公开(公告)号：US09597775B2

公开(公告)日：2017-03-21

申请号：US14520188

申请日：2014-10-21

Applicant: US SYNTHETIC CORPORATION

Inventor： Michael A. Vail

IPC: B24D3/00 ,  B24D3/02 ,  B24D11/00 ,  B24D18/00 ,  C09K3/14 ,  B24D3/10

CPC classification number: B24D3/10 ,  B22F2998/10 ,  E21B10/567 ,  C22C26/00 ,  C23F1/00 ,  B22F3/14

Abstract: Embodiments relate to methods of fabricating polycrystalline diamond compacts (“PDCs”) in which a removing agent includes at least one supercritical fluid component that is used to remove at least one interstitial constituent from at least a portion of a polycrystalline diamond (“PCD”) body and applications for such PDCs. Removing the at least one interstitial constituent using the removing agent including the at least one supercritical fluid component may provide more rapid and effective removal of the at least one interstitial constituent from a PCD body than conventional acid leaching. In an embodiment, a method of fabricating at least partially porous PCD body includes providing a PCD body in which at least one interstitial constituent is disposed throughout, and removing at least a portion of the at least one interstitial constituent from the PCD body with a removing agent including at least one supercritical fluid component.

公开(公告)号：US20160327530A1

公开(公告)日：2016-11-10

申请号：US14011471

申请日：2013-08-27

Applicant: US Synthetic Corporation

Inventor： Julie Ann Kidd ,  Michael A. Vail

IPC: G01N33/00 ,  G06F19/00

CPC classification number: G01N33/00 ,  B01J3/06 ,  B01J3/062 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  G06F19/70

Abstract: Embodiments of the invention relate to methods of modeling leaching behavior of a polycrystalline diamond (“PCD”) material used in leached polycrystalline diamond compacts (“PDCs”) and methods of monitoring leaching of a PCD material. In an embodiment, a method of modeling leaching behavior is disclosed. A PCD table is provided, which includes a plurality of bonded diamond grains defining a plurality of interstitial regions in which a metallic material is disposed. The PCD table is leached with a leaching agent to at least partially remove the metallic material from the PCD table. A leach depth of the PCD table is determined. A concentration of at least one constituent of the leaching agent is also determined. The leach depth is correlated with the concentration of the at least one metal to generate the model of leaching behavior.

Abstract translation: 本发明的实施方案涉及用于浸出多晶金刚石压块（“PDC”）中使用的多晶金刚石（“PCD”）材料的浸出行为的建模方法以及监测PCD材料浸出的方法。 在一个实施例中，公开了一种建模浸出行为的方法。 提供了一种PCD台，其包括限定多个间隙区域的多个结合金刚石晶粒，其中设置有金属材料。 用浸出剂浸出PCD表以至少部分地从PCD表中去除金属材料。 确定PCD表的浸出深度。 还确定了浸出剂的至少一种成分的浓度。 浸出深度与至少一种金属的浓度相关，以产生浸出行为的模型。

公开(公告)号：US08622157B1

公开(公告)日：2014-01-07

申请号：US13689353

申请日：2012-11-29

Applicant: US Synthetic Corporation

Inventor： Kenneth E. Bertagnolli ,  Michael A. Vail

IPC: B32B9/00

CPC classification number: E21B10/567 ,  B24D3/10 ,  B32B9/00 ,  C04B35/52 ,  C04B35/6303 ,  C04B35/645 ,  C04B2235/3201 ,  C04B2235/3203 ,  C04B2235/3206 ,  C04B2235/3208 ,  C04B2235/3213 ,  C04B2235/3225 ,  C04B2235/3234 ,  C04B2235/3256 ,  C04B2235/3272 ,  C04B2235/3274 ,  C04B2235/3427 ,  C04B2235/3821 ,  C04B2235/3843 ,  C04B2235/421 ,  C04B2235/427 ,  C04B2235/44 ,  C04B2235/442 ,  C04B2235/448 ,  E21B10/55 ,  Y10T407/27

Abstract: A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.

Abstract translation: 用于磨损，切割，钻孔，拉伸和类似应用的多晶金刚石压块设置有远离工作表面的第一金刚石区域，其具有金属催化材料和邻近或包括工作表面的第二金刚石区域， 提供了金属催化剂及其制造方法。 这种压块在高温操作中是特别有用的，例如由于工作表面的热稳定性的改善而导致的硬岩凿岩。

公开(公告)号：US11156546B1

公开(公告)日：2021-10-26

申请号：US16835297

申请日：2020-03-30

Applicant: US Synthetic Corporation

Inventor： Michael A. Vail ,  Kenneth E. Bertagnolli ,  Jason K. Wiggins

IPC: G01N19/04 ,  G01N29/14 ,  G01N3/56 ,  G01N29/44 ,  G01N3/40

Abstract: Embodiments of methods are disclosed for characterizing a tested superabrasive element, such as a polycrystalline diamond element. In an embodiment, a method of characterizing the relative strength of a superabrasive element is disclosed. A first superabrasive element and a second superabrasive element are positioned upper surface to upper surface, including an area of overlap between the upper surfaces. A load is applied while the first and second superabrasive elements are overlapped until failure of one or both of the first or second superabrasive elements fail. A relative strength is determined using at least the load during failure as a parameter.

公开(公告)号：US10605721B1

公开(公告)日：2020-03-31

申请号：US16159500

申请日：2018-10-12

Applicant: US Synthetic Corporation

Inventor： Michael A. Vail ,  Kenneth E. Bertagnolli ,  Jason K. Wiggins

IPC: G01N19/04 ,  G01N29/14

Abstract: Embodiments of methods are disclosed for characterizing a tested superabrasive element, such as a polycrystalline diamond element. In an embodiment, a method of characterizing the relative strength of a superabrasive element is disclosed. A first superabrasive element and a second superabrasive element are positioned upper surface to upper surface, including an area of overlap between the upper surfaces. A load is applied while the first and second superabrasive elements are overlapped until failure of one or both of the first or second superabrasive elements fail. A relative strength is determined using at least the load during failure as a parameter.

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：US09643293B1

公开(公告)日：2017-05-09

申请号：US14634395

申请日：2015-02-27

Applicant: US SYNTHETIC CORPORATION

Inventor： David P. Miess ,  Michael A. Vail ,  C. Eugene McMurray

IPC: E21B10/36 ,  B01J3/06 ,  B24D3/04 ,  B24D18/00

CPC classification number: B24D3/04 ,  B24D18/00 ,  B24D18/0009 ,  B24D99/005 ,  E21B10/5735

Abstract: Embodiments of the invention relate to methods of fabricating a polycrystalline diamond compacts and applications for such polycrystalline diamond compacts. In an embodiment, a method of fabricating a polycrystalline diamond body includes mechanically milling non-diamond carbon and a sintering aid material for a time and aggressiveness sufficient to form a plurality of carbon-saturated sintering aid particles and sintering a plurality of diamond particles in the presence of the plurality of carbon-saturated sintering aid particles to form the polycrystalline diamond body.

公开(公告)号：US09623542B1

公开(公告)日：2017-04-18

申请号：US14570506

申请日：2014-12-15

Applicant: US SYNTHETIC CORPORATION

Inventor： David P. Miess ,  Michael A. Vail ,  Kenneth E. Bertagnolli ,  C. Eugene McMurray ,  Paul Douglas Jones

IPC: B24D18/00 ,  B24D3/10 ,  B24D99/00

CPC classification number: B24D18/0009 ,  B24D3/02 ,  B24D3/06 ,  B24D3/10 ,  B24D99/005 ,  E21B10/567 ,  E21B10/5676 ,  E21B2010/561

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) comprising a polycrystalline diamond (“PCD”) table including a thermally-stable region having at least one low-carbon-solubility material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a PCD table bonded to the substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The PCD table further includes at least one low-carbon-solubility material disposed in at least a portion of the plurality of interstitial regions. The at least one low-carbon-solubility material exhibits a melting temperature of about 1300° C. or less and a bulk modulus at 20° C. of less than about 150 GPa.