US Synthetic Corporation

Halliburton Energy Services, Inc.

Jiang Qian

Kenneth Eugene Bertagnolli

Michael Alexander Vail

Jason Keith Wiggins

Debkumar Mukhopadhyay

David Paul Miess

Shawn Casey Scott

Brandon Paul Linford

Kevin Duy Nguyen

Seth Garrett Anderle

Robert W Arfele

Brian Atkins

Ram L Ladi

Jim I Dewberry

Mark Pehrson Chapman

C Eugene McMurray

Daniel Call Mortensen

Trevor Allen Olsen

Arnold D Cooper

Joshua Adam Hawks

Stephen Rudger Adams

Amy Leigh Rodriguez

Lindsay Sue Patton

Casey Wade Swan

Matthew Kimball Baker

Anne-Grethe Slotnaes

Jason Lott

Craig Hodges Cooley

Jair Jahaziel Gonzalez

Michel Vail

Embodiments of the invention relate to polycrystalline diamond compacts ('PDC') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 μm or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Polycrystalline diamond, polycrystalline diamond compacts, methods of making same, and applications

Embodiments of the invention relate to polycrystalline diamond ('PCD') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm/grams (“G·cm/g”) or less. Other embodiments are directed to polycrystalline diamond compacts (“PDCs”) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Polycrystalline diamond compacts

In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.

Polycrystalline diamond compact

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 disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.

Cell assemblies and methods of using the same

Embodiments of the invention relate to polycrystalline diamond ('PCD') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds ('Oe') or more and a specific magnetic saturation of about 15 Gauss&#xb7;cm/grams ('G&#xb7;cm/g') or less. Other embodiments are directed to polycrystalline diamond compacts (&#x201c;PDCs&#x201d;) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Embodiments of the invention relate to polycrystalline diamond compacts ('PDC') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond ('PCD') table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 &#x3bc;m or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.

Carbonate-catalyzed polycrystalline diamond elements, methods of manufacturing the same, and applications therefor

Methods of fabricating a polycrystalline diamond compact

Embodiments of the invention relate to polycrystalline diamond ('PCD') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds ('Oe') or more and a specific magnetic saturation of about 15 Gauss&#xb7;cm/grams (&#x201c;G&#xb7;cm/g&#x201d;) or less. Other embodiments are directed to polycrystalline diamond compacts (&#x201c;PDCs&#x201d;) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Embodiments of the invention relate to polycrystalline diamond ('PCD') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads ('Oe') or more and a specific magnetic saturation of about 15 Gauss&#xb7;cm/grams (&#x201c;G&#xb7;cm/g&#x201d;) or less. Other embodiments are directed to polycrystalline diamond compacts (&#x201c;PDCs&#x201d;) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Growing community of inventors

Cedar Hills, UT, United States of America

Jiang Qian