US Synthetic Corporation

Halliburton Energy Services, Inc.

Other

Kenneth Eugene Bertagnolli

Debkumar Mukhopadhyay

Michael Alexander Vail

Jason Keith Wiggins

Jiang Qian

David Paul Miess

Paul Douglas Jones

Shawn Casey Scott

Jair Jahaziel Gonzalez

Cody William Knuteson

Brandon Paul Linford

Craig Hodges Cooley

C Eugene McMurray

Kevin Duy Nguyen

Damon Bart Crockett

Arnold D Cooper

Mohammad N Sani

Mark Pehrson Chapman

Scott M Schmidt

Stephen Rudger Adams

Seth Garrett Anderle

Robert W Arfele

Ronald W Ward

Ram L Ladi

Nicholas Christensen

Brian Atkins

Brent R Eddy

Jim I Dewberry

Kenneth M Jensen

Daniel Call Mortensen

Trevor Allen Olsen

Joshua Adam Hawks

Amy Leigh Rodriguez

Lindsay Sue Patton

Casey Wade Swan

Matthew Kimball Baker

Anne-Grethe Slotnaes

Jason Lott

S Barrett Peterson

Reinhold Ludwig

Julie Ann Kidd

Gene Bogdanov

Damon B Crocket

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 of the invention relate to polycrystalline diamond compact ('PDC') including a polycrystalline diamond ('PCD') table that bonded to a cobalt-nickel alloy cemented carbide substrate. The cobalt-nickel alloy cemented carbide substrate provides both erosion resistance and corrosion resistance to the cemented carbide substrate. In an embodiment, a PDC includes a cemented carbide substrate including cobalt-nickel alloy cementing constituent. The PDC further includes a PCD table bonded to the cemented carbide substrate.

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

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond ('PCD') table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

Polycrystalline diamond compact, and related methods and applications

Embodiments of methods are disclosed for characterizing a tested superabrasive element, such as a polycrystalline diamond element. In an embodiment, a method of characterizing the relative strength of a superabrasive element is disclosed. A first superabrasive element and a second superabrasive element are positioned upper surface to upper surface, including an area of overlap between the upper surfaces. A load is applied while the first and second superabrasive elements are overlapped until failure of one or both of the first or second superabrasive elements fail. A relative strength is determined using at least the load during failure as a parameter.

Methods for evaluating superabrasive elements

Embodiments relate to polycrystalline diamond compacts ('PDCs') including a polycrystalline diamond ('PCD') table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.

Methods of fabricating a polycrystalline diamond compact

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.

Growing community of inventors

Riverton, UT, United States of America

Kenneth Eugene Bertagnolli