Smith International, Inc.

National Oilwell Dht, L.p.

National Oilwell Varco, L.p.

Guodong Zhan

Youhe Zhang

Yuelin Shen

J Daniel Belnap

Feng Yu

Russell C Gilleylen

Michael D Hughes

Peter Thomas Cariveau

Georgiy Voronin

Michael Scott Nixon

Madapusi K Keshavan

Jiinjen Albert Sue

Harold Sreshta

Deepthi Raj Setlur

Mark Jonathan Francis

Michael S Nixon

Anil Kumar

Gregory Thomas Lockwood

James Robert Streater

Xian Yao

Xinhua Liang

Terry R Matthias

Sean Matthew Donald

Haresh Ghansyam

Xiayang Sheng

Walter Rothrock

Parul Walia Dhall

Biju Pillai Kumar

Adondria M Parker

Harry Pratt

Peter T Cariveau

A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Polycrystalline diamond cutting 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

A method of fabricating a PCD cutter element including a diamond table including a plurality of coated diamond particles fabricated using an atomic layer deposition (ALD) process.

Cutter elements for drill bits and methods for fabricating same

Polycrystalline diamond constructions comprises a diamond body attached to a metallic substrate, and having an engineered metal content. The body comprises bonded together diamond crystals with a metal material disposed interstitially between the crystals. A body working surface has metal content of 2 to 8 percent that increases moving away therefrom. A transition region between the body and substrate includes metal rich and metal depleted regions having controlled metal content that provides improved thermal expansion matching/reduced residual stress. A point in the body adjacent the metal rich zone has a metal content that is at least about 3 percent by weight greater than that at a body/substrate interface. The metal depleted zone metal content increases gradually moving from the body, and has a thickness greater than 1.25 mm. Metal depleted zone metal content changes less about 4 percent per millimeter moving along the substrate.

Polycrystalline diamond construction with controlled gradient metal content

A method for leaching a PCD table for a cutter element includes (a) positioning a PCD table within a leaching chamber. The method also includes (b) submerging the PCD table in an acid within the leaching chamber. In addition, the method includes (c) sealing the leaching chamber. Further, the method includes (d) increasing the pressure within the leaching chamber to a pressure greater than or equal to 20,000 psi after (c).

Apparatus and methods for high pressure leaching of polycrystalline diamond cutter elements

Systems and methods of forming components from CVD single crystal diamonds that can withstand high temperatures and pressures, for example, in a mining and/or drilling environment. This may be accomplished by transforming a graphite powder by hot-filament chemical vapor deposition (HFCVD) into a CVD single diamond crystal powder, growing a plurality of CVD single diamond crystals on a planar surface of a substrate or on a dowel. In one example, if a substrate is used as the growth surface, the plurality of CVD single crystals grow in at least one layer on the substrate and at least a portion of the plurality of CVD single diamond crystals are removed from the substrate in the form of a plurality of discrete intact sheets of CVD single diamond crystals, stacked in a mold, and sintered, for example, to form a CVD single crystal diamond table.

Fixed cutter drill bit cutter elements including hard cutting tables made from CVD synthetic diamonds

A method of making a polycrystalline diamond cutter element includes forming a blend, comprising a first particle size of polycrystalline diamond particles and a second particle size of polycrystalline diamond particles; forming a suspension of nanocrystalline diamond particles suspended in a solvent; and mixing the blend into the suspension to form a polycrystalline diamond mixture comprising nanocrystalline diamond coated polycrystalline diamond particles. The mixture is sintered with a substrate at high temperature and high pressure to form the polycrystalline diamond cutter element.

Preparation of nanocrystalline diamond coated diamond particles and applications thereof

A method is disclosed for leaching a polycrystalline diamond (PCD) cutter element. In an embodiment, the method includes suspending the PCD cutter element above a liquid acid bath. In addition, the method includes elevating the temperature of the liquid acid bath above ambient conditions to transition at least some of the liquid acid bath to acid vapors. Further, the method includes elevating the pressure of the acid vapors above ambient conditions. Still further, the method includes exposing the PCD cutter element to the acid vapors.

Systems and methods for vapor pressure leaching polycrystalline diamond cutter elements

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

The present invention relates to ultra-hard cutting elements, and in particular cutting elements or compacts formed by a pulsed electrical field assisted HPHT sintering process or a spark plasma HPHT sintering process. In an embodiment, a method of forming a polycrystalline ultra-hard material includes providing a mixture of ultra-hard particles, placing the mixture of ultra-hard particles into an enclosure, placing the enclosure into a press cell assembly having a heater, applying a repeated high-energy pulse of direct current to the heater to heat the ultra-hard particles, and pressing the enclosure at sufficient pressure to form a polycrystalline ultra-hard material.

Pulsed electrical field assisted or spark plasma sintered polycrystalline ultra hard material and thermally stable ultra hard material cutting elements and compacts and methods of forming the same

A hardfacing composition for a drill bit that includes an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy is disclosed. Drill bits having hardfacing compositions that include an abrasive phase comprising a plurality of abrasive particles having a barrier coating deposited by atomic layer deposition disposed thereon; and a binder alloy are also disclosed.

Barrier coated granules for improved hardfacing material using atomic layer deposition

Growing community of inventors

Spring, TX, United States of America

Guodong Zhan