US Synthetic Corporation

Halliburton Energy Services, Inc.

Cody William Knuteson

Kenneth Eugene Bertagnolli

Debkumar Mukhopadhyay

Brandon Paul Linford

Craig Hodges Cooley

Timothy Nathan Sexton

Paul Douglas Jones

Daniel Call Mortensen

Jason Dean Blackburn

Brent R Eddy

Steven Swan

Kevin Duy Nguyen

Seth Garrett Anderle

Substrate

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 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 and/or wear resistance 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 such as phosphorous.

Methods of fabricating a polycrystalline diamond compact

Polycrystalline diamond compacts ('PDCs') include a polycrystalline diamond ('PCD') table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. The PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.

The present disclosure relates to an industrial device, such as a drill bit including a thermally stable polycrystalline diamond (TSP) table coupled to a substrate via an attachment joint, with at least one attachment material located in the attachment joint. At least one of the attachment materials includes a metal or metal alloy and an additive material having a hardness higher than the metal or metal alloy or a coefficient of thermal expansion lower than that of the metal or metal alloy.

Thermally stable polycrystalline diamond with enhanced attachment joint

Polycrystalline diamond compacts, and related methods and applications

Embodiments of the invention relate to methods of forming polycrystalline diamond compacts ('PDCs'), wherein the PDC includes a polycrystalline diamond ('PCD') table in which at least one Group VIII metal is at least partially alloyed with phosphorus and/or at least one other alloying element to improve the thermal stability of the PCD table. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.

Polycrystalline diamond compacts ('PDCs') include a polycrystalline diamond ('PCD') table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. For example, a PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.

Growing community of inventors

Salem, UT, United States of America

Cody William Knuteson