US Synthetic Corporation

Daniel Call Mortensen

Trevor Allen Olsen

Cody William Knuteson

Brandon Paul Linford

Shawn Casey Scott

Jason Dean Blackburn

Steven Swan

Lindsay Sue Patton

Casey Wade Swan

Kenneth Eugene Bertagnolli

Jiang Qian

Joshua Adam Hawks

Matthew Kimball Baker

Anne-Grethe Slotnaes

Jason Lott

Heather Marie Schaefer

Daniel Preston Wilding

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

Cutting tool

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 are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent crack propagation into other portions of the PCD table and limit a volume of the PCD table that spalls. 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.

Polycrystalline diamond compacts, methods of fabricating the same, and methods of using the same

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.

Drill bit

Superabrasive compact

A polycrystalline diamond element leaching assembly includes a polycrystalline diamond element, a protective leaching cup surrounding at least a portion of the polycrystalline diamond element, and a protective layer positioned between the polycrystalline diamond element and the protective leaching cup. A method of processing a polycrystalline diamond element includes covering a selected portion of a polycrystalline diamond element with a curable resin layer, curing the curable resin layer to form a protective layer, and exposing at least a portion of the polycrystalline diamond element to a leaching agent. Another method of processing a polycrystalline diamond element includes depositing a curable resin within a protective leaching cup and positioning a polycrystalline diamond element within the protective leaching cup such that the curable resin is displaced so as to surround at least a portion of the polycrystalline diamond element.

Leaching assemblies, systems, and methods for processing superabrasive elements

Growing community of inventors

Provo, UT, United States of America

Daniel Call Mortensen