公开(公告)号：US20170370158A1

公开(公告)日：2017-12-28

申请号：US15683614

申请日：2017-08-22

Applicant: US Synthetic Corporation

Inventor： Cody William Knuteson ,  Paul Douglas Jones ,  Brandon P. Linford ,  Brent R. Eddy ,  Kenneth E. Bertagnolli ,  Debkumar Mukhopadhyay

IPC: E21B10/567 ,  E21B10/55 ,  B24D18/00 ,  B22F3/14 ,  C22C26/00 ,  E21B10/573 ,  B24D3/10 ,  C22C29/08 ,  B22F5/00

CPC classification number: E21B10/567 ,  B22F3/14 ,  B22F2005/001 ,  B22F2999/00 ,  B24D3/10 ,  B24D18/0009 ,  C22C26/00 ,  C22C29/08 ,  E21B10/55 ,  E21B10/5735 ,  B22F2207/01

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

公开(公告)号：US09610555B2

公开(公告)日：2017-04-04

申请号：US14677859

申请日：2015-04-02

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Kenneth E. Bertagnolli ,  Cody William Knuteson

IPC: B24D18/00 ,  B01J3/06 ,  E21B10/56 ,  C22C26/00 ,  B24D3/10 ,  E21B10/55 ,  E21B10/567 ,  E21B10/573 ,  B22F3/14 ,  B22F7/06

CPC classification number: B24D18/0009 ,  B01J3/062 ,  B01J3/065 ,  B22F3/14 ,  B22F7/06 ,  B22F2999/00 ,  B24D3/10 ,  C04B35/52 ,  C04B41/009 ,  C04B41/5177 ,  C04B41/5194 ,  C04B41/88 ,  C04B2235/427 ,  C22C26/00 ,  E21B10/55 ,  E21B10/56 ,  E21B10/567 ,  E21B10/5735 ,  B22F2201/20 ,  B22F2201/10 ,  B22F2201/02 ,  B22F2201/04

Abstract: Embodiments of the invention relate to methods of forming polycrystalline diamond compacts (“PDCs”), wherein the PDC includes a polycrystalline diamond (“PCD”) table in which at least one Group VIII metal is at least partially alloyed with phosphorus and/or at least one other alloying element to improve the thermal stability of the PCD table. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.

公开(公告)号：US09540885B2

公开(公告)日：2017-01-10

申请号：US14857627

申请日：2015-09-17

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Jair J. Gonzalez

IPC: B22F3/14 ,  E21B10/567 ,  B24D3/06 ,  B24D99/00 ,  B24D18/00 ,  B22F7/06 ,  C22C26/00 ,  B22F5/00

CPC classification number: E21B10/567 ,  B22F3/14 ,  B22F7/062 ,  B22F2005/001 ,  B22F2007/066 ,  B22F2999/00 ,  B24D3/06 ,  B24D18/0009 ,  B24D99/005 ,  C04B37/021 ,  C04B2237/363 ,  C04B2237/405 ,  C22C19/03 ,  C22C19/07 ,  C22C26/00 ,  C22C29/02 ,  C22C2026/008 ,  E21B10/55 ,  E21B10/573 ,  B22F7/06 ,  C22C1/1036

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond (“PCD”) table is infiltrated with a low viscosity cobalt-based alloy infiltrant.

Abstract translation: 实施例涉及多晶金刚石压块（“PDC”）以及制造这样的PDC的方法，其中至少部分浸出的多晶金刚石（“PCD”）工作台用低粘度钴基合金渗透剂渗透。

公开(公告)号：US09512681B1

公开(公告)日：2016-12-06

申请号：US14081960

申请日：2013-11-15

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay

IPC: E21B10/42

CPC classification number: E21B10/42 ,  E21B10/567 ,  E21B10/573

Abstract: In an embodiment, a polycrystalline diamond compact includes a cemented carbide substrate including a carbide constituent cemented with a cementing constituent. The cementing constituent has a non-homogenous concentration within the substrate that includes a substantially continuous gradient. A first portion (e.g. at or near a center) of the substrate has a concentration of the cementing constituent that differs from a concentration of the cementing constituent at a second portion (e.g., at or near an outer surface) of the substrate. Thus, the concentration gradient exhibits a substantially smooth gradient, with increasing distance from the first portion of the substrate towards the second portion of the substrate. This provides the substrate with relatively higher wear resistance in one region (e.g., at or near the outer surface) and relatively higher toughness in another region (e.g., at or near the center).

Abstract translation: 在一个实施例中，多晶金刚石复合体包括硬质合金基底，其包括用固结剂组分胶合的碳化物组分。 固化组分在基材内具有不均匀的浓度，其包括基本上连续的梯度。 衬底的第一部分（例如在中心处或附近）具有与基底的第二部分（例如，在外表面处或附近的）处的固着部件的浓度不同的粘结成分的浓度。 因此，浓度梯度表现出基本上平滑的梯度，随着距衬底的第一部分朝向衬底的第二部分的距离的增加。 这提供了在一个区域（例如，在外表面处或附近）处具有相对更高的耐磨性和在另一区域（例如在中心附近或附近）具有相对较高韧性的基底。

公开(公告)号：US20150361727A1

公开(公告)日：2015-12-17

申请号：US14304631

申请日：2014-06-13

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Kenneth E. Bertagnolli ,  Cody William Knuteson ,  Kevin Duy Nguyen

IPC: E21B10/567 ,  B24D18/00 ,  E21B10/55

CPC classification number: E21B10/5735 ,  B01J3/062 ,  B01J2203/062 ,  B22F2005/001 ,  B22F2207/03 ,  B24D3/06 ,  B24D18/0009 ,  B24D99/005 ,  C04B35/528 ,  C04B35/645 ,  C04B2235/405 ,  C04B2235/42 ,  C04B2235/427 ,  C04B2235/6587 ,  C04B2235/661 ,  C04B2235/85 ,  C22C26/00 ,  C22C2204/00 ,  E21B10/55 ,  E21B10/567

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.

Abstract translation: 本发明的实施方案涉及包括多晶金刚石（“PCD”）表的多晶金刚石压块（“PDC”），其中钴与磷合金以提高PCD表的热稳定性。 在一个实施例中，PDC包括基板和PCD台，其包括与结合到基板的界面的间隔开的上表面。 PCD表包括限定多个间隙区域的多个金刚石晶粒。 PCD表还包括包含至少一种VIII族金属和磷的合金。 合金设置在多个间隙区域的至少一部分中。

公开(公告)号：US20130205677A1

公开(公告)日：2013-08-15

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

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: 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.

Abstract translation: 在一个实施例中，公开了一种制造多晶金刚石致密体的方法。 该方法包括在金属 - 溶剂催化剂的存在下烧结多个金刚石颗粒以形成多晶金刚石体; 浸出多晶金刚石体至少部分地从其中去除金属 - 溶剂催化剂，从而形成至少部分浸出的多晶金刚石体; 以及使所述至少部分浸出的多晶金刚石体和硬质合金基底的组件在压力下经受高压/高温过程，以浸润剂渗透至少部分浸出的多晶金刚石体。 高压/高温过程的压力小于在多个金刚石颗粒的烧结过程中使用的压力。

公开(公告)号：US12297153B2

公开(公告)日：2025-05-13

申请号：US16880131

申请日：2020-05-21

Applicant: US SYNTHETIC CORPORATION

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

IPC: C04B37/00 ,  B21C3/02 ,  B24D18/00 ,  C22C26/00 ,  E21B10/567 ,  F16C33/04 ,  F16C33/26 ,  G01N27/12 ,  G01N27/72 ,  G01N27/80 ,  F16C17/02 ,  F16C17/04

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：US20240131583A1

公开(公告)日：2024-04-25

申请号：US18498461

申请日：2023-10-30

Applicant: US Synthetic Corporation

Inventor： Debkumar Mukhopadhyay

IPC: B22F7/06 ,  B22F3/14 ,  C22C29/02 ,  E21B10/567

CPC classification number: B22F7/06 ,  B22F3/14 ,  C22C29/02 ,  E21B10/567 ,  B22F2302/10 ,  B22F2302/406 ,  B22F2304/10

Abstract: Embodiments disclosed herein relate to polycrystalline diamond compacts that have a substrate including a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having and at least one alloying element, wherein the at least one alloying element constitutes less than 12 wt % of the substrate and wherein the cobalt constitutes less than 12 wt % of the substrate; and methods of making the same.

公开(公告)号：US11773654B1

公开(公告)日：2023-10-03

申请号：US17550864

申请日：2021-12-14

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Kenneth E. Bertagnolli

IPC: E21B10/573 ,  B24D3/10 ,  C22C26/00 ,  B22F7/06 ,  B24D18/00

CPC classification number: E21B10/573 ,  B22F7/062 ,  B24D3/10 ,  B24D18/0009 ,  C22C26/00

Abstract: Embodiments of the invention relate to polycrystalline diamond compact (“PDC”) including a polycrystalline diamond (“PCD”) table that bonded to a cobalt-nickel alloy cemented carbide substrate. The cobalt-nickel alloy cemented carbide substrate provides both erosion resistance and corrosion resistance to the cemented carbide substrate. In an embodiment, a PDC includes a cemented carbide substrate including cobalt-nickel alloy cementing constituent. The PDC further includes a PCD table bonded to the cemented carbide substrate.

公开(公告)号：US11525309B2

公开(公告)日：2022-12-13

申请号：US16550843

申请日：2019-08-26

Applicant: US Synthetic Corporation

Inventor： Cody William Knuteson ,  Paul Douglas Jones ,  Brandon P. Linford ,  Brent R. Eddy ,  Kenneth E. Bertagnolli ,  Debkumar Mukhopadhyay

IPC: B24D3/02 ,  B24D18/00 ,  E21B10/567 ,  B24D3/10 ,  E21B10/55 ,  E21B10/573 ,  C22C26/00 ,  B22F3/14 ,  B24D3/00 ,  B24D11/00 ,  C09K3/14 ,  C22C29/08 ,  B22F5/00

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.