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：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.

公开(公告)号：US10399206B1

公开(公告)日：2019-09-03

申请号：US15402525

申请日：2017-01-10

Applicant: US SYNTHETIC CORPORATION

Inventor： Daniel Call Mortensen ,  Lindsay Sue Patton ,  Trevor Allen Olsen ,  Casey Wade Swan ,  Shawn Casey Scott ,  Matthew Kimball Baker ,  Anne-Grethe Slotnaes ,  Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Lott ,  Joshua Adam Hawks

IPC: E21B10/62 ,  E21B10/633 ,  E21B10/567 ,  E21B10/55 ,  B24D3/00 ,  B24D3/10

Abstract: PDCs, methods of fabricating the PDCs, and methods of using the PDCs are disclosed herein. The PDCs include a PCD table bonded to a substrate. The PCD table includes an upper surface having a plurality of recessed features formed therein. The plurality of recessed features are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent crack propagation into other portions of the PCD table and limit a volume of the PCD table that spalls. Methods of fabricating the PDCs include partially leaching the PCD table and, after leaching the PCD table, forming the plurality of recessed features in the upper surface thereof. Method of using the PDCs include rotating a PDC that has spalled relative to a rotary drill bit such that a portion of the upper surface of the PDC that has not spalled forms a cutting surface thereof.

公开(公告)号：US20240410232A1

公开(公告)日：2024-12-12

申请号：US18662563

申请日：2024-05-13

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 ,  B24D18/00 ,  C22C26/00 ,  E21B10/36 ,  E21B10/46 ,  E21B10/55 ,  E21B10/573 ,  F16C17/02 ,  F16C17/04 ,  F16C17/10 ,  F16C33/04 ,  F16C33/26

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：US20200331811A1

公开(公告)日：2020-10-22

申请号：US16880131

申请日：2020-05-21

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Wiggins ,  Michael Vail ,  Debkumar Mukhopadhyay

IPC: C04B37/00 ,  C22C26/00 ,  F16C33/04 ,  F16C33/26 ,  B21C3/02 ,  G01N27/80 ,  G01N27/72 ,  B24D18/00 ,  E21B10/567

Abstract: 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.

公开(公告)号：US10773480B2

公开(公告)日：2020-09-15

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 ,  B30B11/00 ,  B24D18/00 ,  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：US20190211629A1

公开(公告)日：2019-07-11

申请号：US16358281

申请日：2019-03-19

Applicant: US SYNTHETIC CORPORATION

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

IPC: E21B10/36 ,  C22C26/00 ,  B22F7/08 ,  E21B10/573 ,  B24D18/00 ,  F16C33/04

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：US20180179114A1

公开(公告)日：2018-06-28

申请号：US15901124

申请日：2018-02-21

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Wiggins ,  Michael Vail ,  Debkumar Mukhopadhyay

IPC: C04B37/00 ,  G01N27/80 ,  G01N27/72 ,  B21C3/02 ,  B24D18/00 ,  C22C26/00 ,  E21B10/567 ,  F16C33/04 ,  F16C33/26 ,  F16C17/04 ,  F16C17/02

Abstract: 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.

公开(公告)号：US20130205677A1

公开(公告)日：2013-08-15

申请号：US13789099

申请日：2013-03-07

Applicant: US Synthetic Corporation

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

IPC: B24D18/00

CPC classification number: E21B10/36 ,  B22F7/08 ,  B22F2998/00 ,  B24D18/00 ,  C22C26/00 ,  E21B10/5735 ,  F16C33/043 ,  F16C2352/00 ,  Y10T428/24612 ,  Y10T428/24996 ,  Y10T428/249967 ,  C22C29/08

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.

Abstract translation: 在一个实施例中，公开了一种制造多晶金刚石致密体的方法。 该方法包括在金属 - 溶剂催化剂的存在下烧结多个金刚石颗粒以形成多晶金刚石体; 浸出多晶金刚石体至少部分地从其中去除金属 - 溶剂催化剂，从而形成至少部分浸出的多晶金刚石体; 以及使所述至少部分浸出的多晶金刚石体和硬质合金基底的组件在压力下经受高压/高温过程，以浸润剂渗透至少部分浸出的多晶金刚石体。 高压/高温过程的压力小于在多个金刚石颗粒的烧结过程中使用的压力。

公开(公告)号：US12297153B2

公开(公告)日：2025-05-13

申请号：US16880131

申请日：2020-05-21

Applicant: US SYNTHETIC CORPORATION

Inventor： Kenneth E. Bertagnolli ,  Jiang Qian ,  Jason Wiggins ,  Michael Vail ,  Debkumar Mukhopadhyay

IPC: C04B37/00 ,  B21C3/02 ,  B24D18/00 ,  C22C26/00 ,  E21B10/567 ,  F16C33/04 ,  F16C33/26 ,  G01N27/12 ,  G01N27/72 ,  G01N27/80 ,  F16C17/02 ,  F16C17/04

Abstract: 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.