Sacrificial Catalyst Polycrystalline Diamond Element

a technology of polycrystalline diamond and catalyst, which is applied in the direction of cellulosic plastic layered products, instruments, other chemical processes, etc., can solve the problems of assembly being subjected to very high temperature and pressure, surface texture and geometry, and impose a limit on the maximum useful operating temperature of the element, etc., to achieve low contamination level of pcd working surface, aggressive cutting of formation, and optimized for wear and impact strength

US20110171414A1Inactive Publication Date: 2011-07-14NAT OILWELL VARCO LP
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Patent Information

Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
Publication Date
2011-07-14
Estimated Expiration
Not applicable · inactive patent

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Abstract

A superhard composite material comprising a polycrystalline diamond cutter (PDC) having a cutting surface and cutting edges having a polycrystalline diamond thickness of about 3 mm is integrally formed with a sacrificial catalyst source that is removed later in the processing of the of the cutter.
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Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] Disclosed herein are elements of superhard polycrystalline material synthesized in a high-temperature, high-pressure process and used for wear, cutting, drawing, and other applications. These elements have specifically placed superhard surfaces at locations where wear resistance is required. In particular, these elements are polycrystalline diamond and polycrystalline diamond-like (collectively called PCD) elements with tailored wear and impact resistance and methods of manufacturing them.

[0003] 2. Description of the Related Art

[0004] U.S. Pat. No. 4,534,773 discloses a method of producing an abrasive body of diamond particles in diamond-to-diamond bond with second phase of Ni and / or Si under condition of a High Temperature, High Pressure (HPHT) apparatus.

[0005] U.S. Pat. No. 6,861,098 discloses known methods for fabrication of PDC cutter, inserts and tools. Polycrystalline diamond and polycrystalline diamond-like elements...

Examples

Embodiment Construction

[0034]In the following description, it is understood that the composite described hereafter as formed of polycrystalline diamond, PCD, or sintered diamond as the material is often referred to in the industry, but can also be any of the super hard abrasive materials, including, but not limited to, synthetic or natural diamond, cubic boron nitride, and related materials.

[0035]Polycrystalline diamond cutters are well known and used as cutting elements in drilling bits used to form boreholes into the earth, and are primarily used for, but not limited to, drilling tools for exploration and production of hydrocarbon minerals from the earth.

[0036]For illustrative purposes only, a typical drilling operation is shown in FIG. 1. FIG. 1 shows in schematic form a representation of a drill string 2 suspended by a derrick 4 for drilling a borehole 6 into the earth for minerals exploration and recovery, and in particular petroleum. A bottom-hole assembly (BHA) 8 is located at the bottom of the bor...