Smith International, Inc.

General Electric Company

Sandvik Ab

Sandvik Aktiebolag

Rogers Tool Works, Inc.

Sandvik Intellectual Property Ab

Ghanshyam Rai

Madapusi K Keshavan

Zhigang Zak Fang

Xian Yao

J Albert Sue

Scott M Packer

Ronald B Crockett

Ronald K Eyre

David Truax

Peter Littecke

Nathan R Anderson

Matthew W Collier

Lan Carter

Sujian Huang

Gary Ray Portwood

Michael Allen Siracki

Chris Edward Cawthorne

Zhou Yong

Graham Mensa-Wilmot

Stefan S Ederyd

Stephen G Southland

Arturo A Rodriguez

Kuttaripalayam T Kembaiyan

Jimmy W Eason

Vonnie D Hood

In one embodiment, composite constructions of the invention are in the form of a plurality of coated fibers bundled together to produce a fibrous composite construction in the form of a rod. Each fiber has a core formed from a hard phase material, that is surrounded by a shell formed from a binder phase material. In another embodiment of the invention, monolithic sheets of the hard phase material and the binder phase material are stacked and arranged to produce a swirled composite in the form of a rod. In still another embodiment of the invention, sheets formed from coated fibers are arranged to produce a swirled composite. Inserts for use in such drilling applications as roller cone rock bits and percussion hammer bits, and shear cutters for use in such drilling applications as drag bits, that are manufactured using conventional methods from these composite constructions exhibit increased fracture toughness due to the continuous binder phase around the hard phase of the composites. These binder phases increase the overall fracture toughness of the composite by blunting or deflecting the tip of a propagating crack.

Composite constructions with oriented microstructure

Composite constructions of this invention comprise an ordered microstructure made up of multiple structural units that can be the same or different, and that comprise at least a first structural phase and a second structural phase. The first structural phase comprises a hard material that is selected from the group consisting of cermet materials, PCD, PCBN and mixtures thereof. The second structural phase is in contact with the first phase and comprises a material that is different than that selected to form the first structural phase. Additionally, the second structural phase is in contact with at least a portion of the first structural phase. Composite constructions of this invention can also have a multi-layer structures comprising two or more layers, wherein at least one of the layers comprises a composite construction having an ordered microstructure made up of the multiple structural units described above.

Composite constructions having ordered microstructures

Composite construction with oriented microstructure

This invention is directed to cutting elements having an ultra hard cutting layer such as polycrystalline diamond or polycrystalline cubic boron nitride bonded on a cemented carbide substrate. The interface between the substrate and the cutting layer of each such cutting element is non-planar. The non-planar interface is designed to enhance the operating life of the cutting element by reducing chipping, spalling, partial fracturing, cracking and/or exfoliation of the ultra hard cutting layer, and by reducing the risk of delamination of the cutting layer from the substrate.

Non-planar interfaces for cutting elements

A synthetic diamond cutter is disclosed for rock bits having a diamond cutting face at one end of a body supporting the cutting face. A heel portion is formed by the body near the diamond cutting face. The heel portion forms a groove depression or notch about adjacent to a cutting tip of the diamond cutting face. The cutting tip, as a result of the groove, results in a greater rate of penetration of the diamond cutting face due to a reduction of drag as the cutter works in an earthen formation or against a suitable workpiece.

Cutter assembly for rock bits with back support groove

A synthetic gasket material for use in a high-pressure press includes a major proportion of clay mineral powder having sufficient lubricity to flow in a high-pressure press, a minor proportion of at least one hard material powder having a sufficiently greater hardness than the clay mineral to retard flow of the clay mineral and form a seal during pressing in a high-pressure press, and a sufficient amount of binder to form an integral body. The synthetic gasket material is formed by thoroughly mixing together in desired proportions the clay mineral, hard material, and binder. The mixture is compacted into a body near net geometry and having a desired configuration to facilitate use in the high-pressure press. The compacted body is heated for a sufficient time and at a sufficient temperature to remove non-crystallographic water. A synthetic gasket material prepared according to principles of this invention displays improved flow, pressure transmitting, and thermal insulating properties when compared with gasket material made from natural pyrophyllite, due to the improved compositional consistency, i.e., lack of impurities and consistently low moisture content, of the synthetic gasket material.

Synthetic gasket materials for use in high-pressure presses

A polycrystalline diamond cutter having a coating of refractory material applied to the polycrystalline diamond surface increases the operational life of the cutter. The coating typically has a thickness in the range of from 0.1 to 30 .mu.m and may be made from titanium nitride, titanium carbide, titanium carbonitride, titanium aluminum carbonitride, titanium aluminum nitride, boron carbide, zirconium carbide, chromium carbide, chromium nitride, or any of the transition metals or Group IV metals combined with either silicon, aluminum, boron, carbon, nitrogen or oxygen. The coating can be applied using conventional plating or other physical or chemical deposition techniques.

Surface enhanced polycrystalline diamond composite cutters

A polycrystalline cubic boron nitride cutting tool is from 50 to 85% by weight cubic boron nitride crystals bonded together as a polycrystalline mass. A supporting phase commingled with the polycrystalline cubic boron nitride is made from 15 to 40% by weight of a refractory material which is preferably titanium carbonitride or titanium aluminum carbonitride. The starting composition also comprises from 4 to 10% by weight of Co.sub.2 Al.sub.9. Mixed powders of these ingredients are treated in ammonia at a temperature in the range of from 1000.degree. to 1250.degree. C., which significantly increases the nitrogen content and reduces carbon content of titanium carbonitride. Instead of mixed powders of the starting materials, coated particles may be used such as cubic boron nitride coated with titanium carbonitride, or titanium carbonitride coated with cobalt, aluminum or cobalt aluminide. Hexagonal boron nitride may be substituted as a starting material for a portion of the cubic boron nitride.

Method of making a polycrystalline cubic boron nitride cutting tool

A metal cutting insert comprises a carbide substrate, and at least one body of superhard abrasive material, such as PCD or PCBN, bonded to an edge surface of the substrate and extending from one side surface to the other side surface of the substrate. There can be a plurality of superhard bodies disposed at respective corners of the substrate. The abrasive material is applied to the substrate in a container and then sintered and simultaneously bonded to the substrate by an elevated pressure/temperature step. Inserts can be made in rod form (i.e., in one piece) and then the rod can be transversely sliced into thin inserts; or the inserts can be made in separate pieces, with or without separators within the container.

Methods of making metal cutting inserts having superhard abrasive bodies

An anvil for use in ultra high pressure presses capable of operating in the pressure ranges where diamonds, polycrystalline diamond composites and cubic boron nitride are stable, fabricated by diffusion bonding together a plurality of cemented tungsten carbide layers. The anvil has a working layer adjacent to the highest pressure of the press with the remaining plurality of layers behind the working layer for support. The working layer has a higher hardness than the supporting layers and the supporting layers each have higher toughness than the working layer.

Multi-layer anvil for ultra high pressure presses

A polycrystalline diamond layer is bonded to a cemented metal carbide substrate by this process. A layer of dense high shear compaction material including diamond or cubic boron nitride particles is placed adjacent to a metal carbide substrate. The particles of diamond have become rounded instead of angular due to high shear compaction in a multiple roller process. The volatiles in the high shear compaction material are removed and binder decomposed at high temperature, for example, 950.degree. C., leaving residual amorphous carbon or graphite in a layer of ultra hard material particles on the carbide substrate. The substrate and layer assembly is then subjected to a high pressure, high temperature process, thereby sintering the ultra hard particles to each other to form a polycrystalline ultra hard layer bonded to the metal carbide substrate. The layer of high shear compaction material is also characterized by a particle size distribution including larger and smaller particles that are distributed uniformly throughout the layer.

Method for forming a polycrystalline layer of ultra hard material

A cutting tool for woodworking applications has a tungsten carbide substrate and a hard layer bonded to the substrate at high temperature and high pressure, i.e. where diamond or cubic boron nitride is thermodynamically stable. The hard layer comprises polycrystalline diamond or polycrystalline cubic boron nitride, and a supporting cobalt phase including adjuvant alloying materials for providing oxidation and corrosion resistance. Typical alloying elements include nickel, aluminum, silicon, titanium, molybdenum and chromium. Such materials also retard transformation of cobalt from the HCP to the FCC crystal structure at high temperature. The hard layer has an as-pressed surface parallel to the substrate and is only about 0.3 millimeters thick. An additional secondary phase including a carbide, nitride and carbonitride of metals such as titanium may also be present in the PCD or PCBN layer.

PCD or PCBN cutting tools for woodworking applications

Metal cutting inserts having superhard abrasive bodies and methods of

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Ghanshyam Rai