US Synthetic Corporation

Mark Pehrson Chapman

David Paul Miess

Damon Bart Crockett

Jair Jahaziel Gonzalez

Daren Nathaniel Heaton

Jeremy Brett Lynn

Ronald W Ward

Nicholas Christensen

Oakley D Bond

Kenneth Eugene Bertagnolli

Debkumar Mukhopadhyay

Jason Keith Wiggins

Mohammad N Sani

Trent Neil Butcher

Michael James Gleason

Julie Ann Kidd

Matthew Brown

Trevor Allen Olsen

Joshua Adam Hawks

Ryan LeRoy Woodland

Michael Alexander Vail

Jiang Qian

Arnold D Cooper

Jason Dean Blackburn

Stephen Rudger Adams

Amy Leigh Rodriguez

Daniel Marin Scott

Steven L Choate

D Bart Crockett

Jeffery A Gerber

Craig Hodges Cooley

S Barrett Peterson

Paul Douglas Jones

Brent R Eddy

Alberto Castillo

Giovani J Gongora

Roger Vale

Benjamin Michael Spencer

Jedediah Jess Campbell

A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table.

Leached superabrasive elements and systems, methods and assemblies for processing superabrasive materials

A method of processing a polycrystalline diamond material includes exposing at least a portion of a polycrystalline diamond material to a processing solution, the polycrystalline diamond material including a metallic material disposed in interstitial spaces defined within the polycrystalline diamond material. The method includes exposing an electrode to the processing solution, applying a positive charge to the polycrystalline diamond material, and applying a negative charge to the electrode. An assembly for processing a polycrystalline diamond body includes a polycrystalline diamond body and an electrode that are in electrical communication with a volume of processing solution, and a power source configured to apply a positive charge to the polycrystalline diamond body and a negative charge to the electrode.

Leached polycrystalline diamond elements

Methods of laser cutting polycrystalline diamond tables and polycrystalline diamond compacts are disclosed. Laser cutting of the polycrystalline diamond table provides an alternative to electrical-discharge machining ('EDM'), grinding with a diamond wheel, or lapping with a diamond wheel. Grinding or lapping with a diamond wheel is relatively slow and expensive, as diamond is used to remove a diamond material. EDM cutting of the polycrystalline diamond table is sometimes impractical or even impossible, particularly when the cobalt or other infiltrant or catalyst concentration within the polycrystalline diamond table is very low (e.g., in the case of a leached polycrystalline diamond table). As such, laser cutting provides a valuable alternative machining method that may be employed in various processes such as laser scribing, laser ablation, and laser lapping.

Method for laser cutting polycrystalline diamond structures

Method of processing a polycrystalline diamond element may include laser ablating at least a portion of a polycrystalline diamond element to form a laser-shaped surface and exposing at least a portion of the laser-shaped surface to a leaching solution to define a leached polycrystalline diamond volume and an unleached polycrystalline diamond volume.

Leached diamond elements and leaching systems, methods and assemblies for processing diamond elements

Superabrasive elements may be produced by method includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The polycrystalline diamond table includes a superabrasive face and a superabrasive side surface extending around an outer periphery of the superabrasive face. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table by (1) exposing at least a portion of the polycrystalline diamond table to a processing solution, (2) exposing an electrode to the processing solution, and (3) applying a charge to the electrode.

In one or more embodiments, a method includes selecting a cemented carbide substrate from a plurality of cemented carbide substrates in a substrate inventory. Each of the plurality of cemented carbide substrates have a substantially planar top surface. The method also includes emitting a plurality of laser pulses from a laser towards at least the substantially planar top surface of the cemented carbide substrate to ablate selected regions of the cemented carbide substrate thereby forming the cemented carbide substrate into a selected shape.

Methods to shape a cemented carbide substrate using a laser

A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The polycrystalline diamond table includes a superabrasive face and a superabrasive side surface extending around an outer periphery of the superabrasive face. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table by (1) exposing at least a portion of the polycrystalline diamond table to a processing solution, (2) exposing an electrode to the processing solution, and (3) applying a charge to the electrode such that a voltage is generated between the polycrystalline diamond table and the electrode and the voltage is applied to the processing solution. The method includes the use of an improved processing solution, including an organic acid and a divalent (e.g., Group II) metal salt, to increase the leaching depth.

Group II metal salts in electrolytic leaching of superabrasive materials

A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond element that was exposed to the leaching solution from the polycrystalline diamond element.

Leached superabrasive elements and leaching systems, methods and assemblies for processing superabrasive elements

A method of processing a polycrystalline diamond body includes positioning an electrode near the polycrystalline diamond body such that a gap is defined between the electrode and the polycrystalline diamond body, the polycrystalline diamond body having a metallic material disposed in interstitial spaces defined within the polycrystalline diamond body. The method includes applying a voltage between the electrode and the polycrystalline diamond body, and passing a processing solution through the gap. The electrode is a cathode and the polycrystalline diamond body is an anode. An assembly for processing a polycrystalline diamond body includes the polycrystalline diamond body, an electrode positioned such that a gap is defined between the electrode and the polycrystalline diamond body, a processing solution passing through the gap such that the processing solution is in electrical communication with each of the polycrystalline diamond body and the electrode, and at least one power source.

Embodiments of the invention relate to liquid metal embrittlement ('LME')-resistant superabrasive compacts, methods of making the same, and drill bits incorporating the same. The LME-resistant superabrasive compacts include a braze-resistant region on one or more portions of a substrate expected to be under residual tensile stress and susceptible to LME during brazing.

Methods of forming a liquid metal embrittlement resistant superabrasive compact, and superabrasive compacts and apparatuses using the same

A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The polycrystalline diamond table includes a superabrasive face and a superabrasive side surface extending around an outer periphery of the superabrasive face. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table by (1) exposing at least a portion of the polycrystalline diamond table to a processing solution, (2) exposing an electrode to the processing solution, and (3) applying a charge to the electrode such that a voltage is generated between the polycrystalline diamond table and the electrode and the voltage is applied to the processing solution.

Methods for laser cutting a polycrystalline diamond structure

A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond material that was exposed to the leaching solution from the polycrystalline diamond element.

Leached superabrasive elements and leaching systems methods and assemblies for processing superabrasive elements

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.

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Provo, UT, United States of America

Mark Pehrson Chapman