Halliburton Energy Services, Inc.

Dow Global Technolgoies LLC

Gagan Saini

William Brian Atkins

Mehmet Demirors

Enrique Antonio Reyes

Grant O Cook, Iii

Zachary R Murphree

Mridula Babli Kapur

Pradeep Jain

Qi Liang

Andy Cheng Chang

Rongjuan Cong

Selim Bensason

Jozef Van Dun

Cristina Serrat

Mustafa Bilgen

Michael D Turner

Douglas S Ginger

Brian Atkins

Joshua B Gaubert

Tiffany Anne Pinder

Troy M Tambling

Jian Wang

Jain Pradeep

Michael Rutkowske

Paul B Lively

Jozef J Van Dun

Zachary Ryan Murphree

Robert N Reib

The present disclosure provides a sintering assembly and a polycrystalline diamond compact (PDC) including a acid-labile leach-enhancing material, a PDC including cavities formed by removal of an acid-labile leach-enhancing material, and a method of forming a leached PDC using an acid-labile leach-enhancing material. The present disclosure further includes drill bits using PDCs formed suing an acid-labile leach-enhancing material.

Polycrystalline diamond compact with increased leaching surface area and method of leaching a polycrystalline diamond compact

Induced material segregation methods of manufacturing a polycrystalline diamond compact (PDC) cutter result in formation of a polycrystalline diamond/tungsten carbide (WC) composite material having a smooth compositional gradient from maximum WC concentration at one face to maximum diamond concentration at another face. Because the compositional gradient is smooth, very little or no mismatch of coefficient of thermal expansion occurs, which improves a service lifetime of the PDC cutter.

Induced material segregation methods of manufacturing a polycrystalline diamond tool

Chemical methods, optionally in combination with physical methods, may be used to increase the strength of the bond formed by a braze material between a polycrystalline material and a hard composite. Such polycrystalline materials brazed to hard composites may be found in various wellbore tools include drill bit cutters. An exemplary method may include forming a bonding layer on a bonding surface of a polycrystalline material body that comprises a hard material, the bonding surface opposing a contact surface of the polycrystalline material body, and the bonding layer substantially formed by a [111] crystal structure of the hard material, a [100] crystal structure of the hard material, or a combination thereof; and brazing the bonding layer to a hard composite using a braze material.

Chemically strengthened bond between thermally stable polycrystalline hard materials and braze material

The present disclosure relates to a polycrystalline diamond compact (PDC) including a gradient interfacial layer between a thermally stable diamond (TSP) table and a base, such as a substrate or an earth-boring drill bit body. The gradient interfacial layer has a gradient of coefficients of thermal expansion between that of the diamond and the base. The disclosure also relates to methods of forming a gradient interfacial layer and a PDC containing such a layer.

Polycrystalline diamond compact with gradient interfacial layer

A cutter for a drill bit and method of manufacturing same is disclosed. The cutter has a non-leached polycrystalline diamond (PCD) table bonded to a substrate and a leached PCD table bonded to one or both of the substrate and non-leached PCD table. The leached PCD table may be ring-shaped and acts as the working surface of the cutting element. It may have a jagged inner surface which cooperates with complementary jagged-shaped outer surface of the non-leached PCD table to prevent rotation of the leached PCD table relative to the non-leached PCD table during a cutting operation. A surface of the leached PCD table may be tapered and fit together in a complementary manner with an oppositely tapered surface of the non-leached PCD table so as to mechanically lock the leached PCD table to the non-leached PCD table.

Attachment of TSP diamond ring using brazing and mechanical locking

The present disclosure relates to a polycrystalline diamond compact (PDC) with a fiber-reinforces substrate. The disclosure further relates to method of forming such a PDC.

Polycrystalline diamond compact with fiber-reinforced substrate

In accordance with some embodiments of the present disclosure, systems and methods for determining the leaching profile of a cutter on a drilling tool are disclosed. The method includes applying an X-ray impermeable layer to a surface of a leached PCD element with residual infiltrant. The method also includes moving the element through an X-ray beam. The method further includes detecting an X-ray intensity received by an X-ray detector. The method further includes generating a leaching profile of the leached PCD element based on the X-ray intensity.

Determining the leaching profile of a cutter on a drilling tool

The present disclosure is directed to processes for producing ultrasonic sealable film structures and flexible containers with ultrasonic seals. The film structure includes a first multilayer film and a second multilayer film. Each multilayer film includes a backing layer and a seal layer. Each seal layer includes an ultrasonic sealable olefin-based polymer (USOP) having the following properties: (a) a heat of melting, &#x394;Hm, less than 130 J/g, (b) a peak melting temperature, Tm, less than 125&#xb0; C., (c) a storage modulus in shear (G') from 50 MPa to 500 MPa, and (d) a loss modulus in shear (G&#x2033;) greater than 10 MPa. The multilayer films are arranged such that the seal layer of the first multilayer film is in contact with the seal layer of the second multilayer film. The seal layers form an ultrasonic seal having a seal strength from 30 N/15 mm to 80 N/15 mm when ultrasonically sealed at 4 N/mm seal force.

Process for producing ultrasonic seal, and film structures and flexible containers with same

The microstructure of braze joints in polycrystalline diamond compact (PDC) cutters may be tailored to increase the shear strength of the braze joint, for example, by increasing the amount of a dispersed particulate microstructure therein. A method for forming a dispersed particulate microstructure may include brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 5&#xb0; C. above a solidus temperature of the braze alloy and 200&#xb0; C. above a liquidus temperature of the braze alloy; and forming a braze joint between the polycrystalline diamond table and the hard composite substrate that comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 &#x3bc;m to 2.0 &#x3bc;m and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

Braze joints with a dispersed particulate microstructure

An example polycrystalline diamond compact includes a substrate and a diamond table attached to the substrate. A multilayer joint interposes the substrate and the diamond table and comprises at least two component parts selected from the group consisting of a base layer, one or more intermediate layers, and a braze layer. The at least two component parts are formed via a thin film deposition process.

Polycrystalline diamond compacts and methods of manufacture

Catalyst extraction from polycrystalline diamond table may be achieved by treating with a halogen (in the gas phase or dissolved in a nonpolar organic solvent) to convert the catalyzing material to a salt. Then, polar organic solvents may optionally be used to leach the salt from the polycrystalline diamond table. The polycrystalline diamond (with the salt of the catalyzing material present or at least partially leached therefrom) may be brazed to a hard composite substrate to produce a cutter suitable for use in a matrix drill bit.

Catalyst material extraction from polycrystalline diamond tables

The instant invention provides a polyolefin composition suitable for sealant applications, sealant compositions, method of producing the same, and films and multilayer structures made therefrom. The polyolefin composition suitable for sealant applications according to the present invention comprises: an ethylene/&#x3b1;-olefin interpolymer composition having a Comonomer Distribution Constant (CDC) in the range of from 40 to 110, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the ethylene-based polymer composition; a zero shear viscosity ratio (ZSVR) in the range of from 1.01 to 2.0; a density in the range of from 0.908 to 0.922 g/cm, a melt index (Iat 190&#xb0; C./2.16 kg) in the range of from 0.5 to 5.0 g/10 minutes, a molecular weight distribution (defined as the weight average molecular weight divided by the number average molecular weight, M/M) in the range of from 2.0 to 4.0, and tan delta at 0.1 radian/second, determined at 190&#xb0; C., in the range of from 5 to 50.

Sealant composition

The instant invention is a sealant composition, method of producing the same, articles made therefrom, and method for forming such articles. The sealant composition according to the present invention comprises: (a) from 70 to 99.5 percent by weight of an ethylene/&#x3b1;-olefin interpolymer composition, based on the total weight of the sealant composition, wherein said ethylene/&#x3b1;-olefin interpolymer composition comprises an ethylene/&#x3b1;-olefin interpolymer, wherein ethylene/&#x3b1;-olefin interpolymer has a Comonomer Distribution Constant (CDC) in the range of from 15 to 250, and a density in the range of from 0.875 to 0.963 g/cm, a melt index (I2) in a range of from 0.2 to 20 g/10 minutes, and long chain branching frequency in the range of from 0.02 to 3 long chain branches (LCB) per 1000 C; (b) from 0.5 to 30 percent by weight of a propylene/&#x3b1;-olefin interpolymer composition, wherein said propylene/&#x3b1;-olefin interpolymer composition comprises a propylene/&#x3b1;-olefin copolymer or a propylene/ethylene/butene terpolymer, wherein said propylene/&#x3b1;-olefin copolymer has a crystallinity in the range of from 1 percent by weight to 30 percent by weight, a heat of fusion in the range of from 2 Joules/gram to 50 Joules/gram, and a DSC melting point in the range of 25&#xb0; C. to 110&#xb0; C.

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Conroe, TX, United States of America

Gagan Saini