Halliburton Energy Services, Inc.

Christopher John Keller

William Brian Atkins

A cutting element for a drill bit can include a first layer of polycrystalline diamond, a second layer of polycrystalline diamond, wherein a boundary between the first layer and the second layer is nonplanar, and a substrate. The first and second layers can be formed from polycrystalline diamond of different grain sizes. One of the first and second layers can be leached of a catalyzing material. The first layer can be formed on a first substrate having a nonplanar surface feature, removed from the first substrate, and placed over the second layer to form the nonplanar boundary. The first layer can be leached of a catalyzing material prior to being applied to the second layer. A barrier layer can be placed between the first layer and the second layer to prevent sweeping of a catalyzing material into the leached first layer.

Crack mitigation for polycrystalline diamond cutters

PDC cutter

Systems and methods for wellbore drilling may use one or more cutting elements including a cutting face with one or more channels capable of steering chip cuttings into an intended direction off of the cutting face of the cutting element for drilling operations. A method may comprise rotating a drill bit to extend a wellbore into a subterranean formation, flowing a drilling fluid through the drill bit, and directing a plurality of formation cuttings away from one or more cutting elements of the drill bit by moving the cuttings along one or more channels on at least a portion of a cutting face of the one or more cutting elements.

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Magnolia, TX, United States of America

Christopher John Keller