公开(公告)号：US09302236B2

公开(公告)日：2016-04-05

申请号：US13622530

申请日：2012-09-19

Applicant: Baker Hughes Incorporated

Inventor： Anthony A. DiGiovanni ,  Danny E. Scott

IPC: B01J3/06 ,  B24D3/14 ,  B24D18/00 ,  B24D99/00 ,  E21B10/567

CPC classification number: B24D18/0009 ,  B01J3/062 ,  B01J3/067 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B24D3/14 ,  B24D99/005 ,  E21B10/55 ,  E21B10/567

Abstract: Methods for forming cutting elements comprising polycrystalline materials, methods for forming polycrystalline compacts for cutting elements of a drilling tool, methods 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.

Abstract translation: 公开了用于形成包括多晶材料的切割元件的方法，用于形成用于切割钻孔工具的元件的多晶压块的方法，用于形成多晶金刚石压块的方法，以及所得到的多晶压块和切割元件。 将硬质材料的颗粒引入压机中并进行高压高温（HPHT）工艺以烧结晶粒。 然后将系统条件（即，温度和压力）调整到相位或状态变化点之后，在将系统条件调整到最终水平之前，在退火阶段期间保持至少一个系统条件。 因此，所形成的压块和切割元件可以包括与在HPHT处理期间不具有退火阶段形成的多晶压块和切割元件相比，具有更稳定的微结构（例如，较不受应力的微结构）的颗粒间结合的硬质材料颗粒。

公开(公告)号：US09227166B2

公开(公告)日：2016-01-05

申请号：US11988891

申请日：2006-07-21

Applicant: Hitoshi Sumiya

Inventor： Hitoshi Sumiya

IPC: B01J3/06 ,  B82Y30/00 ,  C04B35/52 ,  C04B35/626 ,  C04B35/645

CPC classification number: B01J3/062 ,  B01J2203/0625 ,  B01J2203/0655 ,  B01J2203/068 ,  B01J2203/0685 ,  B82Y30/00 ,  C04B35/52 ,  C04B35/6261 ,  C04B35/645 ,  C04B2235/422 ,  C04B2235/425 ,  C04B2235/427 ,  C04B2235/528 ,  C04B2235/5288 ,  C04B2235/5436 ,  C04B2235/5445 ,  C04B2235/5454 ,  C04B2235/656 ,  C04B2235/78 ,  C04B2235/781 ,  C04B2235/785 ,  C04B2235/96 ,  Y10T428/2982

Abstract: There are provided sufficiently strong, hard, and heat resistant, dense and homogenous polycrystalline diamond applicable to cutting tools, dressers, dies and other working tools and excavation bits and the like, and a cutting tool having a cutting edge of the polycrystalline diamond. The polycrystalline diamond is formed substantially only of diamond formed using a composition of material containing a non diamond type carbon material, the composition of material being converted directly into diamond and sintered at ultra high pressure and ultra high temperature without aid of a sintering aid or a catalyst, and has a mixed microstructure having a fine crystal grain of diamond having a maximal grain size of at most 100 nm and an average grain size of at most 50 nm and a coarse crystal grain of diamond in the form of one of a platelet and a granule having a grain size of at least 50 nm and at most 10,000 nm.

公开(公告)号：US20150345229A1

公开(公告)日：2015-12-03

申请号：US14291862

申请日：2014-05-30

Applicant: Baker Hughes Incorporated

Inventor： Marc W. Bird

IPC: E21B10/567 ,  B24D99/00 ,  E21B10/55 ,  B24D18/00

CPC classification number: E21B10/567 ,  B01J3/00 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B24D18/0009 ,  B24D99/005 ,  E21B10/55

Abstract: A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm3 and a modulus of at least about 1000 GPa. An earth-boring tool may include such a cutting element secured to a body.

Abstract translation: 形成多晶金刚石的方法包括将金刚石颗粒，一氧化碳和二氧化碳包封在容器中。 将包封的金刚石颗粒，一氧化碳和二氧化碳经受至少4.5GPa的压力和至少1400℃的温度以在金刚石颗粒之间形成颗粒间结合。 切割元件包括多晶金刚石材料，其包含金刚石的互相结合的颗粒。 多晶金刚石材料基本上不含石墨碳和金属化合物。 多晶金刚石材料表现出至少约3.49g / cm 3的密度和至少约1000GPa的模量。 钻孔工具可以包括固定到主体上的这种切割元件。

公开(公告)号：US09120204B2

公开(公告)日：2015-09-01

申请号：US13641390

申请日：2011-04-20

Applicant: Robert Fries

Inventor： Robert Fries

IPC: B24D3/00 ,  B24D3/34 ,  B01J3/06 ,  C22C1/05 ,  C22C26/00 ,  E21B10/567

CPC classification number: B24D3/348 ,  B01J3/062 ,  B01J2203/061 ,  B01J2203/062 ,  B01J2203/0645 ,  B01J2203/0655 ,  B01J2203/066 ,  B01J2203/0685 ,  B22F2998/10 ,  C22C1/051 ,  C22C26/00 ,  E21B10/567 ,  C22C1/05 ,  C25D15/00 ,  B22F3/14

Abstract: A polycrystalline superhard material comprises a sintered mass of superhard grains having a mean superhard grain contiguity of at least 62 percent and at most 92 percent. There is also disclosed a method of making such a polycrystalline superhard material. The method comprises providing a precursor body comprising superhard grains and interstices between the superhard grains, and introducing additive particles into the interstices to form a pre-sinter body. The pre-sinter body is submitted to a temperature and pressure at which superhard material is thermodynamically stable, sintering it and forming polycrystalline superhard material.

Abstract translation: 多晶超硬材料包括具有至少62％且至多92％的平均超硬颗粒接近度的超硬颗粒的烧结块。 还公开了制造这种多晶超硬材料的方法。 该方法包括提供包含超硬颗粒和超硬颗粒之间的间隙的前体体，并将添加剂颗粒引入到间隙中以形成预烧结体。 预烧结体承受超硬材料在热力学上稳定的温度和压力，烧结并形成多晶超硬材料。

公开(公告)号：US09061336B2

公开(公告)日：2015-06-23

申请号：US12523545

申请日：2008-01-18

Applicant: Hitoshi Sumiya ,  Makoto Yukawa

Inventor： Hitoshi Sumiya ,  Makoto Yukawa

IPC: B21C3/02 ,  B21C3/18 ,  C30B29/60 ,  B01J3/06 ,  B82Y30/00 ,  C04B35/52 ,  C04B35/645

CPC classification number: B21C3/025 ,  B01J3/062 ,  B01J2203/061 ,  B01J2203/0625 ,  B01J2203/0655 ,  B01J2203/068 ,  B01J2203/0685 ,  B21C3/18 ,  B82Y30/00 ,  C04B35/52 ,  C04B35/645 ,  C04B2235/422 ,  C04B2235/425 ,  C04B2235/427 ,  C04B2235/656 ,  C04B2235/781 ,  C04B2235/783 ,  C04B2235/785 ,  C30B29/605

Abstract: One object of the present invention is to provide a wire drawing die excellent in strength and wear resistance. The wire drawing die has a core formed using highly hard diamond polycrystalline body made substantially only of diamond and produced by directly converting a raw material composition including a non-diamond type carbon material into diamond and sintering the diamond at an ultra high pressure and an ultra high temperature without adding a sintering aid or a catalyst, the polycrystalline body having a mixed construction including fine-grained diamond crystals with a maximum grain size of less than or equal to 100 nm and an average grain size of less than or equal to 50 nm and plate-like or particulate coarse-grained diamond crystals with a minimum grain size of greater than or equal to 50 nm and a maximum grain size of less than or equal to 10000 nm.

Abstract translation: 本发明的一个目的是提供一种强度和耐磨性优异的拉丝模具。 拉丝模具具有使用基本上仅由金刚石制成的高硬度金刚石多晶体形成的芯，其通过将包含非金刚石型碳材料的原料组合物直接转化为金刚石并以超高压和超高压烧结金刚石 高温而不添加烧结助剂或催化剂，所述多晶体具有混合结构，其包括最大粒径小于或等于100nm的细晶粒金刚石晶体和小于或等于50nm的平均粒度 以及最小晶粒尺寸大于或等于50nm并且最大晶粒尺寸小于或等于10000nm的板状或颗粒状粗粒金刚石晶体。

公开(公告)号：US09061264B2

公开(公告)日：2015-06-23

申请号：US13210681

申请日：2011-08-16

Applicant: Robert H. Frushour

Inventor： Robert H. Frushour

IPC: B24D11/00 ,  B01J3/06

CPC classification number: B01J3/062 ,  B01J2203/0605 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685

Abstract: A polycrystalline diamond cutting element for use in rock drilling or other operations that requires very high abrasion resistance with high transverse rupture strength at temperatures above 700 degrees centigrade. The cutting element includes a diamond layer that contains pre-sintered polycrystalline diamond agglomerate (PPDA) bonded to a supporting substrate. The PPDA can be made thermally stable and can be selected to produce a cutting element with any desired abrasion resistance characteristic without affecting internal stress.

Abstract translation: 用于岩石钻探或其他操作的多晶金刚石切割元件，其在高于700摄氏度的温度下需要非常高的耐磨性和高的横向断裂强度。 切割元件包括金刚石层，其包含结合到支撑基底的预烧结多晶金刚石附聚物（PPDA）。 PPDA可以制成热稳定的并且可以选择以产生具有任何期望的耐磨特性的切割元件而不影响内部应力。

公开(公告)号：US08974562B2

公开(公告)日：2015-03-10

申请号：US13084003

申请日：2011-04-11

Applicant: Soma Chakraborty ,  Gaurav Agrawal

Inventor： Soma Chakraborty ,  Gaurav Agrawal

IPC: E21B10/46 ,  B24D3/00 ,  B01J3/06 ,  B24D99/00 ,  B82Y30/00

CPC classification number: B24D99/005 ,  B01J3/062 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B24D18/0009 ,  B82Y30/00 ,  C01B32/28 ,  C04B35/528 ,  C04B35/62625 ,  C04B35/63404 ,  C04B35/63448 ,  C04B35/645 ,  C04B2235/349 ,  C04B2235/3817 ,  C04B2235/3847 ,  C04B2235/386 ,  C04B2235/40 ,  C04B2235/422 ,  C04B2235/425 ,  C04B2235/428 ,  C04B2235/5248 ,  C04B2235/5436 ,  C04B2235/5454 ,  C04B2235/5472

Abstract: A method of forming a substantially homogeneous suspension of nanodiamond particles and microdiamond particles is disclosed The method includes disposing a first functional group on a plurality of nanodiamond particles to form derivatized nanodiamond particles, and combining the derivatized nanodiamond particles with a plurality of microdiamond particles and a solvent to form a substantially homogeneous suspension of the derivatized nanodiamond particles and microdiamond particles in the solvent. A method of making an article is also disclosed. The method includes forming a superabrasive polycrystalline diamond compact by combining: a plurality of derivatized nanodiamond particles, a plurality of derivatized microdiamond particles having an average particle size greater than that of the derivatized nanodiamond particles, and a metal solvent-catalyst. The method also includes combining the polycrystalline diamond with a substrate comprising a ceramic. The method further includes removing a portion of a metal solvent-catalyst from the polycrystalline diamond compact by leaching.

Abstract translation: 公开了形成纳米金刚石颗粒和微金刚石颗粒的基本上均匀的悬浮液的方法。该方法包括在多个纳米金刚石颗粒上设置第一官能团以形成衍生的纳米金刚石颗粒，并将衍生的纳米金刚石颗粒与多个微金刚石颗粒和 溶剂以形成衍生的纳米金刚石颗粒和微金刚石颗粒在溶剂中的基本上均匀的悬浮液。 还公开了制造物品的方法。 该方法包括：通过组合多个衍生的纳米金刚石颗粒，多个衍生化的微粒子颗粒，其平均粒径大于衍生的纳米金刚石颗粒的平均粒径，以及金属溶剂 - 催化剂，形成超硬磨料多晶金刚石压块。 该方法还包括将多晶金刚石与包含陶瓷的基底结合。 该方法还包括通过浸出从多晶金刚石压块中去除一部分金属溶剂 - 催化剂。

公开(公告)号：US20140353047A1

公开(公告)日：2014-12-04

申请号：US14368665

申请日：2012-12-13

Applicant: Element Six Abrasives, S.A.

Inventor： Kaveshini Naidoo

IPC: B24D3/06 ,  E21B10/573 ,  B24D18/00

CPC classification number: B24D3/06 ,  B01J3/062 ,  B01J2203/061 ,  B01J2203/0615 ,  B01J2203/062 ,  B01J2203/0625 ,  B01J2203/0655 ,  B01J2203/0685 ,  B24D18/0009 ,  B82Y30/00 ,  C04B35/52 ,  C04B35/6261 ,  C04B35/645 ,  C04B2235/422 ,  C04B2235/424 ,  C04B2235/425 ,  C04B2235/427 ,  C04B2235/5436 ,  C04B2235/5445 ,  C04B2235/5454 ,  C04B2235/5472 ,  C04B2235/6567 ,  C04B2235/785 ,  C04B2235/786 ,  C22C26/00 ,  E21B10/567 ,  E21B10/5735

Abstract: A method of making polycrystalline diamond material includes providing a fraction of diamond particles or grains and a sintering additive, the sintering additive comprising a carbon source of nano-sized particles or grains, forming the diamond particles and sintering additive into an aggregated mass, consolidating the aggregated mass and a binder material to form a green body, and subjecting the green body to conditions of pressure and temperature at which diamond is more thermodynamically stable than graphite and for a time sufficient to consume the sintering additive, sintering it and forming polycrystalline diamond material that is thermodynamically and crystallographically stable and is substantially devoid of any nano-structures.

Abstract translation: 制造多晶金刚石材料的方法包括提供一部分金刚石颗粒或颗粒和烧结添加剂，所述烧结添加剂包含纳米尺寸颗粒或颗粒的碳源，将金刚石颗粒和烧结添加剂形成为聚集体，将 聚集的物料和粘合剂材料以形成生坯，并使生坯在压力和温度条件下使金刚石比石墨热力学稳定，并且足以消耗烧结添加剂的时间，烧结并形成多晶金刚石材料 在热力学和晶体学上是稳定的，并且基本上没有任何纳米结构。

公开(公告)号：US20140262533A1

公开(公告)日：2014-09-18

申请号：US14153428

申请日：2014-01-13

Applicant: Danny Eugene Scott ,  Jimmy Wayne Eason ,  David Alexander Curry ,  Igor Yuri Konyashin

Inventor： Danny Eugene Scott ,  Jimmy Wayne Eason ,  David Alexander Curry ,  Igor Yuri Konyashin

IPC: E21B10/573 ,  E21B10/55 ,  B24D3/10 ,  E21B10/52

CPC classification number: E21B10/573 ,  B01J3/062 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B22F2005/001 ,  B24D3/10 ,  B24D99/005 ,  C22C29/08 ,  E21B10/46 ,  E21B10/52 ,  E21B10/55 ,  E21B10/5735 ,  Y10T428/25

Abstract: A polycrystalline diamond (PCD) composite compact element comprising a PCD structure bonded to a cemented carbide substrate, in which at least a peripheral region of the substrate comprises cemented carbide material having a mean free path (MFP) characteristic of at least about 0.1 microns and at most about 0.7 microns; and an elastic limit of at least about 1.9 GPa.

Abstract translation: 一种多晶金刚石（PCD）复合压实元件，其包括结合到硬质合金基底的PCD结构，其中所述基底的至少周边区域包括具有至少约0.1微米特征的平均自由程（MFP）的硬质合金材料，以及 最多约0.7微米; 弹性极限为至少约1.9GPa。

公开(公告)号：US20140013671A1

公开(公告)日：2014-01-16

申请号：US14028328

申请日：2013-09-16

Applicant: SMITH INTERNATIONAL, INC.

Inventor： J. DANIEL BELNAP ,  GEORGIY VORONIN ,  FENG YU ,  PETER T. CARIVEAU ,  YOUHE ZHANG ,  YUELIN SHEN ,  GUODONG ZHAN

IPC: B24D3/10

CPC classification number: E21B10/55 ,  B01J3/062 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B22F2003/244 ,  B22F2005/001 ,  B22F2998/10 ,  B22F2999/00 ,  B24D3/10 ,  C22C26/00 ,  C22C2026/006 ,  E21B10/567 ,  E21B10/5735 ,  B22F7/062 ,  B22F3/14 ,  B22F2207/01 ,  B22F2207/13 ,  B22F2207/17

Abstract: The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance.