Polycrystalline diamond compact processing method and application

Abstract

The invention relates to the technical field of superhard materials, and particularly discloses a treatment method and application of a polycrystalline diamond compact. The treatment method of the polycrystalline diamond compact comprises the following steps: placing the polycrystalline diamond compact in a chemical medium for first treatment, and then placing the polycrystalline diamond compact in a physical medium for second treatment; or placing the polycrystalline diamond compact in a mixed medium for third treatment, wherein the mixed medium comprises a chemical medium and a physical medium; the chemical medium reacts with impurities on the surface of the polycrystalline diamond compact to convert the impurities into gas or metal salt dissolved in the chemical medium, and the physical medium collides with the polycrystalline diamond compact under the action of external force in the second treatment process and the third treatment process. Through the combination of the two treatment modes, a pure and uniform roughening layer is formed on the surface of the polycrystalline diamond compact, the welding performance of the polycrystalline diamond compact is improved, the binding force between the polycrystalline diamond compact and the drill bit is enhanced, and the service life of the polycrystalline diamond compact drill bit is prolonged.

Description

Technical Field

[0001] The present application relates to the technical field of superhard materials, and in particular to a polycrystalline diamond composite sheet processing method and application. Background Art

[0002] Polycrystalline Diamond Compacts (PDC) are superhard composite materials composed of polycrystalline diamond layers and cemented carbide layers. Due to its extremely high wear resistance of diamond polycrystalline layers and the impact toughness of cemented carbide, it is widely used in geology and oil drilling. In practical applications, in most cases, polycrystalline diamond composites will be used as part of the drill bit, and will be subjected to corresponding grinding loss or impact loss as the drill bit performs drilling work as a whole. During the operation of the drill bit, in addition to the failure of the polycrystalline diamond composite itself, another failure situation often occurs, that is, the polycrystalline diamond composite is separated from the drill bit as a whole, forming the so-called tooth loss. For this kind of failure, there has been long-term research within the industry. This phenomenon is related to the drilling path of the drill bit, the position of the composite sheet, the stress condition of the composite sheet, the rock formation condition, etc. Among them, the bonding force between the polycrystalline diamond composite sheet and the drill bit is also one of the reasons for the tooth loss.

[0003] At present, in most application scenarios, polycrystalline diamond composite sheets are generally welded directly to the corresponding position of the drill bit after being manufactured. During the drilling process, cracks at the weld grow and spread, causing the entire weld surface to crack and the composite sheet to separate from the tooth hole, which has a bad impact on the working process of the drill bit and reduces the performance and life of the polycrystalline diamond sheet drill bit. Therefore, the existing technology needs to be improved. Summary of the invention

[0004] In view of the above-mentioned deficiencies in the prior art, the purpose of the present application is to provide a polycrystalline diamond composite sheet processing method and application, aiming to solve the problem of insufficient bonding force between the existing polycrystalline diamond composite sheet and the drill bit, resulting in reduced performance and life of the polycrystalline diamond composite sheet drill bit.

[0005] The technical solution of this application is as follows:

[0006] In a first aspect of the present application, a method for processing a polycrystalline diamond compact is provided, comprising the steps of:

[0007] (a) placing the polycrystalline diamond compact in a chemical medium for a first treatment, and then placing it in a physical medium for a second treatment; or (b) placing the polycrystalline diamond compact in a mixed medium for a third treatment, the mixed medium comprising a chemical medium and a physical medium; wherein the chemical medium reacts with impurities on the surface of the polycrystalline diamond compact to convert the impurities into gas or metal salts dissolved in the chemical medium, and the physical medium collides with the polycrystalline diamond compact during the second treatment and the third treatment.

[0008] Preferably, the chemical medium includes a first solvent and a first solute; the first solvent includes one or more of water, ethanol, glycerol, acetone, and isopropanol; the first solute includes one or more of HCl, H2SO4, HNO3, H3PO4, HF, NaCl, KCl, NaNO3, and KNO3.

[0009] Preferably, the concentration of the first solute in the chemical medium is 0.02-0.2 g / mL.

[0010] Preferably, the pH value of the chemical medium is 1-6.5.

[0011] Preferably, the physical medium includes a second solvent and a second solute; the second solvent includes one or more of water, ethanol, glycerol, acetone, and isopropanol; the second solute includes one or more of silicon dioxide particles, silicon carbide particles, diamond particles, ceramic sand particles, and carbide particles.

[0012] Preferably, the mass percentage of the second solute in the physical medium is 30-90%.

[0013] Preferably, the average particle size of the second solute is 0.4-1.5 mm.

[0014] Preferably, the temperature of the first treatment is 10-100°C, and the time is 20-200h; the temperature of the second treatment is 10-100°C, and the time is 20-200h; the temperature of the third treatment is 10-100°C, and the time is 20-200h.

[0015] Preferably, during the second treatment and the third treatment, the physical medium collides with the polycrystalline diamond compact under the action of an external force, and the external force includes at least one of oscillation, rotation and stirring.

[0016] A second aspect of the present application provides an application of a polycrystalline diamond compact obtained by the method for processing a polycrystalline diamond compact according to the first aspect of the present application in preparing a polycrystalline diamond compact drill bit.

[0017] Beneficial effects of this application:

[0018] The present application immerses the polycrystalline diamond composite sheet in a chemical medium, so that impurities existing in oxide, carbide, and alloy phases can be converted into gases, metal salts, etc., so that the impurities are separated from the surface of the polycrystalline diamond composite sheet, and a relatively pure surface phase state is obtained; the polycrystalline diamond composite sheet treated with the chemical medium is placed in a physical medium and the polycrystalline diamond composite sheet and the physical medium are caused to form a periodic motion collision through an external force, so that the residues of impurity elements attached to the polycrystalline diamond composite sheet after the chemical medium treatment can be removed, and a uniform roughening layer is formed on the surface of the polycrystalline diamond composite sheet, thereby improving the welding performance of the polycrystalline diamond composite sheet, and then enhancing the bonding force between the polycrystalline diamond composite sheet and the drill bit, and extending the service life of the polycrystalline diamond composite sheet drill bit. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for describing the embodiments are briefly introduced below.

[0020] Figure 1 Schematic diagram of the cross-sectional structure of a polycrystalline diamond composite sheet;

[0021] Figure 2 This is a microscopic observation of the surface state of the polycrystalline diamond compact after being treated in Example 1 of the present application;

[0022] Figure 3 This is a microscopic observation of the surface state of the polycrystalline diamond compact after being treated in Example 2 of the present application;

[0023] Figure 4 This is a microscopic observation of the surface state of the polycrystalline diamond compact after being treated in Example 3 of the present application;

[0024] Figure 5 This is a microscopic observation of the surface state of an untreated polycrystalline diamond composite sheet. DETAILED DESCRIPTION

[0025] In order to make the purpose, technical solutions and advantages of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below in combination with the drawings and embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the protection scope of the present application. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0026] It should be noted that if there are descriptions involving "first", "second", etc. in the implementation of this application, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance and implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the fact that ordinary technicians in the field can implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0027] See also Figure 1 The polycrystalline diamond composite sheet usually includes a polycrystalline diamond layer and a cemented carbide layer. During the preparation of the polycrystalline diamond composite sheet, there is a certain probability of introducing impurity elements when the cemented carbide layer and the polycrystalline diamond layer are synthesized. The impurity elements include Co, Fe, Cr, C and O, etc., which exist in the form of oxides, carbides, alloy phases, etc. After the polycrystalline diamond composite sheet is welded to the drill bit, the impurities attached to the polycrystalline diamond composite sheet will cause cracks to grow and spread at the weld, causing the entire weld surface to crack, causing the polycrystalline diamond composite sheet to detach from the tooth hole position, which has a bad impact on the working process of the drill bit and reduces the performance and service life of the polycrystalline diamond composite drill bit.

[0028] Based on this, the embodiment of the present application provides a method for processing a polycrystalline diamond compact, comprising the steps of:

[0029] (a) placing the polycrystalline diamond compact in a chemical medium for a first treatment, and then placing it in a physical medium for a second treatment to obtain a treated polycrystalline diamond compact; or

[0030] (b) placing the polycrystalline diamond compact in a mixed medium for a third treatment to obtain a treated polycrystalline diamond compact, wherein the mixed medium includes a physical medium and a chemical medium.

[0031] The chemical medium reacts with impurities on the surface of the polycrystalline diamond composite sheet to convert the impurities into gas or metal salt dissolved in the chemical medium. During the second and third treatments, the physical medium collides with the polycrystalline diamond composite sheet under the action of external force, and the collision mode includes but is not limited to periodic collision.

[0032] By immersing the polycrystalline diamond composite sheet in a chemical medium, impurities in the form of oxides, carbides, and alloy phases can be converted into gases, metal salts dissolved in the chemical medium, etc., so that the impurities are separated from the surface of the polycrystalline diamond composite sheet and a relatively pure surface phase state is obtained. This avoids the accumulation of impurities to form metal particles, bubbles, etc. during the welding process, which reduce the strength, toughness and corrosion resistance of the weld and reduce the risk of product cracking and deformation.

[0033] Placing the polycrystalline diamond composite sheet in a physical medium and using external force to make the polycrystalline diamond composite sheet and the physical medium form a periodic motion collision can remove the residual impurity elements after the chemical medium treatment and obtain a uniform surface roughening layer. The formation of the roughening layer can make the polycrystalline diamond composite sheet have a larger specific surface area, thereby increasing the effective bearing area of ​​the weld of the polycrystalline diamond composite sheet during welding, thereby improving the overall strength and stability of the welded structure. At the same time, during the welding process, the larger contact area can transfer heat faster, promote the melting of the electrode or wire, thereby speeding up the welding speed and improving the welding efficiency.

[0034] In some embodiments, the external force includes at least one of shaking, rotating, and stirring.

[0035] Through the treatment of chemical and physical media, a pure and uniform roughening layer is formed on the surface of the polycrystalline diamond composite sheet (the surface of the cemented carbide layer of the polycrystalline diamond composite sheet), thereby improving the welding performance of the polycrystalline diamond composite sheet, thereby improving the bonding force between the polycrystalline diamond composite sheet and the drill bit, and extending the service life of the polycrystalline diamond composite sheet drill bit.

[0036] In some embodiments, the chemical medium includes a first solvent and a first solute, wherein the first solvent includes one or more of water, ethanol, glycerol, acetone, and isopropanol. The first solute includes one or more of HCl, H2SO4, HNO3, H3PO4, HF, NaCl, KCl, NaNO3, and KNO3. Preferably, the first solute is a mixture of HCl and KCl or a mixture of HNO3 and KNO3.

[0037] In some embodiments, the concentration of the first solute in the chemical medium is 0.02-0.2 g / mL. For example, the concentration of the first solute in the chemical medium is 0.02 g / mL, 0.05 g / mL, 0.08 g / mL, 0.1 g / mL, 0.12 g / mL, 0.15 g / mL, 0.18 g / mL or 0.2 g / mL, etc.

[0038] In some embodiments, the pH value of the chemical medium is 1-6.5 to provide a stable acidic environment for the reaction. For example, the pH value of the chemical medium is 1, 2, 3, 4, 5, 6 or 6.5, etc.

[0039] In some embodiments, the physical medium includes a second solvent and a second solute, the second solvent includes one or more of water, ethanol, glycerol, acetone, and isopropyl ketone, and the second solute includes one or more of silica particles, silicon carbide particles, diamond particles, ceramic sand particles, and carbide particles.

[0040] In some embodiments, the mass percentage of the second solute in the physical medium is 30-90%, for example, the mass percentage of the second solute in the physical medium is 30%, 40%, 50%, 55%, 60%, 70%, 80%, 85% or 90%, etc.

[0041] In some embodiments, the average particle size of the second solute is 0.4-1.5 mm, for example, the average particle size of the second solute is 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm or 1.5 mm, etc. When placed in a physical medium for the second treatment or placed in a mixed medium for the third treatment, if the particle size of the second solute in the physical medium is too small, the effect of removing residual impurities on the polycrystalline diamond compact is not obvious, and if the particle size of the second solute in the physical medium is too large, the second solute in the physical medium may collide with the polycrystalline diamond compact and generate cracks.

[0042] In some embodiments, the time of the first treatment is 20-100 hours, for example, the time of the first treatment is 20 hours, 30 hours, 40 hours, 50 hours, 60 hours, 70 hours, 80 hours, 90 hours or 100 hours, etc. The time of the second treatment is 20-100 hours, for example, the time of the second treatment is 20 hours, 30 hours, 40 hours, 50 hours, 60 hours, 70 hours, 80 hours, 90 hours or 100 hours, etc. The time of the third treatment is 20-100 hours, for example, the time of the third treatment is 20 hours, 30 hours, 40 hours, 50 hours, 60 hours, 70 hours, 80 hours, 90 hours or 100 hours, etc. The time of the first treatment, the time of the second treatment and the time of the third treatment may be the same or different. Specifically, when the polycrystalline diamond composite sheet is first placed in a chemical medium for treatment and then placed in a physical medium for treatment, the time for the first treatment in the chemical medium is 20-100 hours, and the time for the second treatment in the physical medium is 20-100 hours, that is, the total time for treating the polycrystalline diamond composite sheet using scheme (a) is 20-200 hours. When the physical medium and the chemical medium are mixed to obtain a mixed medium, and the polycrystalline diamond composite sheet is placed in the mixed medium for treatment, that is, when the treatment is carried out using scheme (b), the total time for treating the polycrystalline diamond composite sheet can be 20-100 hours.

[0043] In some embodiments, the temperature of the first treatment is 10-100°C, for example, the temperature of the first treatment is 10°C, 20°C, 30°C, 40°C, 50°C, 60°C, 70°C, 80°C, 90°C or 100°C, etc. The temperature of the second treatment is 10-100°C, for example, the temperature of the second treatment is 10°C, 20°C, 30°C, 40°C, 50°C, 60°C, 70°C, 80°C, 90°C or 100°C, etc. The temperature of the third treatment is 10-100°C, for example, the temperature of the third treatment is 10°C, 20°C, 30°C, 40°C, 50°C, 60°C, 70°C, 80°C, 90°C or 100°C, etc. The temperature of the first treatment, the temperature of the second treatment and the temperature of the third treatment may be the same or different.

[0044] In some embodiments, the processing method of the polycrystalline diamond composite sheet of the embodiment of the present application is to process the polycrystalline diamond composite sheet and the physical medium, chemical medium or mixed medium in a processing device, and the processing device generally includes a container, a motor and a power supply. The container is used to hold the polycrystalline diamond composite sheet and the chemical medium or physical medium or mixed medium used, and the power supply is electrically connected to the motor. The motor can cause the container to oscillate or rotate, or drive the stirring member in the container to rotate. When the container is filled with a physical medium or a mixed medium, turn on the power supply, and the container oscillates or rotates under the drive of the motor, or the motor drives the stirring member in the container to rotate. The polycrystalline diamond composite sheet in the container collides with the physical medium or the mixed medium (the solute) by oscillating or rotating the container, or the rotation of the stirring member in the container. The motor is an oscillating motor, a rotating motor or other motors of any form that cause the polycrystalline diamond composite sheet in the container to collide with the physical medium or the mixed medium (the solute). The container is a non-breakable closed container, and its shape can be a common barrel type, a bowl type, etc., and its capacity is determined as needed. The container has a certain degree of airtightness to ensure that the material in the container does not overflow. In some embodiments, the processing device can be an existing oscillator that can hold a certain volume of liquid.

[0045] In some embodiments, the method for treating a polycrystalline diamond compact further comprises the steps of: washing and drying the polycrystalline diamond compact after the first treatment, the second treatment, or the third treatment. The surface residue of the polycrystalline diamond compact is removed by washing, and the excess water is removed by drying, so that the treated polycrystalline diamond compact can be directly used for welding.

[0046] The embodiment of the present application also provides an application of a polycrystalline diamond composite sheet obtained by the processing method of the polycrystalline diamond composite sheet as described above in the embodiment of the present application in the preparation of a polycrystalline diamond composite sheet drill bit, specifically, welding the processed polycrystalline diamond composite sheet to a drill bit to obtain a polycrystalline diamond composite sheet drill bit. By the processing method of the polycrystalline diamond composite sheet as described above in the embodiment of the present application, a pure and uniform roughening layer can be formed on the surface of the polycrystalline diamond composite sheet. When the polycrystalline diamond composite sheet is welded to the drill bit, the overall strength and stability of the welding structure are improved, the bonding force between the polycrystalline diamond composite sheet and the drill bit is enhanced, and the service life of the polycrystalline diamond composite sheet drill bit is thereby improved.

[0047] The following will provide further explanation through specific examples.

[0048] Example 1

[0049] Add an appropriate amount of HF to 1000 mL of water and mix well to obtain a chemical medium. The pH value of the chemical medium is controlled to be 2.0.

[0050] 400 g of ceramic sand silicon particles were added to the chemical medium and mixed evenly to obtain a mixed medium, wherein the ceramic sand particles had an average particle size of 1 mm and a mass percentage of 40%.

[0051] The polycrystalline diamond compact to be treated and the mixed medium are placed in an oscillator, the oscillator is started, and the third treatment is performed for 30 hours at 20° C. After the treatment, the polycrystalline diamond compact is taken out, cleaned, and dried to obtain the treated polycrystalline diamond compact.

[0052] Example 2

[0053] Add an appropriate amount of HNO3 and 100g of KNO3 to 1000mL of water, mix well, and obtain a chemical medium. The pH value of the chemical medium is controlled to be 3.0, and the concentration of KNO3 in the chemical medium is 0.1g / mL.

[0054] 474 g of diamond silicon particles were added to 1000 mL of ethanol and mixed evenly to obtain a physical medium, wherein the average particle size of the diamond silicon particles was 0.5 mm and the mass percentage was 60%.

[0055] The polycrystalline diamond composite sheet to be treated and the chemical medium are placed in an oscillator, the oscillator is started, and the first treatment (standing) is performed at 20° C. for 30 hours. After the first treatment, the polycrystalline diamond composite sheet is taken out, cleaned, and dried to obtain a chemically treated polycrystalline diamond composite sheet.

[0056] The chemically treated polycrystalline diamond composite sheet and the physical medium are placed in a cleaned oscillator, the oscillator is started, and a second treatment is performed at 20° C. for 60 hours. After the treatment, the polycrystalline diamond composite sheet is taken out, cleaned, and dried to obtain a treated polycrystalline diamond composite sheet.

[0057] Example 3

[0058] An appropriate amount of HCl, 50 g of KCl and 900 g of silicon carbide particles are added to 1000 mL of ethanol and mixed evenly to obtain a chemical medium. The pH value of the chemical medium is controlled to be 4.0, and the concentration of KCl in the chemical medium is 0.05 g / mL. The average particle size of the silicon carbide particles is 0.8 mm, and the mass percentage is 90%.

[0059] The polycrystalline diamond compact to be treated and the mixed medium are placed in an oscillator, the oscillator is started, and the third treatment is performed for 100 hours at 20° C. After the treatment, the polycrystalline diamond compact is taken out, cleaned, and dried to obtain the treated polycrystalline diamond compact.

[0060] The treated polycrystalline diamond compacts prepared in Examples 1-3 and the untreated polycrystalline diamond compacts were observed using an optical microscope. The photographed points are Figure 1 The results of optical microscopy observation are shown in Figure 2. Figure 2-5 As shown, Figure 2 The polycrystalline diamond composite sheet after the treatment in Example 1, Figure 3 This is the polycrystalline diamond composite sheet after being processed in Example 2, Figure 4 This is the polycrystalline diamond composite sheet after being processed in Example 3, Figure 5 It is an untreated polycrystalline diamond composite sheet. Figure 2-5 It can be seen that a pure and uniform roughening layer is formed on the cemented carbide layer of the polycrystalline diamond composite sheet after treatment in Examples 1-3, which improves the uniformity and specific surface area of ​​the surface to be welded, increases the effective bearing area of ​​the weld of the polycrystalline diamond composite sheet during welding, thereby improving the welding performance of the cemented carbide substrate, enhancing the bonding force between the polycrystalline diamond composite sheet and the drill bit, and extending the service life of the polycrystalline diamond composite sheet drill bit.

[0061] In summary, the present invention provides a polycrystalline diamond composite sheet and a processing method thereof, wherein the polycrystalline diamond composite sheet is placed in a chemical medium to remove impurity element compounds on its surface through chemical reaction to obtain a relatively pure surface phase state; the polycrystalline diamond composite sheet is placed in a physical medium to cause periodic collision between the polycrystalline diamond composite sheet and the physical medium through external force to obtain a uniform surface roughening layer; through the combination of the two processing methods, a pure and uniform roughening layer is formed on the surface of the cemented carbide layer of the polycrystalline diamond composite sheet, thereby improving the welding performance of the polycrystalline diamond composite sheet, enhancing the bonding force between the polycrystalline diamond composite sheet and the drill bit, and extending the service life of the polycrystalline diamond composite sheet drill bit.

[0062] It should be understood that the application of the present application is not limited to the above examples. For ordinary technicians in this field, improvements or changes can be made based on the above description. All these improvements and changes should fall within the scope of protection of the claims attached to this application.

Claims

1. A method for processing a polycrystalline diamond compact, characterized in that: Includes steps: (a) placing the polycrystalline diamond compact in a chemical medium for a first treatment, and then placing it in a physical medium for a second treatment; or; (b) placing the polycrystalline diamond compact in a mixed medium for a third treatment, wherein the mixed medium includes a chemical medium and a physical medium; The chemical medium reacts with impurities on the surface of the polycrystalline diamond compact to be converted into gas or metal salt dissolved in the chemical medium, and the physical medium collides with the polycrystalline diamond compact during the second treatment and the third treatment.

2. The method for processing a polycrystalline diamond compact according to claim 1, characterized in that: The chemical medium includes a first solvent and a first solute; The first solvent includes one or more of water, ethanol, glycerol, acetone, and isopropanol; The first solute includes one or more of HCl, H2SO4, HNO3, H3PO4, HF, NaCl, KCl, NaNO3, and KNO3.

3. The method for processing a polycrystalline diamond compact according to claim 2, characterized in that: The concentration of the first solute in the chemical medium is 0.02-0.2 g / mL.

4. The method for processing a polycrystalline diamond compact according to claim 2, characterized in that: The pH value of the chemical medium is 1-6.

5.

5. The method for processing a polycrystalline diamond compact according to claim 1, characterized in that: The physical medium includes a second solvent and a second solute; The second solvent includes one or more of water, ethanol, glycerol, acetone, and isopropanol; The second solute includes one or more of silicon dioxide particles, silicon carbide particles, diamond particles, ceramic sand particles, and carbide particles.

6. The method for processing a polycrystalline diamond compact according to claim 5, characterized in that: The mass percentage of the second solute in the physical medium is 30-90%.

7. The method for processing a polycrystalline diamond compact according to claim 5, characterized in that: The average particle size of the second solute is 0.4-1.5 mm.

8. The method for processing a polycrystalline diamond compact according to claim 1, characterized in that: The temperature of the first treatment is 10-100°C and the time is 20-200h; The temperature of the second treatment is 10-100°C and the time is 20-200h; The temperature of the third treatment is 10-100° C. and the time is 20-200 hours.

9. The method for processing a polycrystalline diamond compact according to claim 1, characterized in that: During the second treatment and the third treatment, the physical medium collides with the polycrystalline diamond compact under the action of an external force, wherein the external force includes at least one of oscillation, rotation, and stirring.

10. Use of a polycrystalline diamond compact obtained by the method for treating a polycrystalline diamond compact according to any one of claims 1 to 9 in preparing a polycrystalline diamond compact drill bit.

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