公开(公告)号：US20200031076A1

公开(公告)日：2020-01-30

申请号：US16589279

申请日：2019-10-01

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Michael A. Vail ,  Jiang Qian ,  Jason K. Wiggins ,  Mark P. Chapman ,  Arnold D. Cooper ,  Debkumar Mukhopadhyay ,  Amy Leigh Rodriguez ,  Stephen Rudger Adams

IPC: B30B7/04 ,  B30B15/34 ,  B30B11/00 ,  B24D18/00

Abstract: Embodiments disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.

公开(公告)号：US10315288B2

公开(公告)日：2019-06-11

申请号：US15040818

申请日：2016-02-10

Applicant: US SYNTHETIC CORPORATION

Inventor： Jiang Qian ,  C. Eugene McMurray ,  Debkumar Mukhopadhyay ,  Jason K. Wiggins ,  Michael A. Vail ,  Kenneth E. Bertagnolli

IPC: B24D3/10 ,  B22F7/06 ,  C22C26/00 ,  E21B10/567 ,  F16C33/04 ,  F16C33/10 ,  B24D18/00 ,  E21B10/54 ,  E21B10/56 ,  B01J3/06 ,  B22F5/00

Abstract: In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.

公开(公告)号：US20170210081A1

公开(公告)日：2017-07-27

申请号：US15402925

申请日：2017-01-10

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Michael A. Vail ,  Jiang Qian ,  Jason K. Wiggins ,  Mark P. Chapman ,  Arnold D. Cooper ,  Debkumar Mukhopadhyay ,  Amy Leigh Rodriguez ,  Steven Rudger Adams

IPC: B30B7/04 ,  B30B11/00 ,  B24D18/00 ,  B30B15/34

CPC classification number: B30B7/04 ,  B24D18/0009 ,  B30B11/004 ,  B30B11/007 ,  B30B15/34

Abstract: Embodiments disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.

公开(公告)号：US10703681B2

公开(公告)日：2020-07-07

申请号：US15901124

申请日：2018-02-21

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Wiggins ,  Michael Vail ,  Debkumar Mukhopadhyay

IPC: C04B37/00 ,  G01N27/80 ,  G01N27/72 ,  B21C3/02 ,  B24D18/00 ,  C22C26/00 ,  E21B10/567 ,  F16C33/26 ,  F16C33/04 ,  F16C17/04 ,  F16C17/02

Abstract: Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm3/grams (“G·cm3/g”) or less. Other embodiments are directed to polycrystalline diamond compacts (“PDCs”) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

公开(公告)号：US10287822B2

公开(公告)日：2019-05-14

申请号：US13789099

申请日：2013-03-07

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  David P. Miess ,  Jiang Qian ,  Jason K. Wiggins ,  Michael A. Vail ,  Debkumar Mukhopadhyay

IPC: B24D18/00 ,  E21B10/36 ,  B22F7/08 ,  C22C26/00 ,  E21B10/573 ,  F16C33/04

Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.

公开(公告)号：US20160158918A1

公开(公告)日：2016-06-09

申请号：US15040818

申请日：2016-02-10

Applicant: US SYNTHETIC CORPORATION

Inventor： Jiang Qian ,  C. Eugene McMurray ,  Debkumar Mukhopadhyay ,  Jason K. Wiggins ,  Michael A. Vail ,  Kenneth E. Bertagnolli

IPC: B24D3/10 ,  E21B10/56 ,  E21B10/54 ,  B24D18/00

CPC classification number: B24D3/10 ,  B22F7/062 ,  B22F2005/001 ,  B24D18/0009 ,  C22C26/00 ,  E21B10/54 ,  E21B10/56 ,  E21B10/567 ,  F16C33/043 ,  F16C33/108 ,  F16C2352/00 ,  Y10T408/89

Abstract: In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.

Abstract translation: 在一个实施例中，多晶金刚石致密体包括基底和结合到基底的预成型多晶金刚石台。 该表包括定义间隙区域的结合金刚石颗粒。 桌子包括上表面，粘合到基底的后表面和在它们之间延伸的至少一个侧表面。 桌子包括从上表面和侧表面向内延伸的第一区域。 第一区域表现出第一间隙区域浓度并且包括至少一个置于其中的间隙成分，其可以以至少残留量存在并且包括至少一种金属碳酸盐和/或至少一种金属氧化物。 桌子包括与衬底相邻的第二接合区域，其从后表面向内延伸。 第二结合区域表现出比第一间隙区域浓度大的第二间隙区域浓度，并且其中包括金属渗透剂。

公开(公告)号：US08616306B2

公开(公告)日：2013-12-31

申请号：US13623764

申请日：2012-09-20

Applicant: US Synthetic Corporation

Inventor： Kenneth E. Bertagnolli ,  Michael A. Vail ,  Jason K. Wiggins ,  Jiang Qian ,  David P. Miess ,  Debkumar Mukhopadhyay

IPC: E21B10/36 ,  E21B10/46

CPC classification number: E21B10/36 ,  B22F7/08 ,  B22F2998/00 ,  B24D18/00 ,  C22C26/00 ,  E21B10/5735 ,  F16C33/043 ,  F16C2352/00 ,  Y10T428/24612 ,  Y10T428/24996 ,  Y10T428/249967 ,  C22C29/08

Abstract: Embodiments of the invention relate to a polycrystalline diamond compact. In an embodiment, the polycrystalline diamond compact includes a substrate and a polycrystalline diamond table including a first polycrystalline diamond layer bonded to the substrate and at least a second polycrystalline diamond layer. At least an un-leached portion of the polycrystalline diamond table includes a plurality of diamond grains defining a plurality of interstitial regions and a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oe or more and a specific magnetic saturation of about 15 G·cm3/g or less. The second polycrystalline diamond layer exhibits a second average diamond grain size that is less than a first average diamond grain size of the first polycrystalline diamond layer and/or the first polycrystalline diamond layer includes a tungsten-containing material therein.

Abstract translation: 本发明的实施方案涉及多晶金刚石复合体。 在一个实施例中，多晶金刚石致密体包括衬底和多晶金刚石台，其包括结合到衬底和至少第二多晶金刚石层的第一多晶金刚石层。 至少多晶金刚石台的未浸出部分包括限定多个间隙区域的多个金刚石晶粒和占据多个间隙区域的至少一部分的金属溶剂催化剂。 多个金刚石晶粒和金属 - 溶剂催化剂共同表现出约115Oe以上的矫顽磁力和约15G·cm 3 / g以下的比磁饱和。 第二多晶金刚石层表现出小于第一多晶金刚石层的第一平均金刚石晶粒尺寸的第二平均金刚石晶粒尺寸和/或第一多晶金刚石层在其中包含含钨材料。

公开(公告)号：US20130015001A1

公开(公告)日：2013-01-17

申请号：US13623764

申请日：2012-09-20

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  David P. Miess ,  Jiang Qian ,  Jason K. Wiggins ,  Michael A. Vail ,  Debkumar Mukhopadhyay

IPC: E21B10/46 ,  B32B5/30 ,  B32B9/04 ,  B32B3/10

CPC classification number: E21B10/36 ,  B22F7/08 ,  B22F2998/00 ,  B24D18/00 ,  C22C26/00 ,  E21B10/5735 ,  F16C33/043 ,  F16C2352/00 ,  Y10T428/24612 ,  Y10T428/24996 ,  Y10T428/249967 ,  C22C29/08

Abstract: Embodiments of the invention relate to a polycrystalline diamond compact. In an embodiment, the polycrystalline diamond compact includes a substrate and a polycrystalline diamond table including a first polycrystalline diamond layer bonded to the substrate and at least a second polycrystalline diamond layer. At least an un-leached portion of the polycrystalline diamond table includes a plurality of diamond grains defining a plurality of interstitial regions and a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oe or more and a specific magnetic saturation of about 15 G·cm3/g or less. The second polycrystalline diamond layer exhibits a second average diamond grain size that is less than a first average diamond grain size of the first polycrystalline diamond layer and/or the first polycrystalline diamond layer includes a tungsten-containing material therein.

Abstract translation: 本发明的实施例涉及一种多晶金刚石复合体。 在一个实施例中，多晶金刚石致密体包括衬底和多晶金刚石台，其包括结合到衬底和至少第二多晶金刚石层的第一多晶金刚石层。 至少多晶金刚石台的未浸出部分包括限定多个间隙区域的多个金刚石晶粒和占据多个间隙区域的至少一部分的金属溶剂催化剂。 多个金刚石晶粒和金属 - 溶剂催化剂共同表现出约115Oe以上的矫顽磁力和约15G·cm 3 / g以下的比磁饱和。 第二多晶金刚石层表现出小于第一多晶金刚石层的第一平均金刚石晶粒尺寸的第二平均金刚石晶粒尺寸和/或第一多晶金刚石层在其中包含含钨材料。

公开(公告)号：US12044075B2

公开(公告)日：2024-07-23

申请号：US17183478

申请日：2021-02-24

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  David P. Miess ,  Jiang Qian ,  Jason K. Wiggins ,  Michael A. Vail ,  Debkumar Mukhopadhyay

IPC: E21B10/567 ,  B22F7/08 ,  C22C26/00 ,  E21B10/36 ,  E21B10/46 ,  E21B10/55 ,  E21B10/573 ,  B24D18/00 ,  F16C17/02 ,  F16C17/04 ,  F16C17/10 ,  F16C33/04 ,  F16C33/26

CPC classification number: E21B10/567 ,  B22F7/08 ,  C22C26/00 ,  E21B10/36 ,  E21B10/46 ,  E21B10/55 ,  E21B10/5735 ,  B22F2998/00 ,  B24D18/00 ,  F16C17/02 ,  F16C17/04 ,  F16C17/102 ,  F16C33/043 ,  F16C33/26 ,  F16C2352/00 ,  Y10T428/24612 ,  Y10T428/24996 ,  Y10T428/249967 ,  B22F2998/00 ,  C22C29/08

Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.

公开(公告)号：US11865672B1

公开(公告)日：2024-01-09

申请号：US16518049

申请日：2019-07-22

Applicant: US SYNTHETIC CORPORATION

Inventor： Daniel Call Mortensen ,  Lindsay Sue Patton ,  Trevor Allen Olsen ,  Casey Wade Swan ,  Shawn Casey Scott ,  Matthew Kimball Baker ,  Anne-Grethe Slotnaes ,  Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Lott ,  Joshua Adam Hawks

IPC: C22C1/04 ,  B24D3/00 ,  E21B10/62 ,  B24D3/10 ,  E21B10/567 ,  E21B10/55 ,  E21B10/633 ,  C22C1/05 ,  C22C1/051

CPC classification number: B24D3/007 ,  B24D3/10 ,  C22C1/04 ,  C22C1/05 ,  C22C1/051 ,  E21B10/55 ,  E21B10/5673 ,  E21B10/62 ,  E21B10/633 ,  C22C1/04 ,  C22C1/05 ,  C22C1/051

Abstract: PDCs, methods of fabricating the PDCs, and methods of using the PDCs are disclosed herein. The PDCs include a PCD table bonded to a substrate. The PCD table includes an upper surface having a plurality of recessed features formed therein. The plurality of recessed features are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent crack propagation into other portions of the PCD table and limit a volume of the PCD table that spalls. Methods of fabricating the PDCs include partially leaching the PCD table and, after leaching the PCD table, forming the plurality of recessed features in the upper surface thereof. Method of using the PDCs include rotating a PDC that has spalled relative to a rotary drill bit such that a portion of the upper surface of the PDC that has not spalled forms a cutting surface thereof.