Patent Grant
11865672
Wear-resistant, polycrystalline diamond compacts (“PDCs”) are utilized in a variety of mechanical applications. For example, PDCs are used in drilling tools (e.g., cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and in other mechanical apparatuses.
PDCs have found particular utility as superabrasive cutting elements in rotary drill bits, such as roller-cone drill bits and fixed-cutter drill bits. A PDC cutting element typically includes a superabrasive diamond layer commonly known as a diamond table. The diamond table is formed and bonded to a substrate using a high-pressure/high-temperature (“HPHT”) process that sinters diamond particles under diamond-stable conditions. The PDC cutting element may also be brazed directly into a preformed pocket, socket, or other receptacle formed in a bit body. The substrate may optionally be brazed or otherwise joined to an attachment member, such as a cylindrical backing. A rotary drill bit typically includes a number of PDC cutting elements affixed to the bit body. It is also known that a stud carrying the PDC may be used as a PDC cutting element when attached to a bit body of a rotary drill bit by press-fitting, brazing, or otherwise securing the stud into a receptacle formed in the bit body.
Conventional PDCs are normally fabricated by placing a cemented carbide substrate into a container with a volume of diamond particles positioned on a surface of the cemented carbide substrate. A number of such containers may be loaded into an HPHT press. The substrate(s) and volume of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains defining a polycrystalline diamond (“PCD”) table. The catalyst material is often a metal-solvent catalyst (e.g., cobalt, nickel, iron, or alloys thereof) that is used for promoting intergrowth of the diamond particles.
In a conventional approach, a constituent of the cemented carbide substrate, such as cobalt from a cobalt-cemented tungsten carbide substrate, liquefies and sweeps from a region adjacent to the volume of diamond particles into interstitial regions between the diamond particles during the HPHT sintering process. The cobalt acts as a catalyst to promote intergrowth between the diamond particles, which results in formation of a matrix of bonded diamond grains having diamond-to-diamond bonding there between, with interstitial regions between the bonded diamond grains being occupied by the solvent catalyst.
The presence of the metal-solvent catalyst in the PCD table is believed to reduce the thermal stability of the PCD table at elevated temperatures. For example, the difference in thermal expansion coefficient between the diamond grains and the metal-solvent catalyst is believed to lead to chipping or cracking of the PCD table during drilling or cutting operations, which can degrade the mechanical properties of the PCD table or cause failure. Additionally, some of the diamond grains can undergo a chemical breakdown or back-conversion to graphite via interaction with the solvent catalyst. At elevated high temperatures, portions of diamond grains may transform to carbon monoxide, carbon dioxide, graphite, or combinations thereof, thereby degrading the mechanical properties of the PDC.
One conventional approach for improving the thermal stability of a PDC is to at least partially remove the metal-solvent catalyst from the PCD table of the PDC by acid leaching. Another approach involves infiltrating and bonding an at least partially leached PCD table to a cemented carbide substrate with a metallic infiltrant, and acid leaching to at least partially remove the metallic infiltrant.
Despite the availability of a number of different PDCs, manufacturers and users of PDCs continue to seek PDCs that exhibit improved toughness, wear resistance, and thermal stability.
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 function as stress concentrations that are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent propagation of the cracks into other portions of the PCD table and limit a volume of the PCD table that spalls during cutting operations. 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. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.
In an embodiment, a PDC is disclosed. The PDC includes a substrate. The PDC also includes a PCD table bonded to the substrate. The PCD table includes an interfacial surface bonded to the substrate, an upper surface spaced from the interfacial surface, and at least one lateral surface extending between the upper surface and the interfacial surface. The PCD table also includes a plurality of diamond grains bonded together defining a plurality of interstitial regions. The PCD table further includes an unleached region bonded to the interfacial surface. The unleached region includes at least one interstitial constituent disposed in at least a portion of the plurality of interstitial regions thereof. The PCD table also includes a leached region extending inwardly from the upper surface and at least a portion of the at least one lateral surface. The leached region is at least partially depleted of the at least one interstitial constituent. The PCD table additionally includes a plurality of recessed features extending from the upper surface through a portion of the polycrystalline diamond table. A majority of the plurality of recessed features do not extend into the unleached region.
In an embodiment, a method of fabricating a PDC is disclosed. The method includes leaching at least a portion of at least one interstitial constituent from a polycrystalline diamond table to a leach depth measured inwardly from an upper surface and at least one lateral surface of the polycrystalline diamond table to form a leached region. The method also includes, after leaching the polycrystalline diamond table, forming a plurality of recessed features that extend from the upper surface of the polycrystalline diamond table to a depth less than the leach depth of the leached region. Forming the plurality of recessed features forms a plurality of cells on the upper surface that are at least partially defined by the plurality of recessed features.
In an embodiment, a method of using a PDC is disclosed. The method includes decoupling at least one PDC from a drill bit body. The at least one PDC includes a PCD table bonded to a substrate. A portion of the PCD table includes a spalled region. The PCD table includes an interfacial surface bonded to the substrate, an upper surface spaced from the interfacial surface, and at least one lateral surface extending between the upper surface and the interfacial surface. The PCD table also includes a plurality of diamond grains bonded together defining a plurality of interstitial regions. The PCD table further includes a plurality of recessed features extending from the upper surface of the polycrystalline diamond table through a portion of the polycrystalline diamond table. At least one of the plurality of recessed features partially defines the spall region. Additionally, the PCD table includes an unleached region bonded to the interfacial surface. The unleached region includes an interstitial constituent disposed in at least a portion of the plurality of interstitial regions thereof. Finally, the PCD table includes a leached region extending inwardly from the upper surface and at least a portion of at least one lateral surface. The leached region is at least partially depleted of at least one interstitial constituent. A majority of the plurality of recessed features do not extend into the unleached region. The method also includes rotating the at least one PDC relative to the drill bit body to position a portion of the PCD table that does not include the spalled region in a cutting position. The method further includes coupling the at least one PDC to the drill bit body with the PCD table positioned in the cutting position.
In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes an interfacial surface bonded to the substrate, an upper surface spaced from the interfacial surface, and at least one lateral surface extending between the upper surface and the interfacial surface. The PCD table further includes a plurality of diamond grains bonded together defining a plurality of interstitial regions. The PCD table also includes an unleached region bonded to the interfacial surface, with the unleached region including at least one interstitial constituent disposed in at least a portion of the plurality of interstitial regions thereof; a leached region extending inwardly from the upper surface and at least a portion of the at least one lateral surface, with the leached region being at least partially depleted of the at least one interstitial constituent; and a plurality of recessed features extending from the upper surface through a portion of the PCD table, with the plurality of recessed features forming a plurality of cells. An initial spallation of the PCD table in response to a milling spallation test is about 10% or less of the area of the upper surface of the PCD table.
In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes an interfacial surface bonded to the substrate, an upper surface spaced from the interfacial surface, and at least one lateral surface extending between the upper surface and the interfacial surface. The PCD table further includes a plurality of diamond grains bonded together defining a plurality of interstitial regions. The PCD table also includes a plurality of recessed features extending from the upper surface through a portion of the PCD table; an unleached region bonded to the interfacial surface, with the unleached region including at least one interstitial constituent disposed in at least a portion of the plurality of interstitial regions thereof; and a leached region extending inwardly from the upper surface and at least a portion of the at least one lateral surface, with the leached region being at least partially depleted of the at least one interstitial constituent. The PCD table exhibits a probability of failure less than about 0.4 at a distance cut of at least about 325 inches when tested in a milling spallation test.
Other embodiments include applications utilizing the disclosed PDCs in various articles and apparatuses, such as rotary drill bits, bearing apparatuses, wire-drawing dies, machining equipment, and other articles and apparatuses.
Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.
The drawings illustrate several embodiments of the present disclosure, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.
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 function as stress concentrations that are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent propagation of the cracks into other portions of the PCD table and limit a volume or area of the PCD table that spalls during cutting operations. 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. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.
In some embodiments, a probability of failure as determined in a milling spallation test, which is described in comparative example 1 below, may be less than about 0.1 at a distance cut of about 315 inches or greater (e.g., about 315 inches to about 325 inches, about 325 inches to about 350, about 350 inches or greater), may be less than about 0.3 to about 0.4 at a distance cut of about 325 inches or greater (e.g., about 325 inches to about 350 inches, about 350 inches to about 375 inches, at least about 350 inches, at least about 375 inches, about 375 inches to about 400 inches, or greater than 400 inches), may be less than about 0.75 at a distance cut of about 340 inches or greater (e.g., about 350 inches to about 375 inches, about 375 inches to about 400 inches, about 400 inches to about 425 inches, about 425 inches or greater).
The substrate 104 may include a cemented carbide material. For example, the substrate 104 may include tungsten carbide, titanium carbide, chromium carbide, niobium carbide, tantalum carbide, vanadium carbide, or combinations thereof that may be cemented with iron, nickel, cobalt, combinations thereof, or alloys thereof. For example, the substrate 104 may comprise a cobalt-cemented tungsten carbide. In some embodiments, the substrate 104 may be omitted (e.g., a free-standing PCD table).
The PCD table 102 includes an interfacial surface 110 that is spaced from the upper surface 106 and bonded to the substrate 104. The interfacial surface 110 may be substantially planar (
In the illustrated embodiments shown in
The PCD table 102 includes a plurality of directly bonded together diamond grains that exhibit diamond-to-diamond bonding therebetween (e.g., sp3 bonding). The plurality of directly bonded together diamond grains define a plurality of interstitial regions therebetween. The PCD table 102 may include at least one interstitial constituent that at least partially occupies at least some of the interstitial regions of the PCD table 102. The at least one interstitial constituent may include at least one of a metal-solvent catalyst (e.g., cobalt, iron, nickel, combinations thereof, or alloys thereof), at least one constituent from the substrate (e.g., tungsten and/or tungsten carbide), a nonmetallic catalyst (e.g., one or more alkali metal carbonates, one or more alkaline metal carbonates, one or more alkaline earth metal hydroxides, or combinations thereof), or another suitable interstitial constituent.
The at least one interstitial constituent may be at least partially leached from the PCD table 102. For example,
The PCD table 102 also includes a leached region 118 that extends inwardly from the upper surface 106, at least a portion of the at least one lateral surface 112, and the optional chamfer 114. For example, an interface 119 is located between the leached region 118 and the unleached region 116. The leached region 118 includes at least some of the at least one interstitial constituent removed from the interstitial regions thereof (e.g., the leached region 118 exhibits a lower concentration of the at least one interstitial constituent than the unleached region 116). For example, a residual amount of the at least one interstitial constituent may still remain in the interstitial regions of the leached region 118 after leaching. The residual amount of the at least one interstitial constituent in the interstitial regions of the leached region 118 may be about 0.5% to about 2% by weight (e.g., about 0.8% to about 1.2% by weight), or less than about 0.5% by weight (e.g., substantially completely removed from the interstitial regions of the leached region 118). In an embodiment, the leached region 118 may extend inwardly along at least about 50% of a length of the at least one lateral surface 112 (i.e., from the interfacial surface 110 to a bottommost edge 123 of the chamfer 114), such as along at least about 75% of the at least one lateral surface 112, along at least about 80% of the at least one lateral surface 112, or along at least about 90% of the at least one lateral surface 112. As will be discussed later, increasing the percentage of the at least one lateral surface 112 that is leached may allow the L1* value to increase (
The leached region 118 may exhibit a first leach depth D1 measured substantially perpendicularly inwardly from the upper surface 106 to the interface 119 between the leached region 118 and the unleached region 116. The first leach depth D1 may be about 200 μm to about 900 μm. For example, the first leach depth D1 may be about 200 μm to about 400 μm, about 400 μm to about 500 μm, about 500 μm to about 800 μm, about 800 μm to about 900 μm, less than 200 μm, or greater than 900 μm. In an embodiment, the first leach depth D1 may be substantially uniform along a selected length of the upper surface 106. In an embodiment, the first leach depth D1 may vary long a selected length of the upper surface 106. For example, as will be discussed in more detail below, the first leach depth D1 may be greater at and/or near an edge of the upper surface 106 (e.g., where the upper surface 106 meets the at least one lateral surface 112, the chamfer 114, etc.) than a location spaced from the edge of the upper surface 106. The leached region 118 may also exhibit leach depths measured substantially perpendicularly inwardly from the chamfer 114 and the at least one lateral surface 112, respectively. In an embodiment, the leach depth measured substantially perpendicularly inwardly from at least a portion of the chamfer 114 and at least a portion of the at least one lateral surface 112 may be substantially the same as or similar to the first leach depth D1. In another embodiment, the leached depth measured substantially perpendicularly inwardly from at least a portion of the chamfer 114 and/or a portion of the at least one lateral surface 112 may be different than the first leach depth D1. For example, the leach depth measured substantially perpendicularly inwardly from a portion of the at least one lateral surface 112 may be greater than the first leach depth D1. Additional examples of leach profiles that the leached region 118 may exhibit are disclosed in U.S. Pat. No. 8,596,387, the disclosure of which in incorporated herein, in its entirety, by this reference.
The leach profile (e.g., the leach depth measured inwardly from the upper surface 106, the at least one lateral surface 112, and/or the optional chamfer 114) may be used to predict when the PDC 100 spalls.
During operation, portions of the PCD table 102 may generally wear away along an expected wear front 122. In an embodiment, the expected wear front 122 may be assumed to be generally parallel to the predicted initial wear front 120. In such an embodiment, the expected wear front 122 may be a plane that extends at the angle θ relative to the at least one lateral surface 112. The inventors currently believe that at least of one or more microscopic cracks or other defect forms near the interface 119 between the leached region 118 and the unleached region 116 when the expected wear front 122 extends through the leached region 118 and contacts the unleached region 116. The inventors currently believe that the cracks and/or other defect(s) may form a leach boundary-wear intersection location 124 that increases a likelihood that the PCD table 102 spalls.
The PCD table 102 may be expected to spall in response to the expected wear front 122 intersecting with the interface 119 between the unleached region 116 and the leached region 118 (e.g., the first location where the leach boundary-wear intersection location 124 may form). The shortest distance measured substantially perpendicularly from the predicted initial wear front 120 (e.g., having an angle θ of about 20°) and the interface 119 is referred to as the L1* value (e.g., the distance measured substantially perpendicularly between the predicted initial wear front 120 and the subsequent expected wear front 122 intersecting with the interface 119). In other words, the L1* value is the expected amount of wear into the PCD table 102 before the PCD table 102 becomes more susceptible to spallation. In the illustrated embodiment, the L1* value is measured between the predicted initial wear front 120 and a portion of the interface 119 that is spaced from the at least one lateral surface 112.
The leach profile of the leached region 118 may be configured to maximize the L1* value. For example, in the illustrated embodiment, increasing one or more of the first leach depth D1, the leach depth measured inwardly from the chamfer 114, or the leach depth measured inwardly from the at least one lateral surface may increase the L1* value. In particular, increasing the leach depth measured inwardly from of the at least one lateral surface may increase the L1* value more than increasing the first leach depth D1. Additionally, forming the chamfer 114 in the PCD table 102 prior leaching the PCD table 102 may also increase the L1* value. In an embodiment, the L1* value may be about 50 μm to about 1200 μm. For example, the L1* value may be about 100 μm to about 600 μm, about 100 μm to about 250 μm, about 250 μm to about 500 μm, 500 μm to about 750 μm, or about 750 μm to about 1000 μm. In an embodiment, the L1* value may be less than 50 μm or greater than 1200 μm.
As previously discussed, the PCD table 102 includes the plurality of recessed features 108 formed in the upper surface 106. At least a portion of the plurality of recessed features 108 may also be formed in the at least one lateral surface 112 and/or the chamfer 114. The plurality of recessed features 108 are configured to limit crack propagation and/or spallation in the PCD table 102. In particular, a crack in the PCD table 102 (e.g., formed at the leach boundary-wear intersection location 124) may be attracted to the nearest recessed feature 108 because the nearest recessed feature 108 serves as a stress concentration and a path of least resistance for crack propagation thereto. As such, the plurality of recessed features 108 may limit crack propagation into other regions of the PCD table 102, thereby maintaining a strength and/or a toughness of the other regions of the PCD table 102. For example, a crack may cause a portion of the PCD table 102 to spall. However, since the crack may be attracted to nearby recessed feature 108, the plurality of recessed features 108 may limit the amount of the PCD table 102 that spalls. For instance, at least a portion at least one of the plurality of recessed features 108 may at least partially define a spalled region or area formed in the PCD table 102. The spalled region may be less than 10% the total area of the upper surface 106, such as less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, or less than 5% of a total surface area of the upper surface 106.
Each of the plurality of recessed features 108 includes a base 126 that partially defines each recessed feature 108. The base 126 is the portion of each of the plurality of recessed features 108 that is farthest spaced from the upper surface 106. A depth D3 of each of the plurality of recessed features 108 is measured substantially perpendicularly from the upper surface 106 (e.g., an imaginary continuation of the upper surface 106 that extends over the recessed feature 108) to the base 126. In an embodiment, the depth D3 of each of the plurality of recessed features 108 may be about 50 μm to about 500 μm, such as about 50 μm to about 150 μm, 100 μm to about 250 μm, 200 μm to about 400 μm, or about 300 μm to about 500 μm. In an embodiment, the depth D3 of each of the plurality of recessed features 108 may be less than about 50 μm or greater than 500 μm. The depth D3 of each of the plurality of recessed features 108 may be selected based on a width or area of the respective recessed feature 108, the cross-sectional shape (in side view) of the respective recessed feature 108, the first leach depth D1, the L1* value, the shortest distance between the leach boundary-wear intersection location 124 and the respective recessed feature 108, the application of the PDC 100, etc.
In an embodiment, the plurality of recessed features 108 may potentially adversely affect the strength and toughness of the PCD table 102. For example, the strength and/or toughness of the PCD table 102 may decrease as an average depth of the plurality of recessed features 108 increases. However, the ability of the plurality of recessed features 108 to attract cracks thereto may also increase as the average depth of the plurality of recessed features 108 increases. For example, a recessed feature 108 that is positioned proximate to the leach boundary-wear intersection location 124 or that exhibits a relatively high stress concentration factor may exhibit a depth that is relatively shallow (e.g., about 50 μm to about 250 μm). In another embodiment, a recessed feature 108 that is spaced from leach boundary-wear intersection location 124 or that exhibits a relatively low stress concentration factor may exhibit a depth that is relatively deep (e.g., about 250 μm to about 500 μm, greater than 500 μm).
In an embodiment, at least some of the plurality of recessed features 108 only extend partially through or within the leached region 118. As such, the leach depth of the remaining leached region 118 proximate to the at least some of the plurality of recessed features 108 may be decreased. For example, the leached region 118 may exhibit a second leach depth D2 measured substantially perpendicularly inwardly from the base 126 of each of the at least some of the plurality of recessed features 108 to the interface 119 between the leached region 118 and the unleached region 116. In an embodiment, the second leach depth D2 may be about 1% to about 75% less than the first leach depth D1. For example, the second leach depth D2 may be about 1% less than to about 5% less than, about 5% less than to about 25% less than, about 20% less than to about 40% less than, about 25% less than to about 50% less than, or about 50% less than to about 75% less than the first leach depth D1. For example, if D1 equals about 500 μm, then D2 may be about 20% less than to about 40% less than D1 (i.e., 300 μm to about 400 μm). In another embodiment, the second leach depth D2 may be greater than 0% to about 1% less than the first leach depth D1, about 75% less than the first leach depth D1 to completely through the leached region 118, or about 75% less than the first leach depth D1 to substantially through the PCD table 102. As previously discussed, the percentage of the second leach depth D2 to the first leach depth D1 may potentially affect the performance of the PDC 100. For example, the second leach depth D2 of at least some of the plurality of recessed features 108 may be significantly less than the first leach depth D1 (e.g., about 50% to about 75% less than the first leach depth D1) when the recessed features 108 are positioned proximate to the anticipated leach boundary-wear intersection location 124 and/or exhibits a relatively high stress concentration factor.
In an embodiment, the first leach depth D1 may be about 1.33 to about 20 times greater than the depth D3 of at least some of the plurality of recessed features 108. For example, the first leach depth D1 may be about 1.5 to about 5, about 2 to about 10, about 5 to about 15, about 10 to about 15, or about 15 to about 20 times greater than the depth D3 of at least some of the plurality of recessed features 108. In an embodiment, the first leach depth D1 may be about 1.0 to about 1.33 times greater or more than 20 times greater than depth D3 of at least some of the plurality of recessed features 108. In an embodiment, the depth D3 of at least some of the plurality of recessed features 108 may be greater than the first leach depth D1. As previously discussed, the depth D3 of the plurality of recessed features 108 relative to the first leach depth D1 may affect to the performance of the PDC 100. For example, the first leach depth D1 may be at least about 4 times greater than the depth D3 of at least some of the plurality of recessed features 108 when the recessed features 108 are positioned proximate to the anticipated leach boundary-wear intersection location 124 and/or exhibits a relatively high stress concentration factor.
In an embodiment, the depth D3 of at least some of the plurality of recessed features 108 may vary with location along the upper surface 106. For example, the depth of at least some of the plurality of recessed features 108 may generally increase, decrease, undulate, or vary from a location on the upper surface 106 (e.g., a center of the upper surface 106) towards an edge of the upper surface 106. For example, the depth D3 of at least some of the plurality of recessed features 108 may be greatest at and/or near the edge of the upper surface 106. As another example, the depth D3 of at least some of the plurality of recessed features 108 may be smallest at and/or near the edge of the upper surface 106. In an embodiment, the depth D3 of at least some of the plurality of recessed features 108 may be greatest at, near, and/or inwardly from a location where the expected wear front 122 contacts the unleached portion 116. Varying the depth D3 of at least some of the plurality of recessed features 108 may increase the overall strength and toughness of the PCD table 102 because the average depth of the plurality of recessed features 108 is less than the greatest depth of the plurality of recessed features 108. However, the depth of the plurality of recessed features 108 may be sufficiently deep at certain locations to limit a spalled region formed in the PCD table 102.
In an embodiment, the plurality of recessed features 108 may be formed in only a selected portion of the upper surface 106. Forming the plurality of recessed features 108 in a selected portion of the upper surface 106 may increase the strength and toughness the PCD table 102. For example, the plurality of recessed features 108 may be formed in a radially outer half of the upper surface 106. The plurality of recessed features 108 may be formed in the radially outer half of the upper surface 106 because the leach boundary-wear intersection location 124 may be more likely to occur in the radially outer half of the PCD table 102. In an embodiment, the plurality of recessed features 108 may be formed over the entire upper surface 106 (e.g., uniformly formed on the upper surface 106). For example, forming recessed features 108 in the radially inner half of the upper surface 106 may act as a redundant spallation limiting structure for the plurality of recessed features 108 formed in the radially outer half of the upper surface 106.
In an embodiment, at least some of the plurality of recessed features 108 may extend to an outer edge of the upper surface 106. However, at least some of the plurality of recessed features 108 may extend to other portions of the PCD table 102. For example, at least some of the plurality of recessed features 108 may extend from a location on the upper surface 106 to a location inwardly from outer edge of the upper surface 106. In another example, at least some of the plurality of recessed features 108 may extend from a location on the upper surface 106 to a location beyond the outer edge of the upper surface 106, such as to a location on the chamfer 114 or a location on the at least one lateral surface 112.
The ability of the plurality of recessed features 108 to attract cracks and/or limits spallation may be dependent on the plurality of recessed features' 108 stress concentration factor. In an embodiment, the stress concentration factor of the plurality of recessed features 108 may increase as a ratio of the average depth of the plurality of recessed features 108 to an average width of the plurality of recessed features 108 increases. For example, the ratio may be at least about 1, at least about 1.5, at least about 2, at least about 3, or about 1.5 to about 3.
The plurality of recessed features 108 may exhibit a spacing therebetween configured to cause cracks formed at or near the leach boundary-wear intersection location 124 to be attracted to the nearest recessed feature 108. In an embodiment, two substantially similar immediately adjacent recessed features may be substantially parallel along a selected length thereof. The distance between the substantially parallel lengths of the two immediately adjacent recessed features may be less than about 3 mm, such as less than about 2 mm, less than about 1 mm, about 1 mm to about 3 mm, or about 0.5 mm to about 2 mm. The inventors have found that the two recessed features can exhibit a microscopic spacing therebetween and a propagating crack is still attracted to the nearest recessed feature. In particular, the inventors have found that the two recessed features may exhibit a spacing therebetween of about 650 μm or less (e.g., about 625 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 300 μm or less, or about 250 μm or less, about 250 μm to about 500 μm, or about 300 μm to about 500 μm) and the propagating crack can still be attracted to the nearest recessed feature.
Referring to
The PCD table 202 may include a plurality of recessed features 208 formed in the upper surface 206. In the illustrated embodiment, the leach boundary-wear intersection location 224 may be spaced relatively far from the upper surface 206. As such, in an embodiment, the plurality of recessed features 208 may exhibit a relatively great depth (e.g., 500 μm or greater), an average depth that is greater than an average width thereof (e.g., by a ratio of about 2 or more), and/or another feature configured to attract cracks to the nearest recessed feature 208 and/or limit spallation.
In order to effectively HPHT sinter the mass of diamond particles 330, the mass of diamond particles 330 may be placed adjacent a surface of the substrate 104 to form an assembly 332. The assembly 332 may be placed in a pressure transmitting medium, such as a refractory metal can, graphite structure, pyrophyllite, combinations thereof, or another suitable container or supporting element. The pressure transmitting medium, including the assembly 332, may be subjected to an HPHT process at a temperature of at least about 1000° C. (e.g., about 1100° C. to about 2200° C., or about 1200° C. to about 1450° C.) and a pressure in the pressure transmitting medium of at least about 5 GPa (e.g., at least about 7.5 GPa, at least about 9.0 GPa, at least about 10.0 GPa, at least about 11.0 GPa, at least about 12.0 GPa, at least about 14.0, or about 7.5 GPa to about 9.0 GPa) for a time sufficient to sinter the diamond particles 330 and form a PCD table 302 bonded to the substrate 104 thereby forming the PDC 300.
During the HPHT process, the presence of a catalyst facilitates intergrowth between the mass of diamond particles 330 and forms the PCD table 302 including directly bonded-together diamond grains (e.g., exhibiting sp3 bonding) defining a plurality of interstitial regions. In the illustrated embodiment, the PDC 300 may be formed by sintering the mass of diamond particles 330 on the substrate 104, which may be a cobalt-cemented tungsten carbide substrate. For example, cobalt and/or a cobalt alloy from the substrate 104 liquefies during the HPHT process and infiltrates into the mass of diamond particles 330 to catalyze formation of the PCD table 302. In such an example, some tungsten and/or tungsten carbide (metallic infiltrants) from the substrate 104 may dissolve in or otherwise transfer or alloy with the catalyst. However, in other embodiments, the catalyst may be mixed with the mass of diamond particles 330, provided from a thin foil, another external source, or combinations thereof. Additionally, the catalyst and the metallic infiltrants may react with the mass of diamond particles 330 to form carbides. As such, the interstitial regions of the PCD table 302 may be at least partially occupied by at least one interstitial constituent (e.g., at least one of a metal-solvent catalyst, a metallic infiltrant, one or more formed carbides etc.).
The PCD table 302 so formed may include an interfacial surface 310 bonded to the substrate 104. Examples of interfacial surface geometries for the substrate 104 that may be bonded to the interfacial surface 310 are disclosed in U.S. Pat. No. 8,297,382, the disclosure of which is incorporated herein, in its entirety, by this reference. The PCD table 302 may include an upper surface 306 spaced from the interfacial surface 310 and at least one lateral surface 312 extending between the upper surface 306 and the interfacial surface 310. In an embodiment, the sintered grains of the PCD table 302 may exhibit an average grain size of about 20 μm or less or about 30 μm or less. For example, the average grain size and grain size distribution of the PCD table 302 may be substantially similar or the same as the average diamond particle size and distribution of the mass of diamond particles 330.
Examples of suitable HPHT process conditions that may be used to form any of the PDC embodiments disclosed herein are disclosed in U.S. Pat. No. 7,866,418 which is incorporated herein, in its entirety, by this reference.
After the HPHT process, the PDC 300 may be subsequently shaped to include an optional peripherally-extending chamfer 314. Further, as previously described, the PCD table 302 may be at least partially leached to remove at least a portion of the at least one interstitial constituent therefrom. In an embodiment, the PDC 300 may be at least partially immersed in and/or exposed to a leaching agent (e.g., hydrofluoric acid, nitric acid, a supercritical fluid, a gaseous leaching agent, another suitable leaching agent, or combinations thereof) to at least partially remove at least one interstitial constituent from the PCD table 302 to form a leached region (e.g., leach regions 118, 218 of
In an embodiment, the PCD table 302 may include a plurality of recessed features 308 formed in the upper surface 306 thereof after the PCD table 302 is at least partially leached. For example, the plurality of recessed features 308 may be formed in the upper surface 306 by grinding or machining, such as at least one of laser machining, electrical discharge machining, or water jet machining. Examples of methods of using a laser to cut or machine a PCD table are disclosed in U.S. Pat. No. 9,062,505, the disclosure of which is incorporated herein, in its entirety, by this reference. In another example, the plurality of recessed features 308 may be formed in the upper surface 306 using acid etching, plasma etching, or other suitable etching techniques. Forming the plurality of recessed features 308 after leaching the PCD table 302 may result in a leached region that exhibits a first leach depth D1 and a second leach depth D2 that is less than the first leach depth D1 (
In another embodiment, the PCD table 302 may have the plurality of recessed features 308 formed in the upper surface 306 prior to leaching the PCD table 302. In such an embodiment, the plurality of recessed features 308 may be formed using any of the methods disclosed above. Additionally, the plurality of recessed features 308 may be formed using electrical discharge machining (e.g., wire electrical discharge machining) or pressed into the diamond particles before and/or during the HPHT process. The PCD table 302 including the plurality of recessed features 308 formed therein may then be leached using any of the leaching techniques disclosed herein. Forming the plurality of recessed features 308 prior to leaching the PCD table 302 may result in a leached region that exhibits a substantially uniform leach depth extending inwardly from the upper surface 306 and a base of each of the plurality of recessed features 308. For example, the leached region may be generally complementary to the topography of the outer surface of the top/upper surface of the PCD table 302 including surfaces formed by the recessed features 308.
In an embodiment, the plurality of recessed features 308 are formed in the upper surface 306 after leaching. For example, the plurality of recessed features 308 formed after leaching may be closer to a leach boundary-wear intersection location than if recessed features 308 were formed prior to leaching. As such, the plurality of recessed features 308 formed after leaching may exhibit a smaller average depth than the plurality of recessed features 308 formed prior to leaching.
Any of the recessed features disclosed herein may exhibit a number of suitable side, cross-sectional geometries. For example, any of the PCD tables disclosed herein may include a first plurality of recessed features that exhibits a first cross-sectional geometry (in side view) and a second plurality of recessed features that exhibits a second cross-sectional geometry (in side view) that is different than the first cross-sectional geometry. In another example, any of the PCD table disclosed herein may include a plurality of recessed features that each exhibits a substantially similar cross-sectional geometry.
Referring to
In the illustrated embodiment, the at least one recessed feature 408a exhibits a generally rectangular cross-sectional geometry (in side view). The generally rectangular cross-sectional geometry of the at least one recessed feature 408a may include a base 426a having a length and at least two side surfaces 434a extending from the base 426a to the upper surface 406a. The at least two side surfaces 434a may be substantially parallel, slightly diverge, or slightly converge relative to each other. In an embodiment, the at least two side surfaces 434a may also extend substantially perpendicularly or at an oblique angle relative to the upper surface 406a and/or the base 426a.
The generally rectangular cross-sectional geometry of the at least one recessed feature 408a may also include at least two corners 436a where the at least two side surfaces 434a meet the base 426a. The corners 436a may exhibit a radius of curvature, a fillet, or any other geometry. For example, at least one of the corners 436a may exhibit a relatively small radius of curvature when the corner 436a is sharp or exhibit a relatively large radius of curvature when the corner 436a is rounded. The radius of curvature of the corners 436a may correspond to a stress concentration factor exhibited by the corners. For example, a corner 436a that is sharp is expected to exhibit a relatively larger stress concentration factor than a corner 436a that is rounded. As such, a corner 436a may exhibit a sharp corner when the at least one recessed feature 408a is spaced relatively far from a leach boundary-wear intersection location. In an embodiment, the at least one recessed feature 408a may include a first corner that is relatively sharp and a second corner that is relatively round. In another embodiment, the at least one recessed feature 408a may only exhibit a relatively sharp corner along a selected length of the at least one recessed feature 408a.
Referring to
The at least one recessed feature 408b exhibits a cross-sectional geometry (in side view) that is generally v-shaped. The generally v-shaped cross-sectional geometry may include at least two side walls 434b that extend and diverge from a base 426b to the upper surface 406b. At least one of the two side walls 434b may exhibit an oblique angle relative to the upper surface 406b. In the illustrated embodiment, the base 426b of the at least one recessed feature 408b exhibits a corner 436b. Similar to the at least two corners 436a (
Referring to
The at least one recessed feature 408c exhibits a cross-sectional geometry (in side view) that is arcuate (e.g., generally partially elliptical, such as partially circular). As such, the at least one recessed feature 408c may include a single continuous wall 434c that exhibits a generally concave shape relative to the upper surface 406c. Since the at least one recessed feature 408c does not include any corners, the at least one recessed feature 408c may exhibits a relatively low stress concentration factor. However, cracks formed in the PCD table 402c may be preferentially attracted to the at least one recessed feature 408c at least partially due to a proximity of the at least one recessed feature 408c to the crack.
Any of the recessed features disclosed herein (e.g., grooves, recesses, notches, dimples, channels, or networks) may exhibit any suitable pattern or network when formed in an upper surface of a PCD table.
Referring to
In the illustrated embodiment, the plurality of recessed features 508 extend from and contact an outer edge of the upper surface 506. As such, the plurality of recessed features 508 form four cells 528. Three of the cells 528 are formed along the outer edge of the upper surface 506 and form three distinct cutting surfaces. The plurality of recessed features 508 may limit spalling of one of the cells 528 from significantly adversely affecting the other cells 528. Additionally, the four cells 528 may limit spalling in a radial direction more than in a circumferential direction. Other patterns may form more or less cells and increase or decrease the amount of spalling in a radial and/or circumferential direction.
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
The plurality of recessed features 908a may form any suitable shapes (e.g., generally geometrically expanding or contracting shapes centered about a common point). For example, the plurality of recessed features 908a may form a generally circular shape, a generally rectangular shape, a generally pentagonal shape, a generally hexagonal shape, a generally elliptical shape, a generally crescent shape, or any other suitable shape. In an embodiment, the plurality of recessed features 908a may form a plurality of different shapes that are generally centered about a common point relative to each other. For example, the plurality of recessed features 908a may form an outermost shape that is generally rectangular and another shape that is inwardly generally centered relative to the outermost shape that is generally triangular. In an embodiment, at least one of the generally rectangular shapes may be rotated relative to the outermost generally rectangular shape.
Referring to
The plurality of recessed features 908b illustrate an example of combining two of the patterns disclosed herein to form a single pattern. As such, the plurality of recessed features 908b may exhibit the benefits of the pattern discussed in
In an embodiment, the plurality of first recessed features 908b′ may not include a plurality of generally commonly centered shapes. Instead, the plurality of first recessed features 908b′ may include a plurality of linear, convexly curved, and/or concavely recessed features that extend between the plurality of second recessed features 908b″ in any suitable manner. For example, the plurality of first recessed features 908b′ may form a plurality of shapes that are not generally centered with respect to each other. In another example, at least some of the plurality of first recessed features 908b′ may be radially offset from a circumferentially adjacent first recessed feature 908b′ (e.g., at least some of the plurality of first recessed features 908b′ may not form continuous shapes).
Referring to
The plurality of recessed features 908c′-908c′″ illustrate an example of combining three patterns to form a single network or pattern. For example, the plurality of first recessed features 908c′ may limit spalling in a generally radial direction and the plurality of third recessed features 908c′″ may limit spalling in a generally circumferential direction. The plurality of first, second, and third recessed features 908c′, 908c″, 908c′″ may form further spall-limiting features.
Referring to
In an embodiment, the plurality of recessed features 1008a may form a shape (e.g., cycloid or trochoid) having at least 3 cusps, such as 4, 5, 5-10, 10-15, 15-20, or greater than 20 cusps. The number of cusps of the shape formed from the plurality of recessed features 1008a may correspond to the number of cells 1028a formed radially outwardly from the shape. In an embodiment, the plurality of recessed features 1008a may optionally intersect at the cusps thereof or the plurality of recessed features 1008a may optionally intersect at the cusps thereof and at one or more locations between the cusps thereof.
Referring to
Referring to
Referring to
In an embodiment, the plurality of first recessed features 1008e′ may not form a plurality of generally concentric shapes. Instead, the plurality of first recessed features 1008e′ may include a plurality of curved recessed features that extend between the plurality of second recessed features 1008e″. For example, at least some of the plurality of first recessed features 1008e′ may not intersect at the cusp thereof and may be radially spaced relative to a circumferentially adjacent first recessed feature 1008e′.
The following working examples of the present disclosure set forth various configurations that have been used to form the PDC cutting elements disclosed herein. The following working examples provide further detail in connection with the embodiments described above.
A conventional PDC was formed from a bimodal mixture of diamond particles having respective modes at about 30 μm and about 2 μm. The mixture of diamond particles was positioned adjacent to a cobalt-cemented tungsten carbide substrate. The plurality of diamond particles were sintered and bonded to the substrate in an HPHT process having a cell pressure of about 7.8 GPa and a temperature of about 1360° C. to form the conventional PDC including a PCD table. The PDC table was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. The conventional PDC did not have any recessed features formed in an upper surface thereof.
The conventional PDC was then subjected to a milling spallation test in which the PDC was used to cut a Barre granite workpiece. The test parameters used for the milling test were a back rake angle for the PDC of about 20°, an in-feed for the PDC of about 50.8 cm/min, a rotary speed on the workpiece of about 3000 RPM, an indexing across the workpiece (e.g., in the Y direction) of about 7.62 cm, about 3-5 seconds (no more than 10 seconds) between cutting passes, and the size of the Barre granite workpiece was about 63.5 cm by about 48.3 cm. The PDCs were held in a cutting tool holder, with the substrate of the PDCs tested thermally insulated on its back side via an alumina disc and along its circumference by a plurality of zirconia pins. The conventional PDC was subject to the milling test until the conventional PDC spalled. Spalling of the PDC was determined using a “burnout” method in which spalling was detected when at least one of the operator detected sparks, the operator noticed black marks on the Barre granite, a sharp rise in the detected temperature, or a slight change in the force measurements.
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 2 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 2 using a laser. The plurality of recessed features included a plurality of circumferentially-extending first recessed features and a plurality of radially-extending second recessed features that were substantially similar to the plurality of first recessed features 1008e′ and the plurality of second recessed features 1008e″ (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 3 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 3 using a laser. The plurality of recessed features included a plurality of arcuately-extending first recessed features and a plurality of generally radially-extending second recessed features (e.g., substantially similar to the plurality of first recessed features 1008e′ and the plurality of second recessed features 1008e″ (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 4 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 4 using a laser. The plurality of recessed features included a plurality of arcuately-extending first recessed features and a plurality of generally radially-extending second recessed features (e.g., substantially similar to the plurality of first recessed features 1008e′ and the plurality of second recessed features 1008e″ (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 5 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 5 using a laser. The plurality of recessed features included a plurality of arcuately-extending first recessed features and a plurality of generally radially-extending second recessed features (e.g., substantially similar to the plurality of first recessed features 908b′ and the plurality of second recessed features 908b″ (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 6 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 6 using a laser. The plurality of recessed features included a plurality of arcuately-extending first recessed features and a plurality of generally radially-extending second recessed features (e.g., substantially similar to the plurality of first recessed features 908b′ and the plurality of second recessed features 908b″ (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 7 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 7 using a laser. The plurality of recessed features formed a generally rectangular grid-like pattern (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 8 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 8 using a laser. The plurality of recessed features form a plurality of generally commonly centered hypocycloids (e.g., similar to the plurality of recessed features 1008b (
A PDC was formed as described in comparative example 1 prior to leaching. The PDC table of example 9 was then partially leached to form a leached region having a first leach depth from an upper surface of the PCD table of about 490 μm, a side leach depth of about 80 μm, and a L1* value of about 200 μm. A plurality of recessed features having an average depth of about 75 μm was then formed in the upper surface of the PCD table of example 9 using a laser. The plurality of recessed features included a plurality of spirally-extending first recessed features and a plurality of second recessed features extending between the plurality of first recessed features (e.g., similarly to the plurality of first recessed features 808b′ and the plurality of second recessed features 808b″ (
The PDC of example 9 included a spalled region that was radially and circumferentially limited by the plurality of first and second recessed features, respectively. As such, the spalled region is partially defined by the plurality of first and second recessed features. Additionally, it is believed that the plurality of recessed features limited cracks extending from the spalled region into the PCD table of example 9. As such, the plurality of recessed features may increase the usability of the PDC of example 9. For example, the PDC of example 9 can be subjected to another milling test by rotating the PDC of example 9 such that a portion of the PCD table of example 9 that does not include the spalled region forms the cutting contact surface.
The thermal stability for several of the PDCs disclosed herein were measured by determining a distance that the PDCs cut in a mill test prior to failure. Four PDCs were formed according to the methods disclosed in each of comparative example 1 and working examples 2, 7, 8, and 9. Each of the PDCs were then subjected to a milling test in which the PDCs are used to cut the same Barre granite workpiece without any coolant (e.g., dry cutting of the Barre granite workpiece in air). The test parameters used for the milling test were the same as described above in comparative example 1. Failure is determined when the PDCs can no longer cut the workpiece (e.g., spall). Spalling of the PDC was determined using a “burnout” method where spalling was detected when at least one of the operator detected sparks, the operator noticed black marks on the Barre granite, a sharp rise in the detected temperature, or a slight change in the force measurements. The distance each PDC cut prior to failure was calculated by: (the width of the workpiece)×(the number of complete passes)+(the distance cut on the last pass prior to failure).
The disclosed PDC embodiments may be used in a number of different applications including, but not limited to, use in a rotary drill bit (
With reference to
In an embodiment, the plurality of PDCs 1412 may be secured to the blades 1404 using a brazing technique, a mechanical fastener, a high temperature adhesive, press-fitting, or another suitable technique. The rotary drill bit 1400 may then be used in one or more subterranean drilling operations until at least one of the plurality of PDCs 1412 spall (“spalled PDC”). Spalling of the PDCs 1412 may be detected by sudden changes in force exerted by the plurality of PDCs 1412 against a subterranean surface, visual inspection, audible cues, or combinations thereof, etc. After one or more PDCS 1412 spall, the spalled PDC 1412 may be removed from the rotary drill bit 1400. For example, if the spalled PDC 1412 is brazed to the rotary drill bit 1400, the spalled PDC 1412 may be heated sufficiently to melt at least some of the braze material. The spalled PDC 1412 may then be rotated relative to the rotary drill bit 1400 to position a portion of the spalled PDC 1412 that does not include a spalled region in a cutting position. The spalled PDC 1412 may then be secured to the rotary drill bit 1400 using any of the techniques previously disclosed. The rotary drill bit 1400 may then be used in subterranean drilling operations.
The PDCs disclosed herein may also be utilized in applications other than cutting technology. For example, the disclosed PDC embodiments may be used in wire dies, bearings, artificial joints, inserts, cutting elements, and heat sinks. Thus, any of the PDCs disclosed herein may be employed in an article of manufacture including at least one superabrasive element or compact.
Thus, the embodiments of PDCs disclosed herein may be used in any apparatus or structure in which at least one conventional PDC is typically used. In one embodiment, a rotor and a stator, assembled to form a thrust-bearing apparatus, may each include one or more PDCs (e.g., PDC 100 of
While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiment disclosed herein are for purposes of illustration and are not intended to be limiting. Additionally, the words “including,” having,” and variants thereof (e.g., “includes” and “has”) as used herein, including the claims, shall be open ended and have the same meaning as the word “comprising” and variants thereof (e.g., “comprise” and “comprises”).
This application is a divisional of U.S. application Ser. No. 15/402,525 filed on 10 Jan. 2017, which claims priority to U.S. Provisional Application No. 62/279,271 filed on 15 Jan. 2016, the disclosure of each of which is incorporated herein, in its entirety, by this reference.
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| Number | Date | Country | |
|---|---|---|---|
| 62279271 | Jan 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15402525 | Jan 2017 | US |
| Child | 16518049 | US |
