Baker Hughes Corporation

Baker Hughes Holdings LLC

Baker Hughes, a Ge Compnay, LLC

Baker Hughes Oilfield Operations LLC

Diamond Innovations. Inc.

Marc William Bird

Andrew Gledhill

Wanjun Cao

Andrew Robertson

Danny Eugene Scott

Anthony Albert DiGiovanni

John H Stevens

Wei A Chen

Alexanne Johnson

Nicholas J Lyons

Xu Huang

John A Bomidi

Valery Khabashesku

James Leslie Overstreet

Jack Thomas Oldham

Matthew Ray Isbell

Eric E McClain

Steven W Webb

Konrad Thomas Izbinski

John C Thomas

Timothy P Uno

Jayesh Jain

Curtis Proske

Jair Leal

Konrad T Izbinski

Paul Butler-Smith

Amir Rabani

Lester Dupre

Andy Oxford

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Methods of forming cutting elements

A sintered cemented carbide includes a high entropy carbide or a spinodal decomposed product thereof; and a metallic binder containing at least one of Co, Co—Ru, Ni, Co—Ni, Co—Cr, Co—Ni—Cr, Co—Re, Co—Ni—Re, Co—Ni—Ru, or a high entropy alloy, wherein the high entropy carbide is a single-phase solid solution carbide comprising four to ten metallic elements, and the spinodal decomposed product thereof includes two chemically distinct phases having a same crystal structure. A sintered cemented carbide also includes a carbide including at least one of WC, TiC, ZrC, HfC, NbC, TaC, or CrC; and a metallic binder including a high entropy alloy. The high entropy alloy is an alloy of four to ten alloy elements selected from Al, Be, Fe, Co, Cr, Ni, Cu, W, V, Zr, Ti, Mn, Hf, Nb, Mo, Ru, Re, Ge, Sn, C, B, or Si.

Cemented carbide containing multi-component high entropy carbide and/or multi-component high entropy alloy

Methods of making cutting elements for earth-boring tools may involve intermixing discrete particles of superabrasive material with a binder material in a solvent to form a slurry. The slurry may be vacuum dried or spray dried to disaggregate individual precursor agglomerates including a group of discrete particles suspended in a discrete quantity of the binder material from one another. The precursor agglomerates may be sintered while exposing the precursor agglomerates to a quantity of catalyst material to form agglomerates including discrete quantities of polycrystalline, superabrasive material while inhibiting formation of inter-granular bonds among the agglomerates themselves. The agglomerates may subsequently be sintered while exposing the agglomerates to another quantity of catalyst material to form a table for the cutting element including inter-granular bonds among adjacent grains of the agglomerates.

Techniques for forming polycrystalline, superabrasive materials, and related methods and cutting elements for earth-boring tools

A method of making a cutting element for use on an earth-boring tool may include forming the cutting element including a cutting table formed from a superabrasive polycrystalline material. The method may further include polishing a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table. The cutting element may include a superabrasive polycrystalline cutting table including a cutting surface substantially free of micro-anomalies in the superabrasive material.

Methods of making a cutting element for an earth-boring tool, methods of reprocessing cutting elements, and associated cutting elements

A cutting table for a cutting element, including: a diamond phase; a tungsten carbide phase; a cobalt-tungsten metallic phase; and an intermetallic phase comprising CoWC, where 0≤x≤1. Also disclosed is a method of manufacturing a cutting element, the method including: sintering diamond and tungsten carbide particles in the presence of Co and W to about 1520° C. or greater under pressure of about 57 kbar or greater to form a hard metal-diamond composite compact and solubilize carbon and tungsten within the compact; cooling the cutting element at about 1° C./sec or greater; and subsequent to cooling the cutting element, heat-treating the cutting element to precipitate carbon and tungsten in the compact as an intermetallic phase.

Precipitate-strengthened hard metal-diamond composite

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, AXZ, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Cutting elements, and related earth-boring tools, supporting substrates, and methods

Supporting substrates for cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Selectively leached thermally stable cutting element in earth-boring tools, earth-boring tools having selectively leached cutting elements, and related methods

Cutting elements for earth-boring tools may include a cutting edge located proximate to a periphery of the cutting element. The cutting edge may be positioned and configured to contact an earth formation during an earth-boring operation. The cutting edge may include a first portion having a first radius of curvature and a second portion having a second, larger radius of curvature. The second portion may be circumferentially offset from the first portion.

Cutting elements for earth-boring tools and related earth-boring tools and methods

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Methods of forming cutting elements and supporting substrates for cutting elements

Cutting elements, and related earth-boring tools and methods

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 &#x3bc;m) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 &#x3bc;m). During high pressure-high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Cutting elements, and related structures and earth-boring tools

Cutting elements and structures

Growing community of inventors

Houston, TX, United States of America

Marc William Bird