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公开(公告)号：US10920303B2
公开(公告)日：2021-02-16
申请号：US15569908
申请日：2015-05-28
IPC分类号： E21B10/567 , E21B10/46 , C22C29/08 , C22C1/10 , B22F3/15 , B22F5/00 , B22F7/06 , B23P15/30 , E21B10/02 , C22C26/00
摘要： Induced material segregation methods of manufacturing a polycrystalline diamond compact (PDC) cutter result in formation of a polycrystalline diamond/tungsten carbide (WC) composite material having a smooth compositional gradient from maximum WC concentration at one face to maximum diamond concentration at another face. Because the compositional gradient is smooth, very little or no mismatch of coefficient of thermal expansion occurs, which improves a service lifetime of the PDC cutter.
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公开(公告)号：US10711331B2
公开(公告)日：2020-07-14
申请号：US15562020
申请日：2015-04-28
摘要： The present disclosure relates to a polycrystalline diamond compact (PDC) including a gradient interfacial layer between a thermally stable diamond (TSP) table and a base, such as a substrate or an earth-boring drill bit body. The gradient interfacial layer has a gradient of coefficients of thermal expansion between that of the diamond and the base. The disclosure also relates to methods of forming a gradient interfacial layer and a PDC containing such a layer.
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3.发明申请公开(公告)号：US20200040662A1
公开(公告)日：2020-02-06
申请号：US16338907
申请日：2016-11-02
IPC分类号： E21B10/573 , C22C26/00 , B22F7/06 , B22F3/24
摘要： The present disclosure provides a sintering assembly and a polycrystalline diamond compact (PDC) including a acid-labile leach-enhancing material, a PDC including cavities formed by removal of an acid-labile leach-enhancing material, and a method of forming a leached PDC using an acid-labile leach-enhancing material. The present disclosure further includes drill bits using PDCs formed suing an acid-labile leach-enhancing material.
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4.发明申请公开(公告)号：US20180202234A1
公开(公告)日：2018-07-19
申请号：US15744664
申请日：2015-08-17
IPC分类号： E21B10/573 , B23K1/00 , B23K1/19 , B23K20/16 , B23K20/233
CPC分类号： E21B10/5735 , B23K1/0006 , B23K1/0008 , B23K1/19 , B23K20/026 , B23K20/165 , B23K20/233 , B23K2101/20 , B23K2103/18 , B23K2103/50 , B23K2103/52 , B23K2103/54
摘要： A PCD cutter formed by a reactive/exothermic bond formed between the diamond table and the substrate. The bond is formed by applying a small pulse of localized energy to a bonding agent containing exothermic reactive materials which is disposed at the interface of the diamond table and the substrate. The bonding agent may be formed by depositing a plurality of alternating layers of exothermic foils at the interface between the polycrystalline diamond table and the substrate. Additional layers may also be deposited between the polycrystalline diamond table and the plurality of layers of exothermic foils and between the foils and the substrate. One or more refractory layers may also be disposed between the layers of exothermic material and a masking or non-wetting material may be applied to one or more sides of the substrate and diamond table.
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公开(公告)号：US10655398B2
公开(公告)日：2020-05-19
申请号：US15572651
申请日：2015-06-26
发明人： Gagan Saini
IPC分类号： E21B10/573 , E21B10/56 , E21B10/42
摘要： A cutter for a drill bit and method of manufacturing same is disclosed. The cutter has a non-leached polycrystalline diamond (PCD) table bonded to a substrate and a leached PCD table bonded to one or both of the substrate and non-leached PCD table. The leached PCD table may be ring-shaped and acts as the working surface of the cutting element. It may have a jagged inner surface which cooperates with complementary jagged-shaped outer surface of the non-leached PCD table to prevent rotation of the leached PCD table relative to the non-leached PCD table during a cutting operation. A surface of the leached PCD table may be tapered and fit together in a complementary manner with an oppositely tapered surface of the non-leached PCD table so as to mechanically lock the leached PCD table to the non-leached PCD table.
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公开(公告)号：US10041304B2
公开(公告)日：2018-08-07
申请号：US14905099
申请日：2015-03-10
发明人： Gagan Saini , William Brian Atkins
摘要： An example polycrystalline diamond compact includes a substrate and a diamond table attached to the substrate. A multilayer joint interposes the substrate and the diamond table and comprises at least two component parts selected from the group consisting of a base layer, one or more intermediate layers, and a braze layer. The at least two component parts are formed via a thin film deposition process.
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公开(公告)号：US09878957B2
公开(公告)日：2018-01-30
申请号：US15107004
申请日：2015-06-30
IPC分类号： B23K31/02 , C04B35/528 , B23K1/00 , C22C26/00 , C04B35/64 , C04B35/63 , C04B35/638 , E21B10/567 , B23K101/00 , B23K103/00 , E21B10/54 , E21B10/60
CPC分类号： C04B35/528 , B22F7/062 , B22F2005/001 , B22F2998/10 , B22F2999/00 , B23K1/0008 , B23K2101/002 , B23K2103/50 , C04B35/6303 , C04B35/638 , C04B35/64 , C04B2235/405 , C04B2235/427 , C22C26/00 , E21B10/54 , E21B10/567 , E21B10/602 , B22F2003/244 , B22F2201/00
摘要： Catalyst extraction from polycrystalline diamond table may be achieved by treating with a halogen (in the gas phase or dissolved in a nonpolar organic solvent) to convert the catalyzing material to a salt. Then, polar organic solvents may optionally be used to leach the salt from the polycrystalline diamond table. The polycrystalline diamond (with the salt of the catalyzing material present or at least partially leached therefrom) may be brazed to a hard composite substrate to produce a cutter suitable for use in a matrix drill bit.
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公开(公告)号：US20170198528A1
公开(公告)日：2017-07-13
申请号：US15321396
申请日：2014-08-01
发明人： Gagan Saini , Qi Liang
IPC分类号： E21B10/573 , C23C16/27 , E21B10/55
摘要： The present disclosure related to polycrystalline diamond (PCD) having chemical vapor deposition (CVD) deposits and to PCD elements and drill bits containing such CVD-modified PCD. The present disclosure further relates to method of forming such materials.
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公开(公告)号：US20170107768A1
公开(公告)日：2017-04-20
申请号：US14905099
申请日：2015-03-10
发明人： Gagan Saini , William Brian Atkins
IPC分类号： E21B10/573 , C22C26/00 , B22F7/06 , E21B10/55 , B24D18/00
CPC分类号： E21B10/5735 , B22F7/06 , B22F2998/10 , B24D18/0009 , C22C1/00 , C22C26/00 , E21B10/55 , B22F3/14 , B22F2003/244
摘要： An example polycrystalline diamond compact includes a substrate and a diamond table attached to the substrate. A multilayer joint interposes the substrate and the diamond table and comprises at least two component parts selected from the group consisting of a base layer, one or more intermediate layers, and a braze layer. The at least two component parts are formed via a thin film deposition process.
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公开(公告)号：US20180135357A1
公开(公告)日：2018-05-17
申请号：US15572651
申请日：2015-06-26
发明人： Gagan Saini
IPC分类号： E21B10/573 , E21B10/42
CPC分类号： E21B10/573 , E21B10/42 , E21B2010/564
摘要： A cutter for a drill bit and method of manufacturing same is disclosed. The cutter has a non-leached polycrystalline diamond (PCD) table bonded to a substrate and a leached PCD table bonded to one or both of the substrate and non-leached PCD table. The leached PCD table may be ring-shaped and acts as the working surface of the cutting element. It may have a jagged inner surface which cooperates with complementary jagged-shaped outer surface of the non-leached PCD table to prevent rotation of the leached PCD table relative to the non-leached PCD table during a cutting operation. A surface of the leached PCD table may be tapered and fit together in a complementary manner with an oppositely tapered surface of the non-leached PCD table so as to mechanically lock the leached PCD table to the non-leached PCD table.
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