Smith International, Inc.

Element Six Gmbh

Schlumberger Technology Corporation

General Electric Company

Xian Yao

Ghanshyam Rai

Scott L Horman

Matthew W Collier

Youhe Zhang

Madapusi K Keshavan

Yahua Bao

Michael George Azar

Xiaoge Gan

Yi Fang

John Daniel Belnap

Venkatesh Karuppiah

Lynn L Belnap

Qingyuan Liu

Cheng Peng

Anthony LeBaron

Brian G Bowers

Yuelin Shen

J Daniel Belnap

Feng Yu

Guodong Zhan

Manoj D Mahajan

David P DenBoer

Lan Carter

Manoj Mahajan

Scott Horman

A drilling tool having a body, at least one blade extending from the body, and a first cutting element attached to the at least one blade. The first cutting element includes a cutting face at an opposite axial end from a base, a side surface extending from the base to the cutting face, an edge formed at the intersection between the cutting face and the side surface, and an elongated protrusion formed at the cutting face and extending between opposite sides of the edge. The elongated protrusion has a geometry including a border extending around a concave surface, a face chamfer formed around the border, and sloped surfaces extending between the border and the edge. An edge chamfer is between the face chamfer and the edge.

Downhole cutting tool having cutting element with nonplanar face to improve cutting efficiency and durability

A cutting element has a cutting face at an opposite axial end from a base, a side surface extending from the base to the cutting face, an edge formed at the intersection between the cutting face and the side surface, and an elongated protrusion formed at the cutting face and extending between opposite sides of the edge, wherein the elongated protrusion has a geometry including a border extending around a concave surface and sloped surfaces extending between the border and the edge, and wherein the concave surface has a major axis dimension measured between opposite sides of the border and a minor axis dimension measured perpendicularly to the major axis dimension and ranging from 50 percent to 99 percent of the major axis dimension.

Cutting element with nonplanar face to improve cutting efficiency and durability

The present disclosure relates to the formation of polycrystalline diamond materials with fine diamond grains and nano-sized particles of a grain growth inhibitor. In one embodiment, a method of fabricating a polycrystalline diamond material is provided. The method includes providing a mixture of diamond particles with an average particle size of about 1 micron or less, distributing a plurality of nano-sized titanium-containing particles with the diamond mixture, to act as a grain growth inhibitor, and sintering the mixture of diamond particles and titanium-containing particles at high pressure and high temperature to create a polycrystalline structure of sintered diamond grains. The sintered diamond grains have an average size of about 1 micron or less.

Fabrication of ultrafine polycrystalline diamond with nano-sized grain growth inhibitor

The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.

EDM cuttable, high CBN content solid PCBN compact

EDM cuttable, high cBN content solid PCBN compact

A sintered body for cutting tools that includes hard particle phase comprising a plurality of hard particles, wherein at least a portion of the hard phase particles comprise a coating deposited by atomic layer deposition disposed thereon; and a binder phase is disclosed. The hard particles that may be included in the sintered bodies may include tungsten carbide, diamond, and boron nitride particles.

Atomic layer deposition nanocoatings on cutting tool powder materials

Gradient polycrystalline cubic boron nitride (PCBN) materials are provided as well as tools incorporating such materials.

Gradient polycrystalline cubic boron nitride materials and tools incorporating such materials

A method for forming an ultra hard material layer is provided. The method includes disposing a metallic liner inside the periphery of a refractory metal enclosure, introducing ultra hard material feed stock into the enclosure, and sintering using HPHT processing and cooling to form the ultra hard material layer, substantially free of peripheral cracking, chipping and fracturing.

Method for forming ultra hard sintered compacts using metallic peripheral structures in the sintering cell

The polycrystalline cubic baron nitride cutting tool has a particle size in the range of from 10-17 microns. In addition to CBN, the tool has from 2%-15% by weight of a refractory compound selected from the group consisting of titanium carbonitride, titanium aluminum carbonitride, titanium carbide, titanium nitride, titanium diboride and aluminum diboride. When using one of the carbonitrides, the carbon to nitrogen proportion is preferably in the range of from 30 atomic percent carbon and 70 atomic percent carbon to 70 atomic percent carbon and 30 atomic percent nitrogen, and preferably is about 50/50. In addition, there is an infiltrate containing aluminum and/or silicon. A quantity of diamond crystals more than stoichiometric with the amount of silicon infiltrated is included in the composition for forming silicon carbide. The cutting tool is not formed on a cemented tungsten carbide substrate so is substantially free of cobalt.

Polycrystalline cubic boron nitride cutting tool

The polycrystalline cubic boron nitride cutting tool has a particle size in the range of from 10-17 microns. In addition to CBN, the tool has from 2%-15% by weight of a refractory compound selected from the group consisting of titanium carbonitride, titanium aluminum carbonitride, titanium carbide, titanium nitride, titanium diboride and aluminum diboride. When using one of the carbonitrides, the carbon to nitrogen proportion is preferably in the range of from 30 atomic percent carbon and 70 atomic percent nitrogen to 70 atomic percent carbon and 30 atomic percent nitrogen, and preferably is about 50 atomic percent carbon and 50 atomic percent nitrogen. In addition, there is an infiltrant containing aluminum and/or silicon. The cutting tool is not formed on a cemented tungsten carbide substrate so is substantially free of cobalt.

A synthetic gasket material for use in a high-pressure press includes a major proportion of clay mineral powder having sufficient lubricity to flow in a high-pressure press, a minor proportion of at least one hard material powder having a sufficiently greater hardness than the clay mineral to retard flow of the clay mineral and form a seal during pressing in a high-pressure press, and a sufficient amount of binder to form an integral body. The synthetic gasket material is formed by thoroughly mixing together in desired proportions the clay mineral, hard material, and binder. The mixture is compacted into a body near net geometry and having a desired configuration to facilitate use in the high-pressure press. The compacted body is heated for a sufficient time and at a sufficient temperature to remove non-crystallographic water. A synthetic gasket material prepared according to principles of this invention displays improved flow, pressure transmitting, and thermal insulating properties when compared with gasket material made from natural pyrophyllite, due to the improved compositional consistency, i.e., lack of impurities and consistently low moisture content, of the synthetic gasket material.

Synthetic gasket materials for use in high-pressure presses

A polycrystalline cubic boron nitride cutting tool is from 50 to 85% by weight cubic boron nitride crystals bonded together as a polycrystalline mass. A supporting phase commingled with the polycrystalline cubic boron nitride is made from 15 to 40% by weight of a refractory material which is preferably titanium carbonitride or titanium aluminum carbonitride. The starting composition also comprises from 4 to 10% by weight of Co.sub.2 Al.sub.9. Mixed powders of these ingredients are treated in ammonia at a temperature in the range of from 1000.degree. to 1250.degree. C., which significantly increases the nitrogen content and reduces carbon content of titanium carbonitride. Instead of mixed powders of the starting materials, coated particles may be used such as cubic boron nitride coated with titanium carbonitride, or titanium carbonitride coated with cobalt, aluminum or cobalt aluminide. Hexagonal boron nitride may be substituted as a starting material for a portion of the cubic boron nitride.

Method of making a polycrystalline cubic boron nitride cutting tool

Polycrystallline cubic boron nitride cutting tool

A sintered polycrystalline compact of cubic boron nitride is made by first forming a mixture of about 30 to 60 percent by weight cubic boron nitride, up to about 50 percent by weight hexagonal boron nitride, and from about 2 to 7 percent by weight adjuvant materials, or sintering aids, comprising an aluminum containing material selected from the group consisting of aluminum, aluminum nitride, or aluminum diboride, and up to 50 percent by weight of nitride, carbide, or carbonitride binder material containing a group IVb, Vb, or VIb transition metal. The mixture of cBN crystals, hBN and other materials is compacted into a preform and subjected to heat treatment in a non-oxidizing atmosphere. The preform is placed onto a cemented tungsten-carbide/cobalt substrate and subjected to elevated pressure and temperature conditions at which cubic boron nitride is thermodynamically stable. The elevated pressure and temperature conditions are maintained for a time sufficient to permit the infiltration of the cobalt into the cBN matrix and sinter the compact. The compact is characterized by substantial intergranular cBN to cBN bonding, and has superior abrasive wear stability, chemical resistance, impact resistance and thermal conductivity.

Synthesis of polycrystalline cubic boron nitride

A sintered polycrystalline compact of cubic boron nitride is made by forming a mixture of about 45 to 65 percent by weight cubic boron nitride (cBN), from about 30 to 45 percent by weight hexagonal boron nitride (hBN), and from about 2 to 7 percent by weight an aluminum containing material, preferably aluminum nitride, and cobalt aluminide having a melting temperature lower than the melting temperature of cobalt phase. The mixture of cBN crystals, hBN and adjuvant materials is compacted into preforms and subjected to heat treatment in a non-oxidizing atmosphere. The preforms are placed onto a cemented tungsten carbide substrate containing cobalt and subjected to elevated pressure and temperature conditions at which the boron nitride is thermodynamically stable. The elevated pressure and temperature conditions are maintained for a time sufficient to permit the infiltration of a cobalt phase into the cBN matrix and sinter the compact. Typically, the cobalt phase is infiltrated from a tungsten carbide substrate cemented with cobalt phase. The compact is characterized by substantial intercrystalline cBN to cBN bonding, and has superior abrasive wear resistance, chemical resistance, impact resistance, thermal conductivity and stability. Further, the technique produces a sintered cBN compact that can be machined more efficiently by EDM.

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Sandy, UT, United States of America

Xian Yao