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：US20200024905A1

公开(公告)日：2020-01-23

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: E21B10/567 ,  B24D18/00 ,  B24D3/10 ,  E21B10/55 ,  E21B10/573 ,  C22C26/00 ,  B22F3/14

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：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：US10155301B1

公开(公告)日：2018-12-18

申请号：US14621019

申请日：2015-02-12

Applicant: US SYNTHETIC CORPORATION

Inventor： Paul Douglas Jones ,  Kenneth E. Bertagnolli ,  Debkumar Mukhopadhyay ,  David P. Miess

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

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) comprising a polycrystalline diamond (“PCD”) table including at least a portion having aluminum carbide disposed interstitially between bonded-together 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 bonded-together diamond grains defining a plurality of interstitial regions. The PCD table further includes aluminum carbide disposed in at least a portion of the plurality of interstitial regions.

公开(公告)号：US20180328115A1

公开(公告)日：2018-11-15

申请号：US16034020

申请日：2018-07-12

Applicant: US SYNTHETIC CORPORATION

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

IPC: E21B10/567 ,  B24D18/00 ,  B22F7/06 ,  E21B10/55 ,  C22C26/00 ,  B24D3/10 ,  E21B10/573

CPC classification number: E21B10/567 ,  B22F7/06 ,  B22F2998/10 ,  B22F2999/00 ,  B24D3/10 ,  B24D18/0009 ,  C22C26/00 ,  E21B10/55 ,  E21B10/5735 ,  B22F2207/01 ,  C22C1/05 ,  B22F3/14 ,  B22F2003/244

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 and/or wear resistance 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 such as phosphorous.

公开(公告)号：US20180238116A1

公开(公告)日：2018-08-23

申请号：US15910293

申请日：2018-03-02

Applicant: US SYNTHETIC CORPORATION

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

IPC: E21B10/573 ,  E21B10/55 ,  C22C26/00

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: Polycrystalline diamond compacts (“PDCs”) include a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. For example, 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.

公开(公告)号：US09889541B2

公开(公告)日：2018-02-13

申请号：US14147241

申请日：2014-01-03

Applicant: US SYNTHETIC CORPORATION

Inventor： Mohammad N. Sani ,  Jair J. Gonzalez ,  Andrew E. Dadson ,  Debkumar Mukhopadhyay

IPC: B24D3/02 ,  C09C1/68 ,  C09K3/14 ,  B24D3/10 ,  B22F3/24 ,  B22F5/00 ,  B22F7/06 ,  C22C26/00 ,  B24D18/00

CPC classification number: B24D3/10 ,  B22F3/24 ,  B22F5/00 ,  B22F7/06 ,  B24D18/0009 ,  B24D18/0027 ,  C22C26/00 ,  Y10T428/12028 ,  Y10T428/12056 ,  Y10T428/24355 ,  Y10T428/30

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating polycrystalline diamond tables and PDCs in a manner that facilitates removal of metal-solvent catalyst used in the manufacture of polycrystalline diamond tables of such PDCs.

公开(公告)号：US09718168B2

公开(公告)日：2017-08-01

申请号：US14677821

申请日：2015-04-02

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Robert J. Farr ,  Ronald W. Ward ,  Edwin Sean Cox ,  Damon Bart Crockett ,  Daniel Preston Wilding

IPC: E21B10/46 ,  B22F7/00 ,  B24D3/10 ,  B24D18/00 ,  C22C26/00 ,  E21B10/55 ,  E21B10/567 ,  E21B10/573 ,  B22F3/12 ,  B22F3/14 ,  B22F7/06

CPC classification number: B24D3/10 ,  B22F3/1208 ,  B22F3/14 ,  B22F7/06 ,  B24D18/0009 ,  C22C26/00 ,  E21B10/55 ,  E21B10/567 ,  E21B10/5735

Abstract: Embodiments disclosed herein involve polycrystalline diamond (“PCD”) tables and polycrystalline diamond compacts (“PDCs”) that include PCD tables as well as methods and apparatuses for manufacturing thereof. Some embodiments include a canister assembly that may be used in a high-pressure/high-temperature (“HPHT”) process or other heating process to manufacture the PCD tables and/or the PDCs.

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：US09487847B2

公开(公告)日：2016-11-08

申请号：US13648913

申请日：2012-10-10

Applicant: US Synthetic Corporation

Inventor： Debkumar Mukhopadhyay ,  Jair J. Gonzalez

IPC: B22F7/06 ,  C22C26/00 ,  E21B10/46

CPC classification number: C22C26/00 ,  B22F7/062 ,  B22F2999/00 ,  E21B10/46 ,  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. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (“HPHT”) process. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom to form an at least partially leached PCD table. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process effective to at least partially infiltrate the at least partially leached PCD table with an alloy infiltrant comprising at least one of a cobalt-based or nickel based alloy infiltrant having a composition at or near a eutectic composition of the 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。 在一个实施方案中，一种方法包括在第一高压/高温（“HPHT”）方法中在金属溶剂催化剂存在下形成PCD表。 该方法包括至少部分浸出PCD表以从其中除去至少一部分金属 - 溶剂催化剂以形成至少部分浸出的PCD台。 该方法包括使至少部分浸出的PCD台和基板经受有效的至少部分浸渗的PCD工作台的第二HPHT工艺，所述合金渗透剂包含钴基或镍基合金浸渗剂中的至少一种 具有在合金浸润剂的共晶组成处或附近的组成。