US Synthetic Corporation

Halliburton Energy Services, Inc.

Brandon Paul Linford

Debkumar Mukhopadhyay

Kenneth Eugene Bertagnolli

Cody William Knuteson

Michael Alexander Vail

Jason Keith Wiggins

Jiang Qian

Seth Garrett Anderle

Paul Douglas Jones

Robert W Arfele

Shawn Casey Scott

Daniel Call Mortensen

Brian Atkins

Ram L Ladi

Kevin Duy Nguyen

Brent R Eddy

Jason Dean Blackburn

Steven Swan

Alberto Castillo

Jedediah Chad Clarke

Jed Clarke

Embodiments of the invention relate to polycrystalline diamond compacts ('PDC') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 μm or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Polycrystalline diamond, polycrystalline diamond compacts, methods of making same, and applications

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Polycrystalline diamond compacts and applications therefor

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond ('PCD') table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

Polycrystalline diamond compact, and related methods and applications

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond ('PCD') table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. The plurality of diamond grains includes a first amount being about 5 weight % to about 65 weight % of the plurality of diamond grains and a second amount being about 18 weight % to about 95 weight % of the plurality of diamond grains. The first amount exhibits a first average grain size of about 0.5 &#x3bc;m to about 30 &#x3bc;m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 10 &#x3bc;m to about 65 &#x3bc;m. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond ('PCD') table having a diamond grain size distribution selected for improving leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes diamond grains exhibiting diamond-to-diamond bonding therebetween. The diamond grains includes a first amount being about 30 to about 65 volume % of the diamond grains and a second amount being about 18 to about 65 volume % of the diamond grains. The first amount exhibits a first average grain size of about 8 &#x3bc;m to about 22 &#x3bc;m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 15 &#x3bc;m to about 50 &#x3bc;m. Other embodiments are directed methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Methods of fabricating polycrystalline diamond elements

Embodiments of the invention relate to polycrystalline diamond compacts ('PDC') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond ('PCD') table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 &#x3bc;m or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Embodiments relate to polycrystalline diamond compacts and methods of manufacturing such compacts in which an at least partially leached polycrystalline diamond ('PCD') table is infiltrated with first and second infiltrants. The first infiltrant includes a low viscosity cobalt-based and/or nickel-based alloy infiltrant. The second infiltrant (e.g., copper) is specifically selected to be more easily infiltrated and/or removed (e.g., leached) than a pure cobalt infiltrant. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature ('HPHT') process. The PCD table may be at least partially leached to remove at least a portion of the metal-solvent catalyst therefrom. The leached PCD table and a substrate are subjected to a second HPHT process effective to bond the substrate to the leached PCD table while at least partially infiltrating the PCD table with at least the first and second infiltrants.

Polycrystalline diamond compacts including infiltrated polycrystalline diamond table and methods of making same

Embodiments of the invention relate to polycrystalline diamond compacts including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table. In an embodiment, a polycrystalline diamond compact includes a substrate including at least one side surface and a convexly-curved interfacial surface that may, in some embodiments, extend inwardly directly from the at least one side surface to form at least one peripheral edge therebetween. The polycrystalline diamond compact further includes a polycrystalline diamond table bonded to the convexly-curved interfacial surface of the substrate.

Polycrystalline diamond compact including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table, and related applications

Polycrystalline diamond compact including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table, and related methods and applications

Growing community of inventors

Draper, UT, United States of America

Brandon Paul Linford