| Patent application number | Description | Published |
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| 20080308276 | CUTTING ELEMENTS FOR CASING COMPONENT DRILL OUT AND SUBTERRANEAN DRILLING, EARTH BORING DRAG BITS AND TOOLS INCLUDING SAME AND METHODS OF USE - A drill bit or milling tool includes a bit body on which a plurality of cutting elements are disposed. At least some of the plurality of cutting elements include a diamond table and a superabrasive material non-reactive with iron-based materials disposed over at least a portion of an exterior surface of the diamond table. The diamond table is suitable for drilling through a subterranean formation and the non-reactive superabrasive material is suitable for drilling through a casing or casing-associated component comprising an iron-based material and disposed within the subterranean formation. The diamond table may comprise a PDC and the non-reactive superabrasive material may comprise cubic boron nitride. | 12-18-2008 |
| 20090057031 | CHAMFERED EDGE GAGE CUTTERS, DRILL BITS SO EQUIPPED, AND METHODS OF CUTTER MANUFACTURE - A cutting element for an earth boring bit, wherein the PDC layer of the cutting element has a flat on a periphery thereof terminating longitudinally at en edge spaced from of the cutting face of the PDC layer. A chamfer adjacent the cutting face desirably has a length that exceeds its depth. Embodiments include a chamfer along the entire circumference of the cutting element, multiple step-wise, radially adjacent chamfers, and multiple circumferentially spaced portions of the uppermost radius of the PDC layer of the cutting element that each includes a chamfer with an associated flat. An embodiment including a flat terminating at a radial edge with the cutting face of a PDC layer is also disclosed, as are drill bits incorporating embodiments of the cutting elements of the invention and a method of forming the cutting elements. | 03-05-2009 |
| 20090217597 | ABRASIVE-IMPREGNATED CUTTING STRUCTURE HAVING ANISOTROPIC WEAR RESISTANCE AND DRAG BIT INCLUDING SAME - An abrasive-impregnated cutting structure for use in drilling a subterranean formation is disclosed. The abrasive-impregnated cutting structure may comprise a plurality of abrasive particles dispersed within a substantially continuous matrix, wherein the abrasive-impregnated cutting structure exhibits an anisotropic wear resistance. One or more of the amount, average size, composition, properties, shape, quality, strength, and concentration of the abrasive particles may vary within the abrasive-impregnated cutting structure. Anisotropic wear resistance may relate to a selected direction, such as, for example, one or more of an expected direction of engagement of the abrasive-impregnated cutting structure with the subterranean formation and an anticipated wear direction. Anisotropic wear resistance of an abrasive-impregnated cutting structure may be configured for forming or retaining a formation-engaging leading edge thereof. A rotary drag bit including at least one abrasive-impregnated cutting structure is disclosed. | 09-03-2009 |
| 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 |
| 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 |
| 20110000715 | HARDFACING MATERIALS INCLUDING PCD PARTICLES, WELDING RODS AND EARTH-BORING TOOLS INCLUDING SUCH MATERIALS, AND METHODS OF FORMING AND USING SAME - Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to form diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material. | 01-06-2011 |
| 20110017517 | DIAMOND-ENHANCED CUTTING ELEMENTS, EARTH-BORING TOOLS EMPLOYING DIAMOND-ENHANCED CUTTING ELEMENTS, AND METHODS OF MAKING DIAMOND-ENHANCED CUTTING ELEMENTS - Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles. | 01-27-2011 |
| 20110024198 | BEARING SYSTEMS CONTAINING DIAMOND ENHANCED MATERIALS AND DOWNHOLE APPLICATIONS FOR SAME - Downhole tool bearings are provided with diamond enhanced materials. The diamond enhanced materials comprise diamond grains in a matrix of tungsten or silicon carbide or a silicon bonded diamond material. A brazed diamond grit or diamond particles coated with a reactive braze may be utilized for bearing applications. Bearing rings for use in downhole tools may be formed at least in part with the diamond enhanced material. In one embodiment, the bearing rings may be used in a positive displacement motor. In additional embodiments, the bearing rings may be used in a submersible pump. | 02-03-2011 |
| 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 |
| 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 |
| 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 |
| 20110088950 | CUTTING ELEMENTS CONFIGURED TO GENERATE SHEAR LIPS DURING USE IN CUTTING, EARTH BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING AND USING SUCH CUTTING ELEMENTS AND EARTH BORING TOOLS - Cutting elements for earth-boring tools may generate a shear lip at a wear scar thereon during cutting. A diamond table may exhibit a relatively high wear resistance, and an edge of the diamond table may be chamfered, the combination of which may result in the formation of a shear lip. Cutting elements may comprise multi-layer diamond tables that result in the formation of a shear lip during cutting. Earth-boring tools include such cutting elements. Methods of forming cutting elements may include selectively designing and configuring the cutting elements to form a shear lip. Methods of cutting a formation using an earth-boring tool include cutting the formation with a cutting element on the tool, and generating a shear lip at a wear scar on the cutting element. The cutting element may be configured such that the shear lip comprises diamond material of the cutting element. | 04-21-2011 |
| 20110088954 | POLYCRYSTALLINE COMPACTS INCLUDING NANOPARTICULATE INCLUSIONS, CUTTING ELEMENTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS, 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 form 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. | 04-21-2011 |
| 20110155472 | EARTH-BORING TOOLS HAVING DIFFERING CUTTING ELEMENTS ON A BLADE AND RELATED METHODS - Earth-boring tools include combinations of shearing cutting elements and gouging cutting elements on a blade of the earth-boring tools. In some embodiments, a gouging cutting element may be disposed adjacent to a shearing cutting element on a blade of an earth-boring tool. Methods of forming earth-boring tools include providing such combination of at least one shearing cutting element and at least one gouging cutting element on a blade of an earth-boring tool. | 06-30-2011 |
| 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 |
| 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 |
| 20120005966 | METHODS OF FORMING INSERTS AND EARTH-BORING TOOLS - Methods of forming inserts for earth-boring tools include providing a material in a pattern adjacent a strip, arranging a plurality of superabrasive particles proximate the pattern, and securing at least some of the plurality of superabrasive particles to the strip. The material is configured to attract or secure the plurality of superabrasive particles. Some methods may include imparting like charges to each of a plurality of superabrasive particles, placing the plurality of superabrasive particles over a strip, and securing the superabrasive particles to the strip. In some methods, a first plurality of superabrasive particles may be placed in an array between a first strip and a second strip. A second plurality of superabrasive particles may be placed in an array between the second strip and a third strip. Methods of forming earth-boring rotary drill bits include forming an insert and securing the insert to a body of the bit. | 01-12-2012 |
| 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 |
| 20120056022 | METHODS OF FORMING HARDFACING MATERIALS INCLUDING PCD PARTICLES, AND WELDING RODS INCLUDING SUCH PCD PARTICLES - Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material. | 03-08-2012 |
| 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 |
| 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 |
| 20120102843 | GRAPHENE-COATED DIAMOND PARTICLES, COMPOSITIONS AND INTERMEDIATE STRUCTURES COMPRISING SAME, AND METHODS OF FORMING GRAPHENE-COATED DIAMOND PARTICLES AND POLYCRYSTALLINE COMPACTS - Coated diamond particles have solid diamond cores and at least one graphene layer. Methods of forming coated diamond particles include coating diamond particles with a charged species and coating the diamond particles with a graphene layer. A composition includes a substance and a plurality of coated diamond particles dispersed within the substance. An intermediate structure includes a hard polycrystalline material comprising a first plurality of diamond particles and a second plurality of diamond particles. The first plurality of diamond particles and the second plurality of diamond particles are interspersed. A method of forming a polycrystalline compact includes catalyzing the fox of inter-granular bonds between adjacent particles of a plurality of diamond particles having at least one graphene layer. | 05-03-2012 |
| 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 |
| 20120192501 | 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. | 08-02-2012 |
| 20120222363 | METHODS OF FORMING POLYCRYSTALLINE TABLES AND POLYCRYSTALLINE ELEMENTS AND RELATED STRUCTURES - Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprising a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material. | 09-06-2012 |
| 20120222364 | POLYCRYSTALLINE TABLES, POLYCRYSTALLINE ELEMENTS, AND RELATED METHODS - Polycrystalline elements comprise a substrate and a polycrystalline table attached to an end of the substrate. The polycrystalline table comprises a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability, the at least second region being interposed between the substrate and the first region. Methods of forming a polycrystalline element comprise attaching a polycrystalline table comprising a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability to an end of a substrate, the at least a second region being interposed between the first region and the substrate. Catalyst material is removed from at least the first region of the polycrystalline table. | 09-06-2012 |
| 20120225253 | METHODS OF FORMING POLYCRYSTALLINE ELEMENTS AND STRUCTURES FORMED BY SUCH METHODS - Methods of forming a polycrystalline element comprise forming a polycrystalline table on a first substrate. Catalyst material may be removed from at least a portion of the polycrystalline table. The polycrystalline table and a portion of a first substrate attached to the polycrystalline table may be removed from a remainder of the first substrate. The portion of the first substrate may be attached to another substrate. Polycrystalline elements comprise a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed another substrate attached to the portion of the first substrate. | 09-06-2012 |
| 20120225277 | METHODS OF FORMING POLYCRYSTALLINE TABLES AND POLYCRYSTALLINE ELEMENTS AND RELATED STRUCTURES - Methods of forming a polycrystalline element comprise disposing a first plurality of particles comprising a superabrasive material, a second plurality of particles comprising the superabrasive material, and a catalyst material in a mold. The first and second pluralities of particles are sintered to form a polycrystalline table comprising a first region having a first permeability and a second region having a second, greater permeability. Catalyst material is at least substantially removed from the polycrystalline table. The polycrystalline table is attached to an end of a substrate, the at least a second region being interposed between the first region and the substrate. Polycrystalline elements comprise a substrate. A polycrystalline table comprising a superabrasive material and having a first region exhibiting a first permeability and at least a second region exhibiting a second, greater permeability is attached to an end of the substrate. | 09-06-2012 |
| 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 |
| 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 |
| 20120325562 | DIAMOND ENHANCED CUTTING ELEMENTS, EARTH-BORING TOOLS EMPLOYING DIAMOND-ENHANCED CUTTING ELEMENTS, AND METHODS OF MAKING DIAMOND-ENHANCED CUTTING ELEMENTS - Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles. | 12-27-2012 |
| 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 |
| 20130067825 | METHODS OF FORMING POLYCRSTALLINE COMPACTS AND RESULTING COMPACTS - Methods for forming cutting elements, methods for forming polycrystalline compacts, and related polycrystalline compacts are disclosed. Grains of a hard material are subjected to a high pressure, high temperature process to form a polycrystalline compact. Inclusion of at least one relatively quick spike in system pressure or temperature during an otherwise plateaued temperature or pressure stage accommodates formation of inter-granular bonds between the grains. The brevity of the peak stage may avoid undesirable grain growth. Embodiments of the methods may also include at least one of oscillating at least one system condition (e.g., pressure, temperature) and subjecting the grains to ultrasonic or mechanical vibrations. A resulting polycrystalline compact may include a high density of inter-granularly bonded hard material with a minimized amount of catalyst material, and may provide improved thermal stability, wear resistance, toughness, and behavior during use of a cutting element incorporating the polycrystalline compact. | 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 |
| 20130068538 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body. | 03-21-2013 |
| 20130086847 | COMBINED FIELD ASSISTED SINTERING TECHNIQUES AND HTHP SINTERING TECHNIQUES FOR FORMING POLYCRYSTALLINE DIAMOND COMPACTS AND EARTH-BORING TOOLS, AND SINTERING SYSTEMS FOR PERFORMING SUCH METHODS - Methods of forming polycrystalline diamond compacts include employing field assisted sintering techniques with high temperature and high pressure sintering techniques. For example, a particle mixture that includes diamond particles may be sintered by subjecting the particle mixture to a high temperature and high pressure sintering cycle, and pulsing direct electrical current through the particle mixture during at least a portion of the high temperature and high pressure sintering cycle. The polycrystalline diamond compacts may be used to form cutting elements for earth-boring tools. Sintering systems are configured to perform such sintering processes. | 04-11-2013 |
| 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 |
| 20130105230 | ABRASIVE-IMPREGNATED CUTTING STRUCTURE HAVING ANISOTROPIC WEAR RESISTANCE AND DRAG BIT INCLUDING SAME | 05-02-2013 |
| 20130118813 | CUTTING ELEMENTS HAVING LATERALLY ELONGATED SHAPES FOR USE WITH EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - A cutting element for an earth-boring tool includes a volume of superabrasive material on a substrate. The cutting element has an elongated shape in a lateral dimension parallel to a front cutting face of the cutting element, and has a maximum lateral width in a first direction parallel to the front cutting face of the cutting element and a maximum lateral length in a second perpendicular direction parallel to the front cutting face of the cutting element. The maximum lateral length is significantly greater than the maximum lateral width. An earth-boring tool includes one or more such cutting elements mounted to a body of the earth-boring tool. A method of forming such an earth-boring tool includes selecting at least one such cutting element and mounting the cutting element to a body of an earth-boring tool. | 05-16-2013 |
| 20130152736 | WELDING RODS INCLUDING PCD PARTICLES AND METHODS OF FORMING SUCH WELDING RODS - A welding rod for use in applying hardfacing to a surface of a tool includes an elongated, generally cylindrical body including a metal matrix material. The welding rod also includes particles of polycrystalline diamond material carried by the elongated, generally cylindrical body. The particles of polycrystalline diamond material include a plurality of inter-bonded diamond grains. | 06-20-2013 |
| 20130199856 | SHAPED CUTTING ELEMENTS FOR EARTH-BORING TOOLS AND EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS - Cutting elements for an earth-boring tool include a substrate base and a cutting tip. The cutting tip may include a first generally conical surface, a second, opposite generally conical surface, a first flank surface extending between the first and second generally conical surfaces, and a second, opposite flank surface. In some embodiments, the cutting tip includes a central axis that is not co-linear with a longitudinal axis of the substrate base. In some embodiments, the cutting tip includes a surface defining a longitudinal end thereof that is relatively more narrow in a central region thereof than in a radially outer region thereof. Earth boring tools include a body and a plurality of such cutting elements attached thereto, at least one cutting element oriented to initially engage a formation with the first or second generally conical surface thereof. Methods of drilling a formation use such cutting elements and earth-boring tools. | 08-08-2013 |
| 20130248259 | SELF-SHARPENING CUTTING ELEMENTS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS - Cutting elements for earth-boring tools comprise a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, Ti. A polycrystalline superabrasive material may be attached to the substrate. Earth-boring tools comprise a body. At least one cutting element is attached to the body. The cutting element comprises a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, and Ti. A polycrystalline superabrasive material may be attached to the substrate. Methods of forming cutting elements for earth-boring tools comprise disposing a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, and Ti in a container. Particles of superabrasive material may be disposed in the container. The particles of superabrasive material may be sintered with the substrate in the container to form a polycrystalline superabrasive material attached to the substrate. | 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 |
| 20130270007 | APPARATUSES AND METHODS FOR OBTAINING AT-BIT MEASUREMENTS FOR AN EARTH-BORING DRILLING TOOL - An earth-boring drilling tool comprises a cutting element. The cutting element comprises a substrate, a diamond table, and at least one sensing element formed from a doped diamond material disposed at least partially within the diamond table. A method for determining an at-bit measurement for an earth-boring drill bit comprises receiving an electrical signal generated within a doped diamond material disposed within a diamond table of a cutting element of the earth-boring drill bit, and correlating the electrical signal with at least one parameter during a drilling operation. | 10-17-2013 |
| 20130270008 | APPARATUSES AND METHODS FOR AT-BIT RESISTIVITY MEASUREMENTS FOR AN EARTH-BORING DRILLING TOOL - A cutting element for an earth-boring drilling tool comprises a cutting body having a cutting surface thereon, and a sensor coupled with the cutting surface, the sensor configured to determine resistivity of a contacting formation. An earth-boring drilling tool comprises a bit body and an instrumented cutting element coupled with the bit body. The cutting element includes a cutting body having a cutting surface thereon, and at least one sensor located proximate the cutting surface. The at least one sensor is oriented and configured to determine resistivity of a contacting formation. A method of determining resistivity of a subterranean formation during a drilling operation comprises energizing a sensor of an instrumented cutting element of a drill bit, sensing a return signal flowing on or through the subterranean formation through the instrumented cutting element, and determining a resistivity of the subterranean formation based, at least in part, on the return signal. | 10-17-2013 |
| 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 |
| 20140013670 | METHODS OF FORMING COMPOSITE PARTICLES, COMPOSITIONS OF MATTER COMPRISING COMPOSITE PARTICLES, AND METHODS OF FORMING EARTH-BORING TOOLS - Methods of forming composite particles include forming a source material over a plurality of nucleation cores and forming a catalyst material over the source material. Compositions of matter include a plurality of composite particles, each particle of the plurality comprising a plurality of nucleation cores, a source material disposed over the nucleation cores, and a catalyst material disposed over the source material. Methods of forming earth-boring tools include forming a plurality of composite particles, combining the plurality of composite particles with a plurality of grains of hard material, and catalyzing the formation of inter-granular bonds between the composite particles and the grains of hard material to faun a polycrystalline material. The plurality of in situ nucleated grains of hard material and the plurality of grains of hard material may be interspersed and inter-bonded. | 01-16-2014 |
| 20140047776 | METHODS FOR FORMING INSTRUMENTED CUTTING ELEMENTS OF AN EARTH-BORING DRILLING TOOL - A method of forming an instrumented cutting element comprises forming a free standing sintered diamond table having at least one chamber in the free standing sintered diamond table, providing a doped diamond material within the at least one chamber, and attaching a substrate to the free standing sintered diamond table to form an instrumented cutting element. The instrumented cutting element includes the doped diamond material disposed within the sintered diamond table on the substrate. A method of forming an earth-boring tool comprises attaching at least one instrumented cutting element to a body of an earth-boring tool. The at least one instrumented cutting element has a diamond table bonded to a substrate. The diamond table has at least one sensing element disposed at least partially within the diamond table. The at least one sensing element comprises a doped diamond material. | 02-20-2014 |
| 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 |
| 20140048341 | CUTTING ELEMENTS INCLUDING ADHESION MATERIALS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - A cutting element for an earth-boring drill bit may include a thermally stable cutting table comprising a polycrystalline diamond material. The polycrystalline diamond material may consist essentially of a matrix of diamond particles bonded to one another and a silicon, silicon carbide, or silicon and silicon carbide material located within interstitial spaces among interbonded diamond particles of the matrix of diamond particles. The cutting table may be at least substantially free of Group VIII metal or alloy catalyst material. The cutting element may further include a substrate and an adhesion material between and bonded to the cutting table and the substrate. The adhesion material may include diamond particles bonded to one another and to the cutting table and the substrate after formation of the preformed cutting table. | 02-20-2014 |
| 20140151132 | ROTARY DRAG BITS INCLUDING ABRASIVE-IMPREGNATED CUTTING STRUCTURES - Rotary drag bits comprise a body comprising a face at a leading end of the body. An abrasive-impregnated cutting structure is located at the face of the body. The abrasive-impregnated cutting structure comprises abrasive particles dispersed within a matrix material. The abrasive-impregnated cutting structure exhibits an anisotropic wear resistance. The wear resistance varies at least substantially continuously within the abrasive-impregnated cutting structure. | 06-05-2014 |
| 20140245667 | HARDFACING MATERIALS INCLUDING PCD PARTICLES, EARTH-BORING TOOLS COMPRISING CRUSHED POLYCRYSTALLINE DIAMOND MATERIAL, AND RELATED METHODS - 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. | 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 |
| 20140246253 | 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 volume of superabrasive material having a cutting face and a shaped feature on the cutting face. The shaped feature may include at least one of a recess extending into the volume of superabrasive material from the cutting face and a protrusion extending outward from the cutting face. A first portion of the cutting face may have a first surface roughness, and a second portion of the cutting face may have a second surface roughness greater than the first surface roughness of the first portion of the cutting face. The volume of superabrasive material may be disposed on a substrate. Methods of forming cutting elements may include forming one or more shaped features in a cutting face of the cutting elements. Earth-boring tools may include such cutting elements. | 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 |
| 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 |
| 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 |
| 20140332274 | CUTTING ELEMENTS CONFIGURED TO GENERATE SHEAR LIPS DURING USE IN CUTTING, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING AND USING SUCH CUTTING ELEMENTS AND EARTH-BORING TOOLS - Cutting elements for earth-boring tools may generate a shear lip at a wear scar thereon during cutting. A diamond table may exhibit a relatively high wear resistance, and an edge of the diamond table may be chamfered, the combination of which may result in the formation of a shear lip. Cutting elements may comprise multi-layer diamond tables that result in the formation of a shear lip during cutting. Earth-boring tools include such cutting elements. Methods of forming cutting elements may include selectively designing and configuring the cutting elements to form a shear lip. Methods of cutting a formation using an earth-boring tool include cutting the formation with a cutting element on the tool, and generating a shear lip at a wear scar on the cutting element. The cutting element may be configured such that the shear lip comprises diamond material of the cutting element. | 11-13-2014 |
| 20140353040 | METHODS OF FABRICATING CUTTING ELEMENTS FOR EARTH-BORING TOOLS AND METHODS OF SELECTIVELY REMOVING A PORTION OF A CUTTING ELEMENT OF AN EARTH-BORING TOOL - 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. | 12-04-2014 |
| 20150027787 | CUTTING ELEMENTS, RELATED METHODS OF FORMING A CUTTING ELEMENT, AND RELATED EARTH-BORING TOOLS - A cutting element comprises a supporting substrate, and a polycrystalline compact attached to an end of the supporting substrate. The polycrystalline compact comprises a region adjacent the end of the supporting substrate, and another region at least substantially laterally circumscribing the region and having lesser permeability than the region. A method of forming a cutting element, and an earth-boring tool are also described. | 01-29-2015 |
| 20150034394 | EARTH-BORING TOOLS AND METHODS OF FORMING SUCH EARTH-BORING TOOLS - Earth-boring drill bits may include a bit body including blades extending radially over a face of the earth-boring drill bit and cutting elements attached to each blade. Only cutting elements including planar cutting faces may be attached to at least one of the blades. Only cutting elements including nonplanar cutting faces may be attached to at least another of the blades. Only cutting elements including planar cutting faces or only cutting elements including nonplanar cutting faces may be attached to each of the blades. Only cutting elements including nonplanar cutting faces may be attached to a number of the blades that may be unequal to a number of the blades to which only cutting elements comprising planar cutting faces may be attached. | 02-05-2015 |
| 20150053486 | CUTTING ELEMENTS, BEARINGS, AND EARTH-BORING TOOLS INCLUDING MULTIPLE SUBSTRATES ATTACHED TO ONE ANOTHER - Cutting elements for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed. The portion of the first substrate may exhibit a thickness less than a thickness of the first substrate before a remainder of the first substrate was removed to form the portion of the first substrate. Another substrate may be attached to the portion of the first substrate, the portion of the first substrate being interposed between the polycrystalline table and the other substrate. Earth-boring tools may include such cutting elements secured to bodies of the earth-boring tools. Bearings for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed, the polycrystalline table defining a contact surface. Another substrate may be attached to the portion of the first substrate, | 02-26-2015 |
| 20150075082 | METHODS OF FABRICATING CUTTING ELEMENTS INCLUDING ADHESION MATERIALS FOR EARTH-BORING TOOLS - A cutting element for an earth-boring drill bit may include a thermally stable cutting table comprising a polycrystalline diamond material. The polycrystalline diamond material may consist essentially of a matrix of diamond particles bonded to one another and a silicon, silicon carbide, or silicon and silicon carbide material located within interstitial spaces among interbonded diamond particles of the matrix of diamond particles. The cutting table may be at least substantially free of Group VIII metal or alloy catalyst material. The cutting element may further include a substrate and an adhesion material between and bonded to the cutting table and the substrate. The adhesion material may include diamond particles bonded to one another and to the cutting table and the substrate after formation of the preformed cutting table. | 03-19-2015 |
