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公开(公告)号：US20200331811A1
公开(公告)日：2020-10-22
申请号：US16880131
申请日：2020-05-21
IPC分类号： C04B37/00 , C22C26/00 , F16C33/04 , F16C33/26 , B21C3/02 , G01N27/80 , G01N27/72 , B24D18/00 , E21B10/567
摘要： 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.
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公开(公告)号：US10773480B2
公开(公告)日：2020-09-15
申请号：US16589279
申请日：2019-10-01
发明人： 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
摘要： 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.
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公开(公告)号：US10428589B2
公开(公告)日：2019-10-01
申请号：US15683614
申请日：2017-08-22
发明人： Cody William Knuteson , Paul Douglas Jones , Brandon P. Linford , Brent R. Eddy , Kenneth E. Bertagnolli , Debkumar Mukhopadhyay
IPC分类号： 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
摘要： 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.
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公开(公告)号：US20190211629A1
公开(公告)日：2019-07-11
申请号：US16358281
申请日：2019-03-19
发明人： Kenneth E. Bertagnolli , David P. Miess , Jiang Qian , Jason K. Wiggins , Michael A. Vail , Debkumar Mukhopadhyay
摘要： 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.
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公开(公告)号：US10301882B2
公开(公告)日：2019-05-28
申请号：US14178118
申请日：2014-02-11
IPC分类号： E21B10/573 , E21B10/567 , E21B10/55 , C22C26/00 , B24D3/10 , B22F7/06 , B22F5/00
摘要： In an embodiment, a polycrystalline diamond compact includes a substrate, and a polycrystalline diamond (“PCD”) table bonded to the substrate and including an exterior working surface, at least one lateral surface, and a chamfer extending between the exterior working surface and the at least one lateral surface. The PCD table includes bonded diamond grains defining interstitial regions. The PCD table includes a first region adjacent to the substrate and a second leached region adjacent to the first region and extending inwardly from the exterior working surface to a selected depth. At least a portion of the interstitial regions of the first region include an infiltrant disposed therein. The interstitial regions of the second leached region are substantially free of metal-solvent catalyst. The second region is defined by the exterior working surface, the lateral surface, the chamfer, and a generally horizontal boundary located below the chamfer.
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公开(公告)号：US10179390B2
公开(公告)日：2019-01-15
申请号：US15005765
申请日：2016-01-25
摘要： 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.
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公开(公告)号：US10145181B1
公开(公告)日：2018-12-04
申请号：US15181124
申请日：2016-06-13
IPC分类号： B24D3/00 , E21B10/567 , B24D3/06 , E21B10/50 , E21B10/54 , B24D11/00 , B24D18/00 , C09K3/14 , B24D3/02
摘要： Polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs. In an embodiment, the PDC includes a polycrystalline diamond (“PCD”) table having at least a portion of a metal-solvent catalyst removed therefrom. Removing at least a portion of a metal-solvent catalyst from the PCD table may increase the porosity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst. Likewise, removing at least a portion of a metal-solvent catalyst from the PCD table may decrease the specific magnetic saturation and increase the coercivity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst.
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公开(公告)号：US20180179114A1
公开(公告)日：2018-06-28
申请号：US15901124
申请日：2018-02-21
IPC分类号： C04B37/00 , G01N27/80 , G01N27/72 , B21C3/02 , B24D18/00 , C22C26/00 , E21B10/567 , F16C33/04 , F16C33/26 , F16C17/04 , F16C17/02
摘要： 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.
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公开(公告)号：US20180141185A1
公开(公告)日：2018-05-24
申请号：US15861294
申请日：2018-01-03
CPC分类号： B24D3/10 , B22F3/24 , B22F5/00 , B22F7/06 , B24D18/0009 , B24D18/0027 , C04B35/528 , C04B35/645 , C04B2235/3817 , C04B2235/3847 , C04B2235/427 , C04B2235/5436 , C04B2235/5445 , C04B2235/5472 , C22C26/00 , Y10T428/12028 , Y10T428/12056 , Y10T428/24355 , Y10T428/30
摘要： 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.
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公开(公告)号：US20170370158A1
公开(公告)日：2017-12-28
申请号：US15683614
申请日：2017-08-22
发明人： Cody William Knuteson , Paul Douglas Jones , Brandon P. Linford , Brent R. Eddy , Kenneth E. Bertagnolli , Debkumar Mukhopadhyay
IPC分类号： E21B10/567 , E21B10/55 , B24D18/00 , B22F3/14 , C22C26/00 , E21B10/573 , B24D3/10 , C22C29/08 , B22F5/00
CPC分类号： E21B10/567 , B22F3/14 , B22F2005/001 , B22F2999/00 , B24D3/10 , B24D18/0009 , C22C26/00 , C22C29/08 , E21B10/55 , E21B10/5735 , B22F2207/01
摘要： 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.
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