) cutter having a body of diamond crystals containing cobalt is coated with Teflon which is impervious to hydrofluoric acid. After the Teflon coating is dried, a segment of the Teflon coating is removed and a mixture of 50% hydrofluoric acid and 50% nitric acid is supplied to the diamond crystal body through the template in the Teflon coating to leach out the cobalt catalyzing material contained within the body of diamond crystals. In an alternative embodiment, a similar process is used to coat a PDC drill bit and the PDC cutters mounted in the PDC drill bit. After the Teflon dries, a segment of the coating is removed and the acid mix is applied through the templates in the cutters to leach out the cobalt in each of the bodies of diamond crystals. In another alternative embodiment, a tube is placed over the PDC cutter, the tube having one or more templates exposing only the segment or segments of the cutting surface to the acid mix. | 01-21-2010 |
20100012391 | Method and apparatus for selectively leaching portions of PDC cutters used in drill bits - A polycrystalline diamond compact (PDC) cutter having a body of diamond crystals containing cobalt is coated with Teflon which is impervious to hydrofluoric acid. After the Teflon coating is dried, a segment of the Teflon coating is removed and a mixture of 50% hydrofluoric acid and 50% nitric acid is supplied to the diamond crystal body through the template in the Teflon coating to leach out the cobalt catalyzing material contained within the body of diamond crystals. In an alternative embodiment, a similar process is used to coat a PDC drill bit and the PDC cutters mounted in the PDC drill bit. After the Teflon dries, a segment of the coating is removed and the acid mix is applied through the templates in the cutters to leach out the cobalt in each of the bodies of diamond crystals. In another alternative embodiment, a tube is placed over the PDC cutter, the tube having one or more templates exposing only the segment or segments of the cutting surface to the acid mix. | 01-21-2010 |
20100065338 | Thick Pointed Superhard Material - In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface. The diamond material comprises a 1 to 5 percent concentration of binding agents by weight. | 03-18-2010 |
20100065339 | Thick Pointed Superhard Material - In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a no n-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface. The diamond material comprises a 1 to 5 percent concentration of binding agents by weight. The tool further comprises a central axis which intersects the interface between the diamond material, substrate, and the radius of curvature. | 03-18-2010 |
20100071964 | Thick Pointed Superhard Material - In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius measured from a direction substantially perpendicular to a central axis of the tool. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface. | 03-25-2010 |
20100122853 | ENCAPSULATED DIAMOND PARTICLES, MATERIALS AND IMPREGNATED DIAMOND EARTH-BORING BITS INCLUDING SUCH PARTICLES, AND METHODS OF FORMING SUCH PARTICLES, MATERIALS, AND BITS - Earth-boring tools and components thereof include a particle-matrix composite material having encapsulated diamond particles embedded within a matrix material. Diamonds in the particles comprise less than about 25% by volume of the composite material, the matrix material comprises less than about 50% by volume of the composite material, and encapsulant material surrounding the diamonds at least substantially comprises a remainder of the volume of the composite material. Methods of forming at least a portion of an earth-boring tool include embedding encapsulated diamond particles in a volume of matrix material to form a particle-matrix composite material. The composite material is formed in such a manner as to cause diamonds to comprise less than about 25% of the composite material, the matrix material to comprise less than about 50% of the composite material, and encapsulant material surrounding the diamonds to at least substantially comprise a remainder of the composite material. | 05-20-2010 |
20100200305 | Cutting Element - A cutting element comprises a multilayer polycrystalline diamond element | 08-12-2010 |
20100243336 | BACKFILLED POLYCRYSTALLINE DIAMOND CUTTER WITH HIGH THERMAL CONDUCTIVITY - A front face of a diamond table mounted to a substrate is processed, for example through an acid leach, to remove interstitial catalyst binder and form a thermal channel. A material is then introduced to the front face of the diamond table, the introduced material backfilling the front face of the diamond table to fill interstitial voids left by removal of the catalyst binder in the thermal channel to a desired depth. The material is selected to be less thermally expandable than the catalyst binder and/or more thermally conductive than the catalyst binder and/or having a lower heat capacity than the catalyst binder. | 09-30-2010 |
20100243337 | METHODS FOR BONDING PREFORMED CUTTING TABLES TO CUTTING ELEMENT SUBSTRATES AND CUTTING ELEMENTS FORMED BY SUCH PROCESSES - A cutting element for use with an earth boring drill bit includes a diamond cutting table that is substantially free of a metallic binder. The cutting table may include polycrystalline diamond and a carbonate binder or polycrystalline diamond with silicon and/or silicon carbide dispersed therethrough. A base of the cutting table is secured to a substrate by way of an adhesion layer. The adhesion layer includes diamond. The adhesion layer may also include cobalt or another suitable binder material, which may be mixed with diamond particles from which the adhesion layer is formed, or may leach from the substrate into the adhesion layer as the cutting element is bonded to the substrate. Alternatively, the cutting table may be formed from and consist essentially of chemical vapor deposited diamond that has been diamond bonded to an underlying polycrystalline diamond compact. Processes for securing substantially metallic binder-free cutting elements to substrates are also disclosed. | 09-30-2010 |
20100270088 | 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. | 10-28-2010 |
20100282519 | 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. | 11-11-2010 |
20100294571 | 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. | 11-25-2010 |
20110000718 | INTEGRATED CAST MATRIX SLEEVE API CONNECTION BIT BODY AND METHOD OF USING AND MANUFACTURING THE SAME - A drill bit including a bit body and an upper portion, wherein the bit body and the upper portion are comprised of a matrix material, and wherein the upper portion includes a threaded connection comprised of a machineable matrix material is disclosed. | 01-06-2011 |
20110036643 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND CONSTRUCTIONS - Thermally stable polycrystalline constructions comprise a diamond body joined with a substrate, and may have a nonplanar interface. The construction may include an interlayer interposed between the diamond body and substrate. The diamond body preferably has a thickness greater than about 1.5 mm, and comprises a matrix phase of bonded together diamond crystals and interstitial regions disposed therebetween that are substantially free of a catalyst material used to sinter the diamond body. A replacement material is disposed within the interstitial regions. A population of the interstitial regions may include non-solvent catalyst material and/or an infiltrant aid disposed therein. The diamond body comprises two regions; namely, a first region comprising diamond grains that may be sized smaller than diamond grains in a second region, and/or the first region may comprise a diamond volume that is greater than that in the second region. | 02-17-2011 |
20110042150 | Roof Mining Drill Bit - In one aspect of the invention a rotary mine roof drilling apparatus has an arm attached to and intermediate a drill bit and a platform. The apparatus also has a thrusting mechanism adapted to push the drill bit into a mine roof. The drill bit has a bit body intermediate a shank and a working surface. The working surface has a cutting element with a carbide substrate bonded to a diamond working end with a pointed geometry; and the diamond working end has a 0.050-0.200 inch apex radius. | 02-24-2011 |
20110061945 | Durability of Downhole Tools - An apparatus for downhole operation. The apparatus comprising a support body having a surface located in a borehole and a coating on an at least a portion of the surface of the support body. The coating is an inert material selected for reducing friction and corrosion. | 03-17-2011 |
20110067930 | ENHANCED SECONDARY SUBSTRATE FOR POLYCRYSTALLINE DIAMOND COMPACT CUTTING ELEMENTS - A cutting structure for a drill bit includes a diamond table affixed to one end of a first substrate. A second substrate is affixed to the other end of the first substrate. The second substrate is made from a different material than the first substrate. The first and second substrates are substantially coaxial. | 03-24-2011 |
20110083909 | 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. | 04-14-2011 |
20110174550 | PROCESS FOR MANUFACTURING A PART COMPRISING A BLOCK OF DENSE MATERIAL CONSTITUTED OF HARD PARTICLES AND OF BINDER PHASE HAVING A GRADIENT OF PROPERTIES, AND RESULTING PART - A block of dense material is made up of hard particles, of the same or different nature, dispersed in a binder phase. The material has a solidus temperature T | 07-21-2011 |
20110180331 | Rock bit - The present invention provides a rock bit which enables a reduction in surface pressure from a well wall and which allows possible vibration to be suppressed. A first of the present invention provides a rock bit including a bit body with a journal portion, a cone portion configured to be rotatable with respect to the bit body, a bearing portion located between the cone portion and the journal portion, and a seal provided between the cone portion and the journal portion to seal the bearing portion, wherein the cone portion includes a gauge surface that contacts a side wall of a well, and a diamond composite material is preferably disposed extensively and smoothly on the gauge surface. In a second aspect of the present invention, a ring bit is provided at an outer peripheral portion of a bit body. Furthermore, a cone portion of a tri-cone bit includes no gauge tip or surface chip that contacts the side wall of the well but only cemented carbide tips that contact a bottom of the well. | 07-28-2011 |
20110278075 | IMPREGNATED ROTARY BIT - A drill bit includes a plurality of continuous segments impregnated with diamond that are each mounted to form a corresponding blade. The regions between the blades define a plurality of fluid passages on the bit face. The blades extend radially outwardly to the gage. The continuous segments may be either straight or spiral in design. Furthermore, the design of the segments supports varying one or more of: diamond content, width, back rake angle and/or relief angle along a length of the segment. | 11-17-2011 |
20120012403 | CUTTING TOOL AND METHOD OF MANUFACTURE - A MAX-phase material is provided for a cutting tool and other applications. | 01-19-2012 |
20120067652 | High Toughness Thermally Stable Polycrystalline Diamond - A mixture for fabricating a cutting table, the cutting table, and a method of fabricating the cutting table. The mixture includes a cutting table powder and a binder. The binder includes at least one carbide formed from an element selected from at least one of Groups IV, V, and VI of the Periodic Table. The carbide is in its non-stoichiometric and/or stoichiometric form. The binder can include the element. In certain embodiments, the binder includes one or more of the cutting table powder and a catalyst. The cutting table is formed by sintering the mixture using a solid phase sintering process or a near solid phase sintering process. When forming or coupling the cutting table to a substrate, a divider is positioned and coupled therebetween to ensure that the sintering process that forms the cutting table occurs using the solid phase sintering process or the near solid phase sintering process. | 03-22-2012 |
20120125696 | Polycrystalline Diamond Constructions Having Optimized Material Composition - Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing. | 05-24-2012 |
20120199402 | INFILTRATED DIAMOND WEAR RESISTANT BODIES AND TOOLS - Implementations of the present invention include infiltrated diamond tools with increased wear resistance. In particular, one or more implementations of the present invention include a body comprising at least 10% by volume diamond particles that are infiltrated with a binder. Implementations of the present invention also include drilling systems including such infiltrated diamond tool, and methods of forming and using such infiltrated diamond tools. | 08-09-2012 |
20120273282 | DOWNHOLE TOOLS HAVING MECHANICAL JOINTS WITH ENHANCED SURFACES, AND RELATED METHODS - A downhole tool may comprise a mechanical joint, and a diamond-like coating over at least a portion of a surface of at least one component of the mechanical joint, the diamond-like coating having a thickness greater than 10 micrometers. Methods of manufacturing a mechanical joint of a downhole tool may comprise disposing a diamond-like coating on at least a portion of a surface of a component of the mechanical joint of the downhole tool to a thickness of at least 10 microns and at a temperature less than about 200° C. | 11-01-2012 |
20120279786 | Drill Bits and Drilling Apparatuses Including the Same - A roof-bolt drill bit may have a bit body rotatable about a central axis. At least one coupling pocket may be defined in the bit body. At least one cutting element may be at least partially disposed in the at least one coupling pocket. The at least one cutting element may include a cutting face, an element back surface, and an element side surface extending around an outer periphery of the cutting face. The element side surface may include a first element side surface abutting a first pocket side surface of the at least one coupling pocket and a second element side surface abutting a second pocket side surface of the at least one coupling pocket. At least one of the first element side surface and the second element side surface may have a substantially planar surface. | 11-08-2012 |
20120325565 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND - The present disclosure provides compositions and methods directed to polycrystalline diamond materials. In one embodiment, a polycrystalline diamond material can comprise sintered polycrystalline diamond and a binder alloy, where the binder alloy is a liquid at a sintering temperature of the polycrystalline diamond, forms an intermetallic compound at a low temperature below the sintering temperature, and is substantially all intermetallic phase. | 12-27-2012 |
20130000993 | POLYCRYSTALLINE SUPERHARD CONSTRUCTION - A polycrystalline superhard construction comprises a body of polycrystalline superhard material, and a substrate of hard material bonded thereto along an interface. The body of polycrystalline superhard material comprises a first region abutting the substrate along the interface and a second region bonded to the first region. The second region defines a rake face, a cutting edge, a chamfer and at least a part of a flank face, the cutting edge being defined by an edge of the flank face joined to the chamfer, the chamfer extending between the cutting edge and the rake face. The height of the chamfer in a plane parallel to the plane through which the longitudinal axis of the polycrystalline superhard construction extends is less than the thickness of the second region. The first region comprises a material having coarser grains than the second region. There is also disclosed a method of making the same. | 01-03-2013 |
20130068539 | METHODS OF ATTACHING A POLYCRYSTALLINE DIAMOND COMPACT TO A SUBSTRATE AND CUTTING ELEMENTS FORMED USING SUCH METHODS - Methods of attaching a polycrystalline diamond compact (PDC) element to a substrate include maintaining a gap between the PDC element and an adjacent substrate, and at least substantially filling the gap with a deposition process. Methods of forming a cutting element for an earth-boring tool include forming a PDC element by pressing diamond crystals together, forming a substrate including a particulate carbide material and a matrix material, leaving a gap between at least portions of the PDC element and the substrate, masking surfaces of the PDC element and of the substrate that do not face the gap, and forming an adhesion material on surfaces of the PDC element and of the substrate that face the gap. Cutting elements for earth-boring tools include a PDC element attached to a substrate with at least one of diamond, diamond-like carbon, a carbide material, a nitride material, and a cubic boron nitride material. | 03-21-2013 |
20130068540 | METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND, AND CUTTING ELEMENTS AND EARTH-BORING TOOLS COMPRISING POLYCRYSTALLINE DIAMOND - Methods of fabricating polycrystalline diamond include encapsulating diamond particles and a hydrocarbon substance in a canister, and subjecting the encapsulated diamond particles and hydrocarbon substance to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. 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. | 03-21-2013 |
20130068541 | 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. | 03-21-2013 |
20130105232 | ROTARY DRILL BIT INCLUDING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS | 05-02-2013 |
20130180786 | COMPOSITES COMPRISING CLUSTERED REINFORCING AGENTS, METHODS OF PRODUCTION, AND METHODS OF USE - A composite may generally include a substantially continuous binder phase and a first reinforcing agent cluster infiltrated by the binder phase, the first reinforcing agent cluster comprising a plurality of first reinforcing agent particles. A drill bit may include at least one cutting element for engaging a formation and a bit body, at least a portion of said drill bit being a composite that includes a substantially continuous binder phase and a first reinforcing agent cluster infiltrated by the binder phase. | 07-18-2013 |
20140311810 | POLYCRYSTALLINE DIAMOND COMPOSITE COMPACT ELEMENTS AND METHODS OF MAKING AND USING SAME - A polycrystalline diamond composite compact element comprises a body of polycrystalline diamond material and a cemented carbide substrate bonded to the body of polycrystalline material. The cemented carbide substrate has tungsten carbide particles bonded together by a binder material comprising an alloy of Co, Ni and Cr. The tungsten carbide particles form between 70 weight percent and 95 weight percent of the substrate. The binder material comprises between about 10 to 50 wt. % Ni, between about 0.1 to 10 wt. % Cr, and the remainder weight percent comprising Co. The size distribution of the tungsten carbide particles in the substrate has fewer than 17 percent of the carbide particles with a grain size of equal to or less than about 0.3 microns, between about 20 to 28 percent of the tungsten carbide particles having a grain size of between about 0.3 to 0.5 microns; between about 42 to 56 percent of the tungsten carbide particles having a grain size of between about 0.5 to 1 microns; less than about 12 percent of the tungsten carbide particles being greater than 1 micron; and the mean grain size of the tungsten carbide particles is about 0.6+0.2 microns. | 10-23-2014 |
20150021101 | POLYCRYSTALLINE DIAMOND MATERIALS HAVING IMPROVED ABRASION RESISTANCE, THERMAL STABILITY AND IMPACT RESISTANCE - PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm. | 01-22-2015 |
20150041225 | POLYCRYSTALLINE SUPERHARD MATERIAL AND METHOD FOR MAKING SAME - A method of making a body of polycrystalline superhard material comprising placing an aggregated mass of grains of superhard material into a canister, placing a ceramic layer either in direct contact with the aggregated mass of grains of superhard material or in indirect contact therewith, the ceramic layer being spaced from the grains by an interlayer of material when present, the ceramic layer having a surface with surface topology, the surface topology imprinting a pattern in the aggregated mass of grains of superhard material complementary to the surface topology, the ceramic material and the material of the interlayer being such that they do not react chemically with the superhard material and/or a sinter catalyst material for the grains of superhard material. The aggregated mass of grains of superhard material and ceramic layer are subjected to a pressure of greater than 5.5 GPa and sintered to form a body of polycrystalline superhard material having a surface topology complementary to the surface topology of the ceramic layer. The ceramic layer and interlayer if present are then removed from the body of polycrystalline material. There is also disclosed a body of polycrystalline superhard material having a surface topology on a first surface, the first surface being substantially free of material from a canister used in formation of the body of polycrystalline superhard material. | 02-12-2015 |
20150068817 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND AND METHODS OF MAKING THE SAME - A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material. | 03-12-2015 |
20150075878 | CUTTING ELEMENT FOR A DOWNHOLE TOOL - A cutting element for a cutting tool. The cutting element may be at least partially made from a composite material including a carbide material, a binder material, and a plurality of diamond particles. The carbide material may be from 55 wt % to 97 wt % of a total weight of the composite material. The binder material may be from 3 wt % to 20 wt % of the total weight of the composite material. The plurality of diamond particles may be from 0.1% to 25% of the total weight of the composite material. The carbide material and the binder material may be combined and sintered together prior to being combined with the plurality of diamond particles, such that the carbide material and the binder material form a plurality of pellets having an average cross-sectional length from 10 μm to 250 μm. | 03-19-2015 |
20150083502 | POLYCRYSTALLINE DIAMOND COMPOSITE COMPACT ELEMENTS AND TOOLS INCORPORATING SAME - A polycrystalline diamond (PCD) composite compact element | 03-26-2015 |
20160010396 | DRILLING OR ABRADING TOOL HAVING A WORKING SURFACE WITH AN ARRAY OF BLIND APERTURES PLUGGED WITH SUPER-ABRASIVE MATERIAL | 01-14-2016 |