Patent Application
20170120422
Embodiments of the present disclosure relate generally to polycrystalline compacts and methods of processing polycrystalline compacts.
Earth-boring tools for forming wellbores in subterranean earth formations may include a plurality of cutting elements secured to a body. For example, a fixed-cutter earth-boring rotary drill bit (also referred to as a “drag bit”) includes a plurality of cutting elements fixedly attached to a bit body of the drill bit. Similarly, roller cone earth-boring rotary drill bits include cones mounted on bearing pins extending from legs of a bit body such that each cone is capable of rotating about the bearing pin on which the cone is mounted. A plurality of cutting elements may be mounted to each cone of the drill bit.
The cutting elements used in such earth-boring tools often include polycrystalline diamond cutters (often referred to as “PDCs”), which are cutting elements that include a polycrystalline diamond (PCD) material. Such polycrystalline diamond cutting elements are formed by sintering and bonding together relatively small diamond grains or crystals under conditions of high temperature and high pressure in the presence of a catalyst (such as cobalt, iron, nickel, or alloys or mixtures thereof) to form a layer of polycrystalline diamond material on a cutting element substrate. These processes are often referred to as “high pressure, high temperature” (or “HPHT”) processes. The cutting element substrate may be a cermet material (i.e., a ceramic-metal composite material) such as cobalt-cemented tungsten carbide. In such instances, the cobalt or other catalyst material in the cutting element substrate may be drawn into the diamond grains or crystals during sintering and serve as a catalyst material for forming a diamond table from the diamond grains or crystals. In other methods, powdered catalyst material may be mixed with the diamond grains or crystals prior to sintering the grains or crystals together in an HPHT process. After sintering, portions of the PCD material may be polished or shaped to form the cutting elements. For example, an edge of the PCD material may be ground to form a chamfer.
Cobalt, which is commonly used in sintering processes to form PCD material, melts at about 1495° C. The melting temperature may be reduced by alloying cobalt with carbon or another element, so HPHT sintering of cobalt-containing bodies may be performed at temperatures above about 1450° C.
Upon formation of a diamond table using an HPHT process, catalyst material may remain in interstitial spaces between the grains or crystals of diamond in the resulting polycrystalline diamond table. The presence of the catalyst material in the diamond table may contribute to thermal damage in the diamond table when the cutting element is heated during use, due to friction at the contact point between the cutting element and the formation. Polycrystalline diamond cutting elements in which the catalyst material remains in the diamond table are generally thermally stable up to temperatures of about 750° C., although internal stress within the polycrystalline diamond table may begin to develop at temperatures exceeding about 350° C. This internal stress is at least partially due to differences in the rates of thermal expansion between the diamond table and the cutting element substrate to which it is bonded. This differential in thermal expansion rates may result in relatively large compressive and tensile stresses at the interface between the diamond table and the substrate, and may cause the diamond table to delaminate from the substrate. At temperatures of about 750° C. and above, stresses within the diamond table may increase significantly due to differences in the coefficients of thermal expansion of the diamond material and the catalyst material within the diamond table itself. For example, cobalt thermally expands significantly faster than diamond, which may cause cracks to form and propagate within a diamond table including cobalt, eventually leading to deterioration of the diamond table and ineffectiveness of the cutting element.
To reduce the problems associated with different rates of thermal expansion in polycrystalline diamond cutting elements, so called “thermally stable” polycrystalline diamond (TSD) cutting elements have been developed. Such a thermally stable polycrystalline diamond cutting element may be formed by leaching the catalyst material (e.g., cobalt) out from interstitial spaces between the diamond grains in the diamond table using, for example, an acid. All of the catalyst material may be removed from the diamond table, or only a portion may be removed. Thermally stable polycrystalline diamond cutting elements in which substantially all catalyst material has been leached from the diamond table have been reported to be thermally stable up to temperatures of about 1200° C. It has also been reported, however, that fully leached diamond tables are relatively more brittle and vulnerable to shear, compressive, and tensile stresses than are non-leached diamond tables. In an effort to provide cutting elements having diamond tables that are more thermally stable relative to non-leached diamond tables, but that are also relatively less brittle and vulnerable to shear, compressive, and tensile stresses relative to fully leached diamond tables, cutting elements have been provided that include a diamond table in which catalyst material has been substantially leached from only a portion of the diamond table.
A method of forming a polycrystalline compact includes subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact. The method comprises removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
A method of forming an earth-boring tool includes forming a polycrystalline cutting element and securing the polycrystalline cutting element to a bit body. The polycrystalline cutting element may be formed by subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
A method of forming a polycrystalline diamond compact includes subjecting a plurality of diamond grains and a metal catalyst material to high-temperature and high-pressure conditions to form a diamond table having intergranular bonds and interstitial spaces between adjacent diamond grains. The metal catalyst material is disposed in at least some of the interstitial spaces in the diamond table. The method may further comprise leaching the catalyst material from the interstitial spaces in a first portion of the diamond table to form a partially leached diamond table, mechanically removing a portion of the diamond grains from the first portion of the partially leached diamond table, and leaching the catalyst material from the interstitial spaces in a second portion of the diamond table.
While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:
The illustrations presented herein are not actual views of any particular material, apparatus, system, or method, but are merely idealized representations that are employed to describe example embodiments of the present disclosure. Additionally, elements common between figures may retain the same numerical designation.
Polycrystalline compacts may be formed by subjecting grains of hard material and a catalyst to high-temperature and high-pressure (HTHP) conditions to form intergranular bonds. A portion of the catalyst material may then be removed, and the compacts may be shaped, polished, or otherwise processed after removal of some of the catalyst material.
As used herein, the term “drill bit” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore and includes, for example, rotary drill bits, percussion bits, core bits, eccentric bits, bi-center bits, reamers, expandable reamers, mills, drag bits, roller cone bits, hybrid bits, and other drilling bits and tools known in the art.
As used herein, the term “hard material” means and includes any material having a Knoop hardness value of about 3,000 Kgf/mm2 (29,420 MPa) or more. Hard materials include, for example, diamond and cubic boron nitride.
As used herein, the term “intergranular bond” means and includes any direct atomic bond (e.g., covalent, metallic, etc.) between atoms in adjacent grains of material.
The term “polycrystalline material” means and includes any material comprising a plurality of grains (i.e., crystals) of the material that are bonded directly together by intergranular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.
As used herein, the term “polycrystalline compact” means and includes any structure comprising a polycrystalline material formed by a process that involves application of pressure (e.g., compaction) to the precursor material or materials used to form the polycrystalline material.
As used herein, the term “grain size” means and includes a geometric mean diameter measured from a two-dimensional section through a bulk material. The geometric mean diameter for a group of particles may be determined using techniques known in the art, such as those set forth in Ervin E. Underwood, QUANTITATIVE STEREOLOGY, 103-105 (Addison-Wesley Publishing Company, Inc., 1970), the disclosure of which is incorporated herein in its entirety by this reference.
As used herein, the term “catalyst material” refers to any material that is capable of substantially catalyzing the formation of intergranular bonds between grains of hard material during an HTHP process but at least partially contributes to the degradation of the intergranular bonds and granular material under elevated temperatures, pressures, and other conditions that may be encountered in a drilling operation for forming a wellbore in a subterranean formation. For example, catalyst materials for diamond include, by way of example only, cobalt, iron, nickel, other elements from Group VIIIA of the Periodic Table of the Elements, and alloys thereof.
As used herein, the term “leaching” means and includes removing or extracting materials from a solid material (such as a polycrystalline material) into a carrier, such as by dissolving the materials into the carrier or by converting the materials into a salt.
As used herein with regard to a depth or level, or magnitude of a depth of level, beneath a surface of a polycrystalline compact, the terms “substantially uniform” and “substantially uniformly” mean and include a depth of an area under the surface which is substantially devoid of significant aberrations such as spikes and/or valleys in excess of a general magnitude of such depth. More specifically, a “substantially uniform depth” when referring to a depth of catalyst removal beneath a surface of a polycrystalline compact means and includes a depth of such removal substantially free of significant aberrations such as spikes, valleys and other variations in the region below the surface. In other words, if catalyst is removed to a substantially uniform depth below, for example, a cutting face of a polycrystalline compact, the catalyst is removed from an area below the surface of the cutting face to a depth, the boundary of which with a remainder of the compact including such catalyst while not necessarily constant, is substantially free of significant aberrations such as spikes, valleys and/or other variations.
The hard material 103 may be in the form or crystals of various sizes, such as micron- and/or submicron-sized hard material. The grains of the hard material 103 may form a hard polycrystalline material after sintering. The hard material 103 may include, for example, diamond, cubic boron nitride, etc. The catalyst 104 may include, for example and without limitation, cobalt, iron, nickel, or an alloy or mixture thereof. The catalyst 104 may be formulated to promote the formation of intergranular bonds during sintering.
To form a polycrystalline hard material in an HTHP process, the mixture 102 may be subjected to elevated temperatures (e.g., temperatures greater than about 1,000° C.) and elevated pressures (e.g., pressures greater than about 5.0 gigapascals (GPa)). These conditions may promote the formation of intergranular bonds between the grains of the hard material 103. In some embodiments, the mixture 102 may be subjected to a pressure greater than about 6.0 GPa, greater than about 8.0 GPa, or even greater than about 10.0 GPa. The mixture 102 may be subjected to a temperature in the HTHP process from about 1,200° C. to about 2,000° C., such as a temperature greater than about 1,500° C. HTHP conditions may be maintained for a period of time from about thirty (30) seconds to about sixty (60) minutes to sinter the particles and form a polycrystalline hard material.
In some embodiments, the mixture 102 may include a powder or a powder-like substance. In other embodiments, however, the mixture 102, which may comprise a solution, slurry, gel, or paste, may be processed by (e.g., on or in) another material form, such as a tape or film, which, after stacking to a selected thickness, and undergoing subsequent thermal and or chemical processes to remove the one or more organic processing aids, may be subjected to an HTHP process. One or more organic materials (e.g., processing aids) also may be included with the particulate mixture to facilitate processing. For example, some suitable materials are described in U.S. Patent Application Publication No. US 2012/0211284 A1, published Aug. 23, 2012, and titled “Methods of Forming Polycrystalline Compacts, Cutting Elements and Earth-Boring Tools,” the disclosure of which is incorporated herein in its entirety by this reference.
After sintering the mixture 102 to form the polycrystalline table 202, at least a portion of the catalyst 104 may be removed from the interstitial spaces in the polycrystalline table 202 to form an at least partially leached polycrystalline compact.
Removal of the catalyst 104 may be performed by conventional means, such as by placing the polycrystalline compact in an acid bath. Such a process may be referred to in the art as leaching or acid-leaching. By way of example and not limitation, the polycrystalline table 202 may be leached using a leaching agent and processes such as those described more fully in, for example, U.S. Pat. No. 5,127,923, issued Jul. 7, 1992, and titled “Composite Abrasive Compact Having High Thermal Stability;” and U.S. Pat. No. 4,224,380, issued Sep. 23, 1980, and titled “Temperature Resistant Abrasive Compact and Method for Making Same;” the disclosure of each of which patent is incorporated herein in its entirety by this reference. Specifically, aqua regia (a mixture of concentrated nitric acid (HNO3) and concentrated hydrochloric acid (HCl)) may be used to at least substantially remove catalyst material from the interstitial spaces between the inter-bonded grains of hard material in the polycrystalline table 202. It is also known to use boiling hydrochloric acid (HCl) and boiling hydrofluoric acid (HF) as leaching agents. One particularly suitable leaching agent is hydrochloric acid (HCl) at a temperature of above 110° C., which may be provided in contact with the hard material of the polycrystalline table 202 for a period of about two hours to about sixty hours, depending upon the size of the body comprising the hard material. After leaching the hard material, the interstitial spaces between the inter-bonded grains within the hard material may be at least substantially free of catalyst material used to catalyze formation of intergranular bonds between the grains in the hard polycrystalline material. In some embodiments, leaching may be selectively applied to specific regions of the polycrystalline table 202, and not to other regions. For example, in some embodiments, a mask may be applied to a region of the polycrystalline table 202, and only the unmasked regions may be leached.
Other methods of removing catalyst material are described in U.S. Pat. Application Pub. 2011/0258936, published Oct. 27, 2011, and titled “Methods of Forming Polycrystalline Compacts,” the disclosure of which is incorporated herein in its entirety by this reference.
The catalyst 104 may be substantially removed from a volume of the polycrystalline table 202 to a substantially uniform depth from surfaces 210, 212 (
After the catalyst 104 has been substantially removed from at least a portion of the polycrystalline table 202, a portion of the hard material 103 may be removed from the polycrystalline table 202. For example, a volume of leached hard polycrystalline material may be removed from the polycrystalline table 202 to improve cutting performance of the polycrystalline compact 200. In some embodiments, removal may include polishing or smoothing of one or more surfaces 210, 212 (
For example, surfaces 210, 212 may be polished to have a surface finish with irregularities or roughness (measured vertically from the surface) less than about 10 μin. (about 0.254 μm) RMS (root mean square). In further embodiments, the polycrystalline table 202 may have a surface roughness less than about 2 μin. (about 0.0508 μm) RMS. In yet further embodiments, the polycrystalline table 202 may have a surface roughness less than about 0.5 μin. (about 0.0127 μm) RMS, approaching a true “mirror” finish. The foregoing surface roughness measurements of the polycrystalline table 202 may be measured using a calibrated HOMMEL® America Model T 4000 diamond stylus profilometer contacting the surface of the polycrystalline table 202.
In some embodiments, portions of the hard material 103 may be removed from the polycrystalline table 202 to form shaped surfaces on the polycrystalline compact 200. For example, the polycrystalline table 202 may be machined or otherwise shaped to form non-planar surfaces, such as described in U.S. Patent Publication 2012/0103698, published May 3, 2012, and titled “Cutting Elements, Earth-boring Tools Incorporating Such Cutting Elements, and Methods of Forming Such Cutting elements;” U.S. Patent Publication 2013/0068534, published Mar. 21, 2013, and titled “Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements and Related Methods;” U.S. Patent Publication 2013/0068537, published Mar. 21, 2013, and titled “Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements and Related Methods;” U.S. Patent Publication 2013/0068538, published Mar. 21, 2013, and titled “Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements, and Related Methods;” the entire disclosure of each of which are incorporated herein in their entirety by this reference.
In some embodiments, one or more recesses may be formed that extend into a surface of the polycrystalline table 202. For example,
The polycrystalline compact 300 may be formed as illustrated in
Substantial removal of the catalyst 104 (
An earth-boring tool may be formed by securing a polycrystalline cutting element formed as described herein to a bit body. As a non-limiting example,
Additional non limiting example embodiments of the disclosure are described below.
A method of forming a polycrystalline compact, comprising subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
The method of Embodiment 1, wherein substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact comprises acid-leaching the catalyst material from the interstitial spaces in the at least a portion of the polycrystalline material.
The method of Embodiment 1 or Embodiment 2, wherein substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material comprises forming an interface between a first volume of polycrystalline material and a second volume of polycrystalline material, the first volume of polycrystalline material having a first concentration of the catalyst material and the second volume of polycrystalline material having a second, substantially higher concentration of the catalyst material.
The method of Embodiment 3, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises removing a portion of the first volume of polycrystalline material from the at least partially leached polycrystalline compact.
The method of any of Embodiments 1 through 4, further comprising substantially removing the catalyst material from the interstitial spaces in an additional portion of the polycrystalline material having substantial catalyst material therein after removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
The method of any of Embodiments 1 through 5, wherein removing a portion of the polycrystalline material from which the catalyst has been substantially removed from the at least partially leached polycrystalline compact comprises polishing at least one surface of the at least partially leached polycrystalline compact.
The method of Embodiment 6, wherein polishing at least one surface of the at least partially leached polycrystalline compact comprises polishing at least a portion of the polycrystalline material from which the catalyst material has been substantially removed to form a surface having a surface roughness less than about 10 μin. root mean square (RMS).
The method of any of Embodiments 1 through 7, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming one or more non-planar areas on a front cutting face on the at least partially leached polycrystalline compact.
The method of any of Embodiments 1 through 8, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a recess extending into the polycrystalline material.
The method of any of Embodiments 1 through 9, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
The method of Embodiment 10, wherein exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises exposing the polycrystalline material to laser irradiation.
The method of any of Embodiments 1 through 11, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a chamfer adjacent a front cutting surface of the at least partially leached polycrystalline compact.
The method of any of Embodiments 1 through 12, wherein subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions comprises forming a polycrystalline compact comprising polycrystalline material bonded to a substrate.
The method of any of Embodiments 1 through 13, wherein subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions comprises subjecting a plurality of grains of diamond interspersed with the catalyst material to high-temperature and high-pressure conditions to form polycrystalline diamond.
A method of forming an earth-boring tool, comprising forming a polycrystalline cutting element and securing the polycrystalline cutting element to a bit body. The polycrystalline cutting element is formed by subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.
The method of Embodiment 15, further comprising substantially removing an additional portion of the catalyst material from the interstitial spaces in the polycrystalline material having substantial catalyst material therein after removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact and before securing the polycrystalline cutting element to the bit body.
The method of Embodiment 15 or Embodiment 16, wherein forming a polycrystalline cutting element comprises forming the polycrystalline material on a substrate.
The method of any of Embodiments 15 through 17, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a front cutting face comprising one or more non-planar surfaces on the at least partially leached polycrystalline compact.
A method of forming a polycrystalline diamond compact, comprising subjecting a plurality of diamond grains and a metal catalyst material to high-temperature and high-pressure conditions to form a diamond table having intergranular bonds and interstitial spaces between adjacent diamond grains. The metal catalyst material is disposed in at least some of the interstitial spaces in the diamond table. The method further comprises leaching the catalyst material from the interstitial spaces in a first portion of the diamond table to form a partially leached diamond table; mechanically removing a portion of the diamond grains from the first portion of the partially leached diamond table; and leaching the catalyst material from the interstitial spaces in a second portion of the diamond table.
The method of Embodiment 19, wherein mechanically removing a portion of the diamond grains from the first portion of the partially leached diamond table comprises polishing at least one surface of the diamond table.
While the present invention has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the invention as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the invention as contemplated by the inventors. Further, embodiments of the disclosure have utility with different and various types and configurations of cutting elements, drill bits, and other tools.
| Number | Date | Country | |
|---|---|---|---|
| 20150266163 A1 | Sep 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| 60985339 | Nov 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12265462 | Nov 2008 | US |
| Child | 14221097 | US |
