Smith International, Inc.

Schlumberger Technology Corporation

Other

University of Houston System

Feng Yu

J Daniel Belnap

Georgiy Voronin

Peter Thomas Cariveau

Benjamin Randall

Youhe Zhang

Yuelin Shen

Guodong Zhan

Cheng Peng

Ronald K Eyre

Yahua Bao

Yi Fang

Kenneth W White

Madapusi K Keshavan

Jeffrey B Lund

John Daniel Belnap

Xian Yao

Michael David France

Haibo Zhang

Anatoliy Garan

Qingyuan Liu

Charles Jeffrey Claunch

Gregory Caron

Guojiang Fan

John Parker

Douglas Marsh

A cutting element may include a substrate having a non-planar upper surface with a peripheral edge, and an ultrahard layer. The upper surface may include at least one depression formed at least proximate the peripheral edge; and a compressive stress hoop extending around the upper surface adjacent the peripheral edge, extending into the at least one depression, and configured to reduce tensile stress in the ultrahard layer. The ultrahard layer may be on the substrate and may have a non-planar top surface and an interface formed between the ultrahard layer and the substrate.

Non planar cutting element with non planar interface design and tools incorporating such elements

A cutting element includes a substrate and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer having a ridge extending along a major dimension of the top surface from an edge of the top surface, where the ridge has a peak with at least two different roof radii of curvature, and at least two sidewalls sloping in opposite directions from the peak of the ridge at a roof angle, where a first roof angle of the ridge proximate the edge is smaller than a second roof angle in a central portion of the ridge around a longitudinal axis of the cutting element.

Ridge shaped element

A cutting device for use in a drill bit has a body including an ultrahard material. The body has a top surface, a front surface, and at least one lateral surface adjacent the top surface. The lateral surface is oriented at a surface angle relative to the top surface between 30 and 150 degrees. One or more locking features are located on the lateral surface.

Mechanical locking of cutting element with carbide matrix

PCD constructions as disclosed comprise a ultra-hard body attached with a metallic substrate along a substrate extending between the body and the substrate. The construction includes a protective feature or element that is configured to protect a metal rich region or zone existing in the construction from unwanted effects of corrosion or erosion. The protective element extends from the body over the interface and along a portion of the substrate and may be integral with the.

Polycrystalline diamond constructions with protective element

The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance.

Cutting elements, methods for manufacturing such cutting elements, and tools incorporating such cutting elements

Roller cutters comprise a diamond-bonded body joined to an infiltration substrate. An extension is joined to the substrate and includes first section having a diameter sized the same as the substrate, and an integral second section having a diameter smaller than the substrate. The extension is joined to the substrate during an HPHT process. The first section has a thickness greater than that of the infiltration substrate. The second section has an axial length greater than the combined thickness of the substrate and the first section. The extension has a strength and/or toughness greater than the substrate as a result of its material composition, e.g., the amount of binder phase material and/or the size of hard phase material. The roller cutter is rotatably disposed within a pocket internal cavity, wherein the pocket is attached to a drill bit.

Roller cutting element construction

Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing.

Polycrystalline diamond constructions having optimized material composition

Ultra-hard constructions comprise polycrystalline diamond-body having a first metallic substrate attached thereto, and having a second metallic substrate attached to the first metallic substrate. The first and second substrates each comprise a first hard particle phase, e.g., WC, and a second binder material phase, e.g., Co, wherein the hard particles in the second substrate are sized larger than those in the first substrate. The first substrate may contain a larger amount of binder material than the second substrate. Constructed in this matter, the first substrate is engineered to facilitate sintering diamond body during HPHT conditions, while the second substrate is engineered to provide an improved degree of erosion resistance when placed in an end-use application. The construction may be formed during a single HPHT process. The second substrate may comprise 80 percent or more of the combined thickness of the first and second substrates.

Ultra-hard constructions with erosion resistance

A method of forming a metal deposit on an ultra-hard material. In an embodiment, the method includes providing a plurality of ultra-hard particles, mixing the ultra-hard particles in a solution with a metal salt, drying the solution to create a mixture of metal salt particles adhered to surfaces of the ultra-hard particles, heating the mixture to convert the metal salt particles into metal deposits on the surfaces of the ultra-hard particles, and HTHP sintering the mixture of ultra-hard particles with the metal deposits to form a polycrystalline ultra-hard material.

Method of forming metal deposits on ultrahard materials

Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element.

Diamond bonded construction with thermally stable region

The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having high diamond frame strength and methods for forming and evaluating such polycrystalline diamond bodies. A polycrystalline diamond body is provided, having a top surface, a cutting edge meeting the top surface, and a first region including at least a portion of the cutting edge. The first portion exhibits a diamond frame strength of about 1200 MPa or greater, or about 1300 MPa or greater.

High diamond frame strength PCD materials

A method of forming a cutting element is disclosed, wherein the method includes forming a substrate body, forming an intermediate layer on the substrate body, forming a diamond table, and positioning the diamond table on the intermediate layer, such that the intermediate layer is disposed between the substrate body and the diamond table. The intermediate layer has a base portion having a base height and a ring portion having a ring height H, wherein the intermediate layer has a height Hequal to the sum of the base height and ring height. The diamond table has a cutting layer having a cutting layer diameter Dand a cutting layer height Hand a protrusion having a protrusion diameter Dand a protrusion height H.

Interface design of TSP shear cutters

A sintered body for cutting tools that includes hard particle phase comprising a plurality of hard particles, wherein at least a portion of the hard phase particles comprise a coating deposited by atomic layer deposition disposed thereon; and a binder phase is disclosed. The hard particles that may be included in the sintered bodies may include tungsten carbide, diamond, and boron nitride particles.

Atomic layer deposition nanocoatings on cutting tool powder materials

A method for facilitating infiltration of an infiltrant material into a TSP material during re-bonding of the TSP material to a substrate, by enhancing the porosity of the TSP material near the interface with the substrate is provided. Cutting elements formed by such method and downhole tools including such cutting elements are also provided.

Growing community of inventors

Lindon, UT, United States of America

Feng Yu