Smith International, Inc.

Megastir Technologies LLC

Advanced Metal Products, Inc.

Sii Megadiamond, Inc.

Monte E Russell

Scott M Packer

Russell J Steel

Madapusi K Keshavan

Ronald K Eyre

Jonathan A Babb

Dah-Ben Liang

A method of forming one or more TSP compacts is provided. The method includes placing one or more TSP material layers in an enclosure and surrounding each TSP material layer with at least one of a pre-sintered tungsten carbide powder, pre-cemented tungsten carbide powder, tungsten carbide powder, or partially sintered tungsten carbide substrates. The method also includes exposing the enclosure to a high temperature high pressure process wherein the at least one of a pre-sintered tungsten carbide powder, pre-cemented tungsten carbide powder, tungsten carbide powder, or partially sintered tungsten carbide substrates bond to the TSP material layers forming a stack of TSP material layers including the TSP material layers one over the other with tungsten carbide bonded to each of the TSP material layers and encapsulating each of the TSP material layers.

Methods of making and attaching TSP material for forming cutting elements, cutting elements having such TSP material and bits incorporating such cutting elements

An ultra-hard construction is disclosed that is prepared by a method comprising the steps of treating a material microstructure having a polycrystalline matrix first phase material and a second phase material from at least a partial region of the material microstructure, wherein the second phase material is disposed within interstitial regions of the material microstructure, and wherein removal of the second phase material creates a porous material microstructure characterized by a plurality of empty voids and replacing the removed second phase material with a replacement material having a thermal characteristic that more closely matched polycrystalline matrix first phase that the second phase material.

Ultra-hard constructions with enhanced second phase

A mandrel that provides a counter-force to the pressure exerted on the outside of a pipe or other arcuate surface by a friction stir welding tool, wherein the mandrel is expandable through the use of a wedge, and wherein the mandrel enables multiple friction stir welding heads to simultaneously perform welding on the arcuate surface.

Expandable mandrel for use in friction stir welding

Ultra-hard constructions include an ultra-hard body having a first region including a polycrystalline matrix first phase and a second phase material interposed therein. The first region is substantially free of a catalyst material used to form the first phase. The body is formed by removing the catalyst material and then replacing it with the second phase material. A second region is disposed within the body and includes the polycrystalline matrix first phase and a catalyst material used to form the first phase. The second phase material has a thermal characteristic that is more closely matched to the matrix first phase than the catalyst material. The body may be joined to a substrate, and the ultra-hard body may consist entirely of the first region. The second phase material can include non-refractory metals, ceramics, silicon, silicon-containing compounds, diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof.

A drill bit has means at one end for connecting the bit to a drill string and a plurality of inserts at the other end for crushing the rock to be drilled. The inserts have a cemented tungsten carbide body partially embedded in the drill bit and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and particles of carbide or carbonitride of elements selected from the group consisting of W, Ti, Ta, Cr, Mo, Cb, V, Hf and Zr. The remaining layers adjacent the polycrystalline diamond layer are transition layers each comprising a composite containing diamond crystals, particles of tungsten carbide, and particles of titanium carbonitride. The average size of the diamond particles in the polycrystalline diamond layer is greater than the average size of the carbide or carbonitride particles; and the average size of the diamond particles in the transition layers is greater than the average sizes of the carbide and carbonitride particles. In particular, the transition layers contain particles of carbide and/or carbonitride with average grain sizes of less than one micrometer. The outermost layer of polycrystalline diamond extends along at least a portion of the length of the grip portion of the carbide body embedded in the drill bit.

Growing community of inventors

Orem, UT, United States of America

Monte E Russell