公开(公告)号：US09443042B1

公开(公告)日：2016-09-13

申请号：US14628091

申请日：2015-02-20

Applicant: US SYNTHETIC CORPORATION

Inventor： Craig H. Cooley ,  Debkumar Mukhopadhyay ,  Kenneth E. Bertagnolli

IPC: G06K9/00 ,  G06F17/50 ,  G06F17/10

CPC classification number: G06F17/5009 ,  G01N23/046 ,  G01N2223/606 ,  G01N2223/615 ,  G06F17/10 ,  G06T7/0004 ,  G06T2207/10081 ,  G06T2207/30132

Abstract: Embodiments of systems and methods are disclosed for evaluating a superabrasive material by a three-dimensional model generated using a computed tomography scanner. The model is analyzed to identify a superabrasive matrix within the model and at least one performance characteristic of the superabrasive material is determined according to at least one property of the superabrasive matrix. Methods are also disclosed for characterizing crystal-to-crystal bonding regions and non-superabrasive material within an interstitial matrix of the superabrasive matrix.

Abstract translation: 公开了用于通过使用计算机断层摄影扫描仪产生的三维模型来评估超级磨料的系统和方法的实施例。 分析该模型以识别模型内的超研磨基质，并根据超级磨料基质的至少一种性质确定超级磨料材料的至少一种性能特征。 还公开了用于表征超研磨基质的间隙基质内的晶体 - 晶体结合区域和非超研磨材料的方法。

公开(公告)号：US20160136785A1

公开(公告)日：2016-05-19

申请号：US15005765

申请日：2016-01-25

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Jair J. Gonzalez

IPC: B24D3/06 ,  B24D18/00 ,  E21B10/56

CPC classification number: B24D3/06 ,  B01J3/062 ,  B01J2203/062 ,  B01J2203/0655 ,  B01J2203/0685 ,  B24D18/0009 ,  B24D99/005 ,  C04B35/528 ,  E21B10/46 ,  E21B10/56

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 a cobalt-based alloy infiltrant having a composition at or near a eutectic composition of the 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。 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台的第二HPHT方法，所述第二HPHT工艺具有钴基合金浸渗剂，所述钴基合金浸渗剂具有或接近共晶组成 钴基合金浸润剂。

公开(公告)号：US20150211306A1

公开(公告)日：2015-07-30

申请号：US14677875

申请日：2015-04-02

Applicant: US SYNTHETIC CORPORATION

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

IPC: E21B10/567 ,  E21B10/573 ,  B24D18/00 ,  E21B10/55

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.

Abstract translation: 实施方案涉及包括多晶金刚石（“PCD”）表的多晶金刚石压块（“PDC”），其中金属 - 溶剂催化剂与至少一种合金元素合金以提高PCD表的热稳定性和/或耐磨性。 在一个实施例中，PDC包括基板和与基板结合的PCD台。 PCD表包括定义间隙区域的金刚石颗粒。 PCD表包括包含至少一种VIII族金属和至少一种金属合金元素如磷的合金。

公开(公告)号：US20130228383A1

公开(公告)日：2013-09-05

申请号：US13860110

申请日：2013-04-10

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay ,  Kenneth E. Bertagnolli ,  Jair J. Gonzalez

IPC: E21B10/573

CPC classification number: E21B10/573 ,  B01J3/062 ,  B01J2203/063 ,  B01J2203/0655 ,  B24D99/005 ,  C04B35/528 ,  C04B2235/3847 ,  C04B2237/36 ,  C04B2237/363 ,  C04B2237/555 ,  C22C19/07 ,  C22C29/08 ,  C22C2204/00 ,  E21B10/567 ,  E21B10/5735 ,  F16C33/043 ,  F16C2352/00 ,  Y10T428/30

Abstract: In an embodiment, a rotary drill bit includes a bit body having a leading end structure configured to facilitate drilling a subterranean formation, and a plurality of cutting elements mounted to the bit body. At least one of the plurality of cutting elements includes a polycrystalline diamond compact (“PDC”) comprising a cemented carbide substrate including a first cemented carbide portion and a second cemented carbide portion bonded to the first cemented carbide portion and exhibiting an erosion resistance that is greater than the first cemented carbide portion. The PDC further comprises a polycrystalline diamond (“PCD”) table bonded to the first cemented carbide portion. The PCD table includes a plurality of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween, with the plurality of bonded diamond grains defining a plurality of interstitial regions.

Abstract translation: 在一个实施例中，旋转钻头包括具有构造成便于钻探地层的前端结构的钻头体和安装到钻头体上的多个切割元件。 多个切割元件中的至少一个包括多晶金刚石复合体（“PDC”），其包括硬质合金基体，该硬质合金基底包括第一硬质合金部分和第二硬质合金部分，该第二硬质合金部分结合到第一硬质合金部分并且具有耐侵蚀性， 大于第一硬质合金部分。 PDC还包括结合到第一硬质合金部分的多晶金刚石（“PCD”）台。 PCD表包括多个结合的金刚石晶粒，其间形成金刚石 - 金刚石结合，多个结合的金刚石晶粒限定多个间隙区域。

公开(公告)号：US20240383104A1

公开(公告)日：2024-11-21

申请号：US18788897

申请日：2024-07-30

Applicant: US Synthetic Corporation

Inventor： Debkumar Mukhopadhyay ,  Paul Douglas Jones ,  Daren Nathaniel Heaton ,  Kevin Alexander Shirley

IPC: B24D3/06 ,  B24D18/00

Abstract: Embodiments disclosed herein are directed to assemblies for forming polycrystalline diamond compacts and methods for forming the polycrystalline diamond compacts with the assemblies. An example assembly includes a substrate and a diamond material positioned adjacent to an interfacial surface of the substrate. The assembly also includes an enclosure defining a chamber. The substrate and the diamond material are disposed in the chamber. In an embodiment, the assembly includes a sealant and the sealant includes at least one of cobalt or a copper-nickel alloy. In an embodiment, the substrate includes a concave bottom surface that is opposite the interfacial surface.

公开(公告)号：US20240227007A9

公开(公告)日：2024-07-11

申请号：US18498461

申请日：2023-10-31

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：US11661798B1

公开(公告)日：2023-05-30

申请号：US16789825

申请日：2020-02-13

Applicant: US SYNTHETIC CORPORATION

Inventor： Debkumar Mukhopadhyay

IPC: B24D18/00 ,  E21B10/55 ,  E21B10/42 ,  E21B10/567 ,  B24D3/00 ,  B24D11/00 ,  C09K3/14

CPC classification number: E21B10/567 ,  E21B10/42 ,  E21B10/55

Abstract: Embodiments relate to a polycrystalline diamond compact (“PDC”) including a polycrystalline diamond (“PCD”) table bonded to a cemented carbide substrate including tungsten carbide grains having a fine average grain size to provide one or more of enhanced wear resistance, corrosion resistance, or erosion resistance, and a PDC with enhanced impact resistance. In an embodiment, a PDC includes a cemented carbide substrate having a cobalt-containing cementing constituent cementing tungsten carbide grains together exhibiting an average grain size of about 1.5 μm or less. The substrate includes an interfacial surface and a depletion zone depleted of the cementing constituent that extends inwardly from the interfacial surface to a depth of, for example, about 30 μm to about 60 μm. The PDC includes a PCD table bonded to the interfacial surface of the substrate. The PCD table includes diamond grains bonded together exhibiting an average grain size of about 40 μm or less.

公开(公告)号：US20210262295A1

公开(公告)日：2021-08-26

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 ,  E21B10/573 ,  E21B10/46 ,  E21B10/55 ,  E21B10/36

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：US10858892B2

公开(公告)日：2020-12-08

申请号：US16034020

申请日：2018-07-12

Applicant: US SYNTHETIC CORPORATION

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

IPC: B24D3/02 ,  B24D18/00 ,  E21B10/567 ,  E21B10/55 ,  E21B10/573 ,  B24D3/10 ,  C22C26/00 ,  B22F7/06 ,  B24D3/00 ,  B24D11/00 ,  C09K3/14

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 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：US10507565B2

公开(公告)日：2019-12-17

申请号：US15080379

申请日：2016-03-24

Applicant: US SYNTHETIC CORPORATION

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

IPC: B24D3/10 ,  E21B10/567 ,  F16C33/04 ,  C22C26/00 ,  F16C33/26 ,  B22F5/00 ,  F16C17/02 ,  F16C17/04

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDC”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 μm or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, 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.