System and method for joining large size diamond blanks

Abstract

An apparatus can include a needle having a tapered surface toward a distal end and a proximal portion opposite the distal end in an axial direction, wherein the surface of the needle includes polycrystalline diamond. An apparatus can include a base including a non-diamond material positioned about a proximal portion, wherein the base is connected to the proximal portion of the needle by a press fit.

Description

[0001] Cross-reference to related applications

[0002] Related Application This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 535516, filed August 30, 2023, entitled “System and Method for Joining Large-Size Diamond Billets,” the subject of which is incorporated herein by reference in its entirety. Background Technology

[0003] Large diamond blanks possess excellent wear resistance and, when manufactured using diamond materials with reliable mechanical properties, can be used to create components with superior utility and value. However, joining large diamond blanks or components made from large diamond blanks to other parts is challenging due to factors such as the hardness of diamond limiting processing options, the coefficient of thermal expansion limiting adhesives and brazing joints, the reactivity of diamond limiting welding and other heat-based joining techniques, and others. Summary of the Invention

[0004] In some respects, the technology described herein relates to a device comprising: a needle body having a tapered surface toward a distal end and a proximal portion opposite the distal end in an axial direction, wherein the surface of the needle body comprises polycrystalline diamond; and a base comprising a non-diamond material positioned around the proximal portion, wherein the base is press-fitted to the proximal portion of the needle body.

[0005] In some aspects, the technology described herein relates to a device comprising: a needle body having a tapered surface toward a distal end and a proximal portion opposite the distal end in an axial direction, wherein the surface of the needle body comprises polycrystalline diamond; a base comprising a non-diamond material; diamond threads in the polycrystalline diamond-component surface located on the proximal portion of the needle body; and base threads positioned on the base and complementaryly engaging with the diamond threads.

[0006] In some respects, the technology described herein relates to a method for joining diamonds, the method comprising: machining diamond threads in a monolithic diamond blank; forming base threads in a base; and screwing the diamond threads into the base threads.

[0007] In some respects, the technology described herein relates to a method of bonding diamond, the method comprising: inserting a proximal portion of a diamond blank into a base such that at least a portion of the base circumferentially surrounds the proximal portion; and compressing the proximal portion of the diamond blank with the base.

[0008] This summary is provided to introduce some concepts that will be further described in the following detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help limit the scope of the claimed subject matter.

[0009] Additional features and aspects of the embodiments of this disclosure will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing these embodiments. The features and aspects of these embodiments can be implemented and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more apparent from the following description and the appended claims, or may be learned by practicing the embodiments set forth below. Attached Figure Description

[0010] To describe how the above and other features of this disclosure can be obtained, a more specific description will be presented by reference to specific embodiments illustrated in the accompanying drawings. For better understanding, in the various drawings, the same elements are denoted by the same reference numerals. While some drawings may be schematic or exaggerated representations of concepts, non-illustrative drawings should be considered to scale for some embodiments of this disclosure, but not to scale for other embodiments considered herein. It should be understood that the drawings depict some exemplary embodiments, and the embodiments will be described and explained with additional features and details using the drawings, wherein:

[0011] Figure 1 This is a side sectional view of the throttle valve in the open position.

[0012] Figure 2 This is a side sectional view of a throttle valve having a large-sized diamond needle body according to at least some embodiments of the present disclosure.

[0013] Figure 3-1 This is a side sectional view of a throttle valve with a large-sized diamond needle in the open position, according to at least some embodiments of the present disclosure.

[0014] Figure 3-2 This is a side sectional view of a throttle valve having a large-sized diamond needle body with pressure balancing features, according to at least some embodiments of the present disclosure.

[0015] Figure 4 This is a side sectional view of a large-sized diamond needle with threads according to at least some embodiments of the present disclosure.

[0016] Figure 5 This is a side sectional view of a large-sized diamond needle body with threaded and pressure-balanced features according to at least some embodiments of the present disclosure.

[0017] Figures 6-1 to 6-3This is a side sectional view of a large-size diamond blank that conforms to a diamond thread according to at least some embodiments of the present disclosure, making the complementary thread base conform to the diamond thread.

[0018] Figure 7-1 and Figure 7-2 This is a side sectional view of a base thread that deforms during mating, according to at least some embodiments of the present disclosure.

[0019] Figure 8-1 This is a side view of laser-machined threads in a large-size diamond blank according to at least some embodiments of the present disclosure.

[0020] Figure 8-2 This is a side sectional view of a large-size diamond blank according to at least some embodiments of the present disclosure.

[0021] Figure 9 This is a perspective sectional view of a throttle valve having a segmented needle body and a segmented valve seat according to at least some embodiments of the present disclosure.

[0022] Figure 10 This is a perspective cross-sectional view of a needle body with a washer according to at least some embodiments of the present disclosure.

[0023] Figure 11 This is a perspective sectional view of a needle body having a tapered thread portion according to at least some embodiments of the present disclosure.

[0024] Figure 12 This is a perspective cross-sectional view of a needle body including a cutting element according to at least some embodiments of the present disclosure. Detailed Implementation

[0025] Embodiments of this disclosure generally relate to apparatus, systems, and methods for joining or securing large-size diamond billets to non-diamond substrates. More specifically, some embodiments of this disclosure relate to joining or securing large-size diamond billets to metal or metal alloy substrates having a different coefficient of thermal expansion and / or a different microstructure than the diamond billet. The large-size diamond billet is a polycrystalline diamond composite (PDC) formed as a monolithic body. The microstructure is substantially continuous throughout the diamond billet, without seams, joints, or junctions. In some embodiments, the large-size diamond billet is formed in a single high-temperature, high-pressure sintering process, producing a solid monolithic PDC body greater than 1.0 cubic centimeters (cc). In some embodiments, the large-size diamond billet has a length of at least 10 millimeters (mm). In some embodiments, the large-size diamond billet has a length of at least 10 mm and a width of at least 10 mm. In some embodiments, the large-size diamond billet is cylindrical and has an axial length of at least 10 mm. In some embodiments, the large-volume diamond billet is cylindrical and has an axial length of at least 10 mm and a diameter of at least 10 mm. To achieve reasonable manufacturing yield and sufficient reliability in use, in some embodiments, the PDC billet is composed of a material having a flexural strength greater than 800 MPa, a fracture toughness greater than 8 MPa / m, and a diamond volume fraction greater than 90 vol%. PDC materials meeting these requirements are determined to have an average grain size of 15-25 micrometers, for example, measured by electron backscatter diffraction (EBSD). To achieve uniformity throughout the large-volume PDC billet, it is further preferred that the second phase consists essentially of a pure cobalt solvent catalyst, which is infiltrated in a vacuum-sealed container under high pressure and high temperature conditions of 1400-1500°C and 5.5-7.0 GPa. Furthermore, it is desirable to heat-treat the PDC billet to produce a residual stress release of 100-500 MPa as measured by Raman spectroscopy.

[0026] In some embodiments, the diamond billet exhibits a coefficient of thermal expansion (CTE) of approximately 1.1 to 1.2 micrometers per meter-degree Celsius (μm / m°C). Given the difference in CTE between the diamond billet and the metal or metal alloy substrate, joining or securing the diamond billet to a metal or metal alloy component using conventional brazing or other bonding techniques presents challenges. In at least one example, steel exhibits a CTE approximately one order of magnitude larger than that of diamond, between approximately 10 μm / m°C and 17.3 μm / m°C. During operation, components may experience relatively large temperature variations, and components including diamond billets bonded to or brazed to a metal substrate may experience cracking or joint failure, at least in part due to strain caused by the CTE difference. Smaller diamond billets experience lower strain on the contact surface and can be brazed or otherwise bonded to non-diamond components, whereas, as described herein, brazing or bonding large-sized diamond billets is not feasible in demanding applications.

[0027] The diamond component geometry and joining methods according to some embodiments of this disclosure allow for the mechanical joining of large-size diamond blanks to metal or metal alloy components. More specifically, some embodiments of the components described herein provide a mechanical joining of large-size diamond blanks to a metal base, wherein the component is subjected to tension during operation. For example, throttle valves in surface drilling rigs, downhole components, or other parts of drilling systems experience high fluid pressure differentials, and the flow of fluid through the throttle valve can erode the valve seat and / or needle body. Including PDC (e.g., large-size diamond blanks) or the valve seat and / or needle body of a throttle valve made of PDC can limit and / or prevent erosion in the throttle valve.

[0028] Figure 1 This is a side sectional view of an embodiment of the throttle valve 100, in which fluid 102 flows through the throttle valve 100. In the open position, fluid 102 flows through the throttle valve 100 by flowing around the needle body 104 and through the annular valve seat 106 of the throttle valve 100. Moving the needle body 104 axially relative to the valve seat 106 changes the cross-sectional area of ​​the annular space between the needle body 104 and the valve seat 106, which regulates the pressure differential and flow velocity of the fluid 102 through the throttle valve 100. In some cases, when the throttle valve 100 is positioned in the open position but the needle body 104 is close to the valve seat 106, the flow velocity and erosive energy of the fluid 102 may damage the needle body 104, the valve seat 106, the base 108 connected to the needle body 104, or other components of the throttle valve 100.

[0029] In some embodiments, one or both of the needle body 104 and the valve seat 106 comprise or are made of large-size diamond blanks. In some embodiments, fluid 102 applies a drag force and / or surface pressure to the valve seat 106 in the flow direction of the throttle valve 100, which compresses the valve seat 106 toward the body 110 of the throttle valve 100 supporting the valve seat 106. In some embodiments, fluid 102 applies a drag force to the needle body 104 in the flow direction of the throttle valve 100 and / or creates a low-pressure region downstream of the needle body 104, which applies tension to the connection between the needle body 104 and the base 108. The connection between the large-size diamond blank needle body 104 and the metal or metal alloy base 108 presents challenges, at least for the reasons described herein. Compared to tool steel or tungsten carbide, diamond blanks resist conventional threading, cannot be welded, and present other joining challenges. In some embodiments according to this disclosure, a large diamond blank needle body is coupled to a non-diamond (e.g., metal or metal alloy) base by a mechanical engagement (such as a shrink fit or threaded connection), which may include one or more pressure balancing features.

[0030] Diamond exhibits advantageous properties such as wear resistance, strength, toughness, low coefficient of friction, and low CTE. However, diamond can be difficult to process, press, or otherwise form into desired geometries. In some embodiments, the needle body and / or needle body and base include one or more features to provide a stronger connection between a large-size diamond blank and another component. It should be understood that while this disclosure relates to diamond blanks and / or large-size diamond blanks, the joining and joining methods described herein are equally applicable to needle bodies and other components having surfaces or layers including polycrystalline diamond. For example, a tungsten core with a diamond outer surface or layer may exhibit the same or similar joining challenges as the diamond blanks described herein. Any embodiment of the apparatus including the diamond blanks described herein (e.g., regarding...) Figures 2 to 11 It may include elements (such as needles or valve seats) that include a surface or layer of polycrystalline diamond on a non-diamond body.

[0031] Figure 2 This is a side sectional view of an embodiment of a large-sized diamond needle body 204 connected to a metal or metal alloy base 208. It should be understood that while this disclosure will refer to embodiments and examples of components used in throttle valves, the diamond bonding geometry and techniques described herein are applicable to other components, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements bonded to non-diamond bases.

[0032] In some embodiments, a large diamond needle 204 is engaged to a metal alloy base 208 by a contraction fit and / or compression fit around the proximal portion 212 of the large diamond needle 204. In some embodiments, the base 208 is heated to a temperature above the intended operating temperature to expand the inner diameter 214 of the base 208 to a size greater than the outer diameter 216 to receive the proximal portion 212 of the large diamond needle 204. Upon cooling, the base 208 contracts and compresses the proximal portion 212 of the large diamond needle 204 to retain the large diamond needle 204 within the base. In some embodiments, the proximal portion 212 contacts and is compressed by the base 208 along the length 218 of the large diamond needle 204 in the axial direction 220 for at least 25% of the length. In some embodiments, the proximal portion 212 contacts and is compressed by the base 208 for at least 30% of the length 218 of the large-size diamond needle 204 in the axial direction 220. In some embodiments, the proximal portion 212 contacts and is compressed by the base 208 for at least 40% of the length 218 of the large-size diamond needle 204 in the axial direction 220.

[0033] In some embodiments, the large-size diamond needle 204 has a truncated distal end 222 opposite to the proximal portion 212 and located axially away from the base 208 in the direction 220. In conventional materials, the distal end tapers to an approximate point to allow fluid flow through the needle, while exhibiting limited erosion and / or turbulence at the distal end. In some embodiments, the large-size diamond needle 204 has sufficient wear resistance and / or erosion resistance such that the truncated distal end 222 allows the use of a large-size diamond needle 204 with a relatively short overall length 218 without significant erosion, which can reduce manufacturing and / or operating costs and increase the production yield of large-size diamond blanks.

[0034] While the large diamond needle 204 exhibits relatively high corrosion resistance, other components (such as the base 208) are more susceptible to corrosion. Figure 3-1 and Figure 3-2 Examples of erosion limiting and / or pressure balancing features are shown. Figure 3-1 This is a side sectional view of an embodiment of a throttle valve 300, which includes a large-diamond needle body 304 and a diamond valve seat 306 in the open position. When fluid 302 flows through the space between the needle body 304 and the valve seat 306, a pressure difference across the throttle valve 300 creates a low-pressure region 324 at the distal end 322 of the needle body 304. In some embodiments, the low-pressure region 324 exerts a force on the distal end 322 of the truncated portion of the needle body 304, thereby pulling the needle body 304 away from the base 308 in the axial direction 320.

[0035] In some embodiments, the large-size diamond needle body 304 and / or base 308 include one or more pressure balancing features to limit and / or prevent the needle body 304 from disconnecting from the base 308. For example, in some embodiments, the base 308 includes a pressure balancing cavity 326 located adjacent to the proximal portion 312 of the needle body 304 in the axial direction 320. The pressure balancing cavity 326 may allow a portion of fluid 302 to flow between the proximal portion 312 and the base 308 and through a pressure balancing orifice 328 in the needle body 304. While conventional needle bodies are solid (e.g., without orifices) to prevent fluid from flowing through the needle body when the throttle valve is in the closed position, embodiments of the large-size diamond needle body 304 according to this disclosure, including a pressure balancing orifice 328, may allow the throttle valve 300 to "leak" fluid 302 through its throttle valve to limit and / or prevent catastrophic failure in which the diamond needle body 304 disconnects from the base 308. In some embodiments, in the closed position, the throttle valve 300 will leak fluid 302 in a detectable manner before a failure, thereby allowing for detection and repair before a catastrophic failure. In some embodiments, the pressure balancing orifice 328 is electrically electrically machined (EDM) in the needle body 304.

[0036] For example, the relatively wear-prone metal of the base 308 can wear around the proximal portion 312 at a higher rate than the diamond needle body 304, causing fluid 302 to enter the proximal end of the needle body 304. The pressure balancing orifice 328 allows fluid 302 to flow away from the proximal end to the low-pressure region 324 to reduce the pressure differential. In some embodiments, the needle body 304 includes erosion-limiting features on its surface to limit and / or prevent erosion of the base 308 near the needle body 304.

[0037] In some embodiments, the needle body 304 has a deflection surface 330 between a tapered surface 332 and a radially outermost surface 334 of the needle body 304. The deflection surface 334 is oriented axially 320 at a larger angle than the tapered surface 332, so that fluid flow is deflected away from the base 308 at the proximal portion 312 of the needle body 304. In some embodiments, the deflection surface 330 limits the region of the base 308 exposed to the highest flow rate of the fluid 302.

[0038] In some embodiments, a spacer 336 on the axial 320 between the deflection surface 330 and / or the tapered surface 332 of the needle body 304 and the base 308 limits the region of highest flow velocity of the base 308 exposed to the fluid 302. In some embodiments, the spacer 336 is at least 10% of the length of the needle body in the axial direction 320. In some embodiments, the spacer 336 is at least 20% of the length of the needle body in the axial direction 320. In some embodiments, the spacer 336 is at least 30% of the length of the needle body in the axial direction 320.

[0039] Figure 3-2 yes Figure 3-1 A side sectional view of an embodiment of the throttle valve 300, wherein fluid enters the pressure balancing chamber 326. In some embodiments, fluid 302 is capable of flowing between the proximal portion 312 of the needle body 304 and the base 308. Fluid 302 may erode a portion of the base 308 to open a leakage passage 338 into the pressure balancing chamber 326 near the rear surface of the needle body 304. In some embodiments, the pressure balancing chamber is provided with fluid communication to a low-pressure region 324 via a pressure balancing orifice 328 to reduce the pressure difference across the throttle valve 300. In some embodiments, as described herein, leakage through the leakage passage 338 is detectable to provide controlled and detectable failure prior to catastrophic failure of the base 308 of the large-diameter diamond needle body 304.

[0040] In some embodiments, the leakage channel 338 is initiated due to machining defects and / or tolerances in the needle body 304 and / or base 308. In at least one embodiment, machining large-size diamond blanks to precise and / or consistent dimensions on the surface of large-size diamonds is challenging. For example, diamond is one of the hardest materials known, and variations in surface dimensions or geometry can be difficult to control.

[0041] Figure 4 This is a side sectional view of the threaded connection between a large-size diamond needle body 404 and a non-diamond base 408. As described herein, while this disclosure will refer to embodiments and examples of components used in throttle valves, the diamond bonding geometry and techniques described herein are applicable to other components, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements bonded to non-diamond bases. In some embodiments, the large-size diamond blank includes diamond threads 440 on the radially outward surface of the proximal portion 412 of the large-size diamond blank (e.g., the large-size diamond needle body 404) relative to the axial direction 420. In some embodiments, the diamond threads 440 complementarily engage with base threads 442 on the base 408. When the threaded connection is screwed together, the threaded connection of the diamond threads 440 and the base threads 442 applies a compressive force between the needle body 404 and the base 408 to counteract the pressure difference on the throttle valve, for example, regarding... Figure 3-1 and Figure 3-2 As described.

[0042] Figure 5 This is a side sectional view of the threaded connection between a large-diameter diamond needle body 504 and a non-diamond base 508, characterized by pressure balance. In some embodiments, the threaded connection between the needle body 504 and the base 508 restricts and / or prevents, for example, regarding... Figure 3-2The formation of the described leakage path. In some embodiments, the threaded connection of the needle body 504 and the base 508 limits and / or prevents catastrophic failure (e.g., release) of the needle body 504 from the base 508. In some embodiments, the leakage path can still be formed, and the needle body 504 and / or base 508 having a pressure balancing chamber 526 and a pressure balancing hole 528 allows for controlled failure of the throttle valve and detection of erosion before catastrophic failure.

[0043] Figures 6-1 to 6-3 An embodiment of a method for manufacturing a large-size diamond needle with a threaded connection is shown. In some embodiments, the needle body 604 has a diamond thread 640, and the base 608 has a base thread 642. In some embodiments, the diamond thread 640 and the base thread 642 have substantially the same pitch, but different shapes and / or depths. In some embodiments, the base thread 642 is plastically deformed to at least partially mate with the diamond thread 640, thus mating the diamond thread 640 and the base thread 642. Because machining diamonds into a large-size diamond needle body 604 is challenging, in some embodiments, the base thread 642 conforms to the diamond thread 640 and any variations thereof.

[0044] Now for reference Figure 6-2 In some embodiments, the diamond thread 640 of the needle body 604 has a diamond radius of curvature (ROC) 644, which differs from the base ROC 646 of the base thread 642 on the base 608. For example, although diamond has relatively high toughness, the microstructure of the diamond blank may contain residual strain, and it is beneficial to avoid stress rise and stress concentration in the large-size diamond needle body 604 and diamond thread 640. In some embodiments, the diamond ROC is at least 10% of the diamond thread depth 650. In some embodiments, the diamond ROC is at least 15% of the diamond thread depth 650. In some embodiments, the diamond ROC is at least 20% of the diamond thread depth 650. In some embodiments, the diamond ROC is at least 25% of the diamond thread depth 650.

[0045] In some embodiments, the diamond thread 640 of the needle body 604 has a diamond ROC 644, which is greater than the base ROC 646 of the base thread 642 on the base 608. In some embodiments, the diamond ROC 644 is the same at the groove between the end of the diamond thread and the diamond thread 640. In some embodiments, the diamond thread depth 650 is different from the base thread depth 652. In some embodiments, the diamond thread depth 650 is less than the base thread depth 652.

[0046] In some embodiments, the harder and tougher diamond in the diamond thread 640 cold-works or cold-forges the metal of the base 608 to alter the shape of the base thread 642 without heating the base thread 642 before screwing the connection together. In some embodiments, the base thread 642 exhibits a cold-forged microstructure after mating with the diamond thread 640. In some embodiments, when the diamond is exposed to iron at elevated temperatures, the iron-based material can react with the diamond to generate a carbide phase within the diamond. The carbide phase can be avoided by mating the connection and deforming the base material at ambient temperature. In some embodiments, the relatively low coefficient of friction of the diamond further limits the temperature rise during the threaded connection mating, limiting and / or preventing the formation of the carbide phase.

[0047] Now for reference Figure 6-3 In some embodiments, after the threaded connection of the mating needle body 604 and the base 608, the base thread 642 substantially matches the geometry of the diamond thread 640. For example, the base thread depth 652 is changed to be substantially equal to the diamond thread depth 650. In some embodiments, the base ROC 646 is changed to be substantially equal to the diamond ROC 644.

[0048] In some embodiments, additional material may be located between at least a portion of the diamond thread 640 and the base thread 642. For example, an adhesive or other filler material may be positioned on one or both threads before the base 608 and the needle body 604 are mated. In some embodiments, the adhesive may facilitate microstructural bonding between the base 608 and the needle body 604. In some embodiments, the adhesive may adhere the base 608 to the needle body 604. In some embodiments, filler material fills at least one gap between the diamond thread 640 and the base thread 642 to seal the space between the base 608 and the needle body 604. Such an adhesive or filler material may limit and / or prevent leakage through the threaded connection between the needle body 604 and the base 608.

[0049] Figure 7-1 and Figure 7-2 A variation of an embodiment of the base thread 742 is shown during the mating of the diamond blank and the base. In some embodiments, the diamond thread compresses the base thread 742 in the radial direction 754, thereby shortening the base thread 742. In some embodiments, compressing the base thread 742 causes the material of the base thread 742 to be displaced in the axial direction 720 to form Figure 7-2 The shorter, wider base thread 742.

[0050] As described in this article, machining diamond is challenging. Grinding and grinding can create surfaces in diamond blanks, but cannot create detailed geometries such as threads. In some embodiments, diamond threads are formed in large-size diamond blanks by laser processing (e.g., laser ablation). Figure 8-1 This is a perspective view of laser-machined diamond threads in a large-size diamond blank. In some embodiments, laser processing can induce a heat-affected zone that graphitizes the diamond. Graphitizing the diamond changes the microstructure from a cubic crystal structure to a planar crystal structure, thereby significantly altering the material's hardness and toughness. In some embodiments, laser processing can oxidize the diamond, further damaging the microstructure.

[0051] In some embodiments, according to this disclosure, a large-size diamond needle body 804 or other large-size diamond blank is laser-processed by a laser source 856, the laser source 856 being positioned such that a laser 858 is substantially tangential to the diamond thread 840 being processed. For example... Figure 8-2 yes Figure 8-1 An end view of an embodiment of the needle body 804 and laser source 856, wherein the laser 858 is oriented at an angle 860 of less than 20° with respect to the tangent 862. In some embodiments, the laser 858 is oriented at an angle 860 of less than 15° with respect to the tangent 862. In some embodiments, the laser 858 is oriented at an angle 860 of less than 10° with respect to the tangent 862. In some embodiments, the laser 858 is oriented at an angle 860 of less than 5° with respect to the tangent 862.

[0052] In some embodiments, the substantially tangential laser machining of the diamond thread 840 in the diamond limits and / or prevents the heat-affected zone and graphitization within the heat-affected zone. However, in some embodiments, some graphitization and / or thermal strain may occur in the diamond microstructure. In some embodiments, sandblasting of the diamond thread 840 after laser machining removes graphitized carbon and / or releases thermal strain in the diamond before the diamond thread mates with the base thread, for example, in relation to Figures 5 to 7-2 In any of the embodiments described, sandblasting includes sandblasting diamond threads with silicon carbide abrasive.

[0053] While this disclosure describes a method for creating threads in a diamond needle body, it should be understood that at least some of the embodiments described herein can be used to create threads in other large-size diamond blanks, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements that are coupled to non-diamond bases.

[0054] Figure 9This is a perspective sectional view of an embodiment of a throttle valve 900 including a needle body 904 and a valve seat 906. As described herein, the processing of diamond materials is challenging and resource-intensive. In some embodiments, manufacturing and / or machining diamond into the geometry and / or dimensions of the throttle valve 900 is expensive or impossible with a given sintering machine. In some embodiments, the throttle valve 900 includes a needle body 904 and / or a valve seat 906 having multiple integral diamond blanks as corner segments 964-1, 964-2, 964-3. Although corner segments 964-1, 964-2, 964-3 are described herein as part of the needle body 904, it should be understood that this description applies to the corner segments of the valve seat 906.

[0055] In some embodiments, corner segments 964-1, 964-2, and 964-3 are each themselves diamond blanks. For example, each corner segment 964-1, 964-2, and 964-3 may be a large-size diamond blank having the material properties described herein, sintered according to the method described herein. In some embodiments, corner segments 964-1, 964-2, and 964-3 are positioned to segmentally form the needle body 904 around an axial direction 966. Corner segments 964-1, 964-2, and 964-3 are combined to circumferentially form the needle body 904 around an axial direction 966. In some embodiments, the needle body 904 includes at least two corner segments 964-1, 964-2, and 964-3. Figure 9 In the illustrated embodiment, the needle body 904 comprises a total of six segments, of which three corner segments 964-1, 964-2, and 964-3 are shown in the cross-sectional view. In some embodiments, the corner segments 964-1, 964-2, and 964-3 allow for easier machining of the pressure balancing hole 928 by machining grooves in each of the corner segments 964-1, 964-2, and 964-3, which, when assembled in the needle body 904, form the pressure balancing hole 928.

[0056] In some embodiments, corner segments 964-1, 964-2, and 964-3 have an arc length 968 relative to the axial direction 966. For example, the arc length 968 can be measured in degrees and / or as a percentage of a circumference around and perpendicular to the axial direction 966. In some embodiments, the arc length 968 of each of the plurality of corner segments 964-1, 964-2, and 964-3 is equal. In some embodiments, the arc length 968 of at least one corner segment differs from the arc length of a second corner segment.

[0057] In some embodiments, corner segments 964-1, 964-2, and 964-3 contact each other at corner interface 972 on interface surface 970. In some embodiments, corner interface 972 is radially oriented relative to axial direction 966. In such embodiments, radial compression from base 908 (e.g., due to different CTEs as described herein) creates compression at corner interface 972 between corner segments 964-1, 964-2, and 964-3.

[0058] In some embodiments, the interface surfaces 970 of adjacent corner segments 964-1, 964-2, 964-3 are in direct contact with each other without any other material between them. In some embodiments, the interface surfaces 970 are ground, overlapped, or otherwise machined to produce a smooth interface surface 970 and a fluid-tight corner interface 972. In some embodiments, the interface surfaces 970 have surface textures, surface features, or sintered articles that create one or more voids at the corner interface 972 between corner segments 964-1, 964-2, 964-3. In some embodiments, radial compression of the corner segments 964-1, 964-2, 964-3 at the corner interface 972 deforms the interface surfaces 970 to create a fluid-tight interface. In some embodiments, the voids or other spaces between corner segments 964-1, 964-2, 964-3 allow fluid to flow through in the axial direction 966, thus eliminating the need for a pressure balancing orifice 928.

[0059] Figure 9 An embodiment of a needle body 904 radially compressed by a base 908 is shown. In some embodiments, the needle body 904, comprising multiple corner segments 964-1, 964-2, 964-3, includes threads, such as those relating to… Figures 4 to 7-2 As described. For example, diamond threads in the needle body can be formed in corner sections 964-1, 964-2, 964-3, wherein each of corner sections 964-1, 964-2, 964-3 has at least a portion of thread. Threads can be formed in the outer surfaces of corner sections 964-1, 964-2, 964-3 such that at least one thread is continuous between adjacent corner sections 964-1, 964-2, 964-3.

[0060] In some embodiments, additional material may be located between at least two of the corner segments 964-1, 964-2, and 964-3. For example, an adhesive or other filler material may be positioned on one or both interface surfaces 970 at the corner interface 972. In some embodiments, the adhesive may facilitate microstructural bonding between the corner segments 964-1, 964-2, and 964-3. In some embodiments, the adhesive may adhere to the corner segments 964-1, 964-2, and 964-3. In some embodiments, filler material fills at least one gap between the corner segments 964-1, 964-2, and 964-3 to seal the corner interface 972. Such an adhesive or filler material may limit and / or prevent leakage through the corner interface 972 and through the needle body 904.

[0061] Figure 10 This is a side sectional view of an embodiment of a throttle valve 1000 having a seal at the longitudinal end of the needle body 1004. The seal can be formed by deformation of the gasket material or the base material itself. In some embodiments, the diamond thread 1040 and the base thread 1042 cooperate to apply a force in the axial direction 1066. The axial force applies compressive force in the axial direction 1066 between the chamfer 1074, bent edge, or other angled edge of the needle body 1004 and the circumferential edge 1076 of the base 1008. In some embodiments, the circumferential edge 1076 is located near a pressure balancing cavity or other clearance in the base 1008 (e.g., regarding...). Figure 5 The pressure balancing chamber 526 is described. In some embodiments, the compressive force causes the diamond of the needle body 1004 to deform the base material at the circumferential edge 1076 to create a fluid-tight seal and ensure that any fluid flows through the planned channels (e.g., pressure balancing holes).

[0062] In some embodiments, the throttle valve 1000 further includes a washer 1078, which is compressible in the axial direction 1066 between the needle body 1004 and the base 1008 to further seal the threaded portion and limit and / or prevent leakage. In some embodiments, the washer 1078 comprises a polymer material. In some embodiments, the washer 1078 comprises a malleably deformable metal. In some embodiments, the washer 1078 is adhered to the needle body 1004. In some embodiments, the washer 1078 is adhered to the base 1008.

[0063] Figure 11This is a side sectional view of an embodiment of a throttle valve 1100, which has a tapered (i.e., gradually tapering) needle thread portion to form a longitudinal seal within the thread portion. For example, the needle body 1104 tapers in the axial direction 1166 by at least a portion of diamond thread 1140. In some embodiments, the needle body 1104 and the base 1108 taper in the axial direction 1166 by at least a portion of diamond thread 1140 and at least a portion of base thread 1142, respectively. In some embodiments, the tapered (i.e., gradually tapering) thread portion of the needle body generates a radially oriented compressive force between the diamond thread 1140 and the base thread 1142 to concentrate the compressive force and further promote deformation of the base thread 1142. In some embodiments, the base 1108 is tapered in the base thread portion (e.g., a female box) to concentrate the compressive force and further promote deformation of the base thread 1142.

[0064] Figure 12 This is a side cross-sectional view of an embodiment of the throttle valve 1200, wherein cut surfaces of the needle body 1204 and / or base 1208 cut into or deform contact surfaces to form a seal. In some embodiments, the shoulder surface 1280 of the base 1208 and the flange surface 1282 of the needle body 1204 contact each other to restrict and / or prevent fluid flow therebetween. In some embodiments, fluid flow therebetween is further restricted by a cut structure 1284 located on or in the flange surface 1282. When the needle body 1204 is screwed into or otherwise pressed into the base 1208, the cut structure 1284 cuts into and / or applies force to the shoulder surface 1280 of the base 1208. The cut structure 1284 can plastically or elastically deform the shoulder surface 1280 to form a fluid seal on the shoulder surface 1280. In some embodiments, the cut structure 1284 is continuous around the circumference of the flange surface 1282. In some embodiments, the flange surface 1282 has a plurality of discrete cutting elements that plastically or elastically deform the shoulder surface 1280 to form a fluid seal on the shoulder surface 1280.

[0065] In at least one embodiment of this disclosure, the throttle valve (including a needle body and / or seat made of large-size diamond blank, and / or a needle body and / or seat made of segments of large-size diamond blank) has a longer operating life and provides a longer uptime compared to conventional steel throttle valves.

[0066] Industrial application

[0067] Embodiments of this disclosure generally relate to apparatus, systems, and methods for joining or securing large-size diamond billets to non-diamond substrates. More specifically, some embodiments of this disclosure relate to joining or securing large-size diamond billets to metal or metal alloy substrates having a different coefficient of thermal expansion and / or a different microstructure than the diamond billet. The large-size diamond billet is a polycrystalline diamond composite (PDC) formed as a monolithic body. The microstructure is substantially continuous throughout the diamond billet, without seams, joints, or junctions. In some embodiments, the large-size diamond billet is formed in a single high-temperature, high-pressure sintering process, producing a solid monolithic PDC body greater than 1.0 cubic centimeters (cc). In some embodiments, the large-size diamond billet has a length of at least 10 millimeters (mm). In some embodiments, the large-size diamond billet has a length of at least 10 mm and a width of at least 10 mm. In some embodiments, the large-size diamond billet is cylindrical and has an axial length of at least 10 mm. In some embodiments, the large-size diamond blank is cylindrical and has an axial length of at least 10 mm and a diameter of at least 10 mm.

[0068] In some embodiments, the diamond billet exhibits a coefficient of thermal expansion (CTE) of approximately 1.1 to 1.2 micrometers per meter-degree Celsius (μm / m°C). Given the difference in CTE between the diamond billet and the metal or metal alloy substrate, joining or securing the diamond billet to a metal or metal alloy component using conventional brazing or other bonding techniques presents challenges. In at least one example, steel exhibits a CTE approximately one order of magnitude larger than that of diamond, between approximately 10 μm / m°C and 17.3 μm / m°C. During operation, components may experience relatively large temperature variations, and components including diamond billets bonded to or brazed to a metal substrate may experience cracking or joint failure, at least in part due to strain caused by the CTE difference. Smaller diamond billets experience lower strain on the contact surface and can be brazed or otherwise bonded to non-diamond components, whereas, as described herein, brazing or bonding large-sized diamond billets is not feasible in demanding applications.

[0069] The diamond component geometry and joining methods according to some embodiments of this disclosure allow for the mechanical joining of large-size diamond blanks to metal or metal alloy components. More specifically, some embodiments of the components described herein provide a mechanical joining of large-size diamond blanks to a metal base, wherein the component is subjected to tension during operation. For example, throttle valves in surface drilling rigs, downhole components, or other parts of drilling systems experience high fluid pressure differentials, and the flow of fluid through the throttle valve can erode the valve seat and / or needle body. Including PDC (e.g., large-size diamond blanks) or the valve seat and / or needle body of a throttle valve made of PDC can limit and / or prevent erosion in the throttle valve.

[0070] In the open position, fluid flows through the throttle valve by flowing around the needle and through the annular seat. Axial movement of the needle relative to the seat alters the cross-sectional area of ​​the annular space between the needle and the seat, thus regulating the pressure differential and flow velocity of the fluid through the throttle valve. In some cases, when the throttle valve is positioned in the open position but the needle is close to the seat, the fluid velocity and erosive energy can damage the needle, the seat, the base attached to the needle, or other components of the throttle valve.

[0071] In some embodiments, one or both of the needle body and the valve seat comprise or are made of a large-size diamond blank. In some embodiments, fluid exerts a drag force and / or surface pressure on the valve seat in the flow direction of the throttle valve, which compresses the valve seat toward the body of the throttle valve supporting the valve seat. In some embodiments, fluid exerts a drag force on the needle body in the flow direction of the throttle valve and / or creates a low-pressure region downstream of the needle body, which applies tension to the connection between the needle body and the base. The connection between the large-size diamond blank needle body and the metal or metal alloy base presents challenges, at least for the reasons described herein. In some embodiments according to this disclosure, the large-size diamond blank needle body is coupled to a non-diamond (e.g., metal or metal alloy) base by a mechanical engagement (such as a shrink fit or threaded connection), which may include one or more pressure balancing features.

[0072] Diamond exhibits advantageous properties such as wear resistance, strength, toughness, low coefficient of friction, and low CTE. However, diamond can be difficult to process, press, or otherwise form into the desired geometry. In some embodiments, the needle body and / or needle body and base include one or more features to provide a stronger connection between a large-size diamond blank and another component.

[0073] It should be understood that although this disclosure will refer to embodiments and examples of components used in throttle valves, the diamond bonding geometry and techniques described herein are applicable to other components, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements bonded to non-diamond bases.

[0074] In some embodiments, a large diamond needle is joined to a metal alloy base by a contraction fit and / or compression fit around the proximal portion of the large diamond needle. In some embodiments, the base is heated to a temperature above the intended operating temperature to expand the inner diameter of the base to be greater than the outer diameter to receive the proximal portion of the large diamond needle. Upon cooling, the base contracts and compresses the proximal portion of the large diamond needle to retain the large diamond needle within the base. In some embodiments, the proximal portion contacts and is compressed by the base along at least 25% of the length of the large diamond needle in the axial direction. In some embodiments, the proximal portion contacts and is compressed by the base along at least 30% of the length of the large diamond needle in the axial direction. In some embodiments, the proximal portion contacts and is compressed by the base along at least 40% of the length of the large diamond needle in the axial direction.

[0075] In some embodiments, the large-size diamond needle has a truncated distal end opposite the proximal portion and axially away from the base. In conventional materials, the distal end tapers to an approximate point to allow fluid flow through the needle, with limited erosion and / or turbulence at the distal end. In some embodiments, the large-size diamond needle has sufficient wear resistance and / or erosion resistance such that the truncated distal end allows the use of large-size diamond needles with a shorter overall length without significant erosion, which can reduce manufacturing and / or operating costs and increase the production yield of large-size diamond blanks.

[0076] While large diamond needles exhibit relatively high corrosion resistance, other components, such as the base, are more susceptible to corrosion. As fluid flows through the space between the needle and the seat, a pressure differential across the throttle valve creates a low-pressure region at the distal end of the needle. In some embodiments, this low-pressure region exerts a force on the distal end of the needle's truncated section, thereby pulling the needle axially away from the base.

[0077] In some embodiments, the large-size diamond needle body and / or base includes one or more pressure balancing features to limit and / or prevent the needle body from disconnecting from the base. For example, in some embodiments, the base includes a pressure balancing cavity located axially adjacent to a proximal portion of the needle body. The pressure balancing cavity can allow a portion of fluid to flow between the proximal portion and the base and through a pressure balancing orifice in the needle body. While conventional needle bodies are solid (e.g., without orifices) to prevent fluid flow through the needle body when the throttle valve is in the closed position, embodiments of the large-size diamond needle body according to this disclosure, including a pressure balancing orifice, can allow the throttle valve to "leak" fluid through it to limit and / or prevent catastrophic failure in which the diamond needle body disconnects from the base. In some embodiments, in the closed position, the throttle valve will leak fluid in a detectable manner prior to failure, thereby allowing for detection and repair before a catastrophic failure. In some embodiments, the pressure balancing orifice is electrically electrically machined (EDM) in the needle body.

[0078] For example, the relatively wear-prone metal of the base can wear around the proximal portion at a higher rate than the diamond needle body, causing fluid to enter the proximal end of the needle body. Pressure balancing orifices allow fluid to flow away from the proximal end to a low-pressure region to reduce the pressure differential. In some embodiments, the needle body includes erosion-limiting features on its surface to limit and / or prevent erosion of the base near the needle body.

[0079] In some embodiments, the needle body has a deflection surface between a tapered surface and the outermost radial surface of the needle body. The deflection surface is oriented axially at a larger angle than the tapered surface to deflect fluid flow away from the base at the proximal portion of the needle body. In some embodiments, the deflection surface limits the area of ​​the base exposed to the highest fluid flow velocity.

[0080] In some embodiments, the axial gap between the deflecting surface and / or tapered surface of the needle and the base limits the region of highest fluid velocity exposed to the base. In some embodiments, the gap is at least 10% of the axial length of the needle. In some embodiments, the gap is at least 20% of the axial length of the needle. In some embodiments, the gap is at least 30% of the axial length of the needle.

[0081] In some embodiments, fluid can flow between the proximal portion of the needle body and the base. The fluid may erode a portion of the base to open a leakage path into the pressure equalization chamber near the rear surface of the needle body. In some embodiments, the pressure equalization chamber provides fluid communication with a low-pressure region via a pressure equalization orifice to reduce the pressure difference across the throttle valve. In some embodiments, as described herein, leakage through the leakage path is detectable to provide controlled and detectable failure before catastrophic failure of the base of a large-diameter diamond needle body.

[0082] In some embodiments, leakage channels begin due to machining defects and / or tolerances in the needle body and / or base. In at least one embodiment, machining large-size diamond blanks to precise and / or consistent dimensions on the surface of large-size diamonds is challenging. For example, diamond is one of the hardest known materials, and variations in surface dimensions or geometry can be difficult to control.

[0083] As described herein, diamond bonding geometries and techniques are applicable to other components, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements bonded to non-diamond bases. In some embodiments, a large-size diamond blank (e.g., a large-size diamond needle body) includes diamond threads on the radially outward surface of the proximal portion of the large-size diamond blank relative to the axial direction. In some embodiments, the diamond threads complementarily engage with base threads on the base. When the threaded connection is screwed together, the threaded connection of the diamond threads and the base threads applies a compressive force between the needle body and the base to counteract pressure differentials on the throttle valve, as described herein.

[0084] In some embodiments, the threaded connection between the needle body and the base limits and / or prevents the formation of leakage pathways, such as those described herein. In some embodiments, the threaded connection between the needle body and the base limits and / or prevents catastrophic failure (e.g., release) of the needle body from the base. In some embodiments, leakage pathways can still be formed, and the needle body and / or base having a pressure balancing chamber and a pressure balancing orifice allows for controlled failure of the throttle valve and detection of erosion prior to catastrophic failure.

[0085] In some embodiments, the needle body has diamond threads, and the base has base threads. In some embodiments, the diamond threads and base threads have substantially the same pitch, but different shapes and / or depths. In some embodiments, the base threads are plastically deformed to at least partially mate with the diamond threads. Because machining large-sized diamond needles is challenging, in some embodiments, the base needle body conforms to diamond threads and any variations thereof.

[0086] In some embodiments, the diamond thread of the needle body has a diamond radius of curvature (ROC) that differs from the base ROC of the base thread on the base. For example, although diamond has relatively high toughness, the microstructure of the diamond blank may contain residual strain, and it is beneficial to avoid stress rise and stress concentration in large-diameter diamond needle bodies and diamond threads. In some embodiments, the diamond ROC is at least 10% of the diamond thread depth. In some embodiments, the diamond ROC is at least 15% of the diamond thread depth. In some embodiments, the diamond ROC is at least 20% of the diamond thread depth. In some embodiments, the diamond ROC is at least 25% of the diamond thread depth.

[0087] In some embodiments, the diamond thread of the needle body has a diamond ROC that is greater than the base ROC of the base thread on the base. In some embodiments, the diamond ROC is the same at the end of the diamond thread and at the groove between the diamond thread and the base thread. In some embodiments, the diamond thread depth is different from the base thread depth. In some embodiments, the diamond thread depth is less than the base thread depth.

[0088] In some embodiments, the harder and tougher diamond in the diamond thread cold-works or cold-forges the base metal to alter the shape of the base thread without heating the base thread before screwing the connection together. In some embodiments, the base thread exhibits a cold-forged microstructure after mating with the diamond thread. In some embodiments, when the diamond is exposed to iron at elevated temperatures, the iron-based material can react with the diamond to generate a carbide phase within the diamond. This carbide phase can be avoided by mating the connection and deforming the base material at ambient temperature. In some embodiments, the relatively low coefficient of friction of diamond further limits the temperature rise during the threaded connection mating, limiting and / or preventing the formation of the carbide phase.

[0089] In some embodiments, after the threaded connection between the mating needle body and the base, the base thread substantially matches the geometry of the diamond thread. For example, the base thread depth is changed to be substantially equal to the diamond thread depth. In some embodiments, the base ROC is changed to be substantially equal to the diamond ROC.

[0090] In some embodiments, the diamond thread compresses the base thread in the radial direction, thereby shortening the base thread. In some embodiments, compressing the base thread causes the material of the base thread to shift in the axial direction to form a shorter, wider base thread.

[0091] As described herein, machining diamond is challenging. Grinding and abrasion can create surfaces in diamond blanks, but cannot create detailed geometries such as threads. In some embodiments, diamond threads are formed in large-size diamond blanks by laser processing (e.g., laser ablation). In some embodiments, laser processing can induce a heat-affected zone that graphitizes the diamond. Graphitizing the diamond changes the microstructure from a cubic crystal structure to a planar crystal structure, thereby significantly altering the material's hardness and toughness. In some embodiments, laser processing can oxidize the diamond, further damaging the microstructure.

[0092] In some embodiments, according to this disclosure, large-size diamond needles or other large-size diamond blanks are laser-processed by a laser source positioned such that the laser is substantially tangential to the diamond thread being processed. In some embodiments, the needle and laser source are positioned such that the laser is oriented at an angle of less than 15° to the tangent. In some embodiments, the laser is oriented at an angle of less than 10° to the tangent. In some embodiments, the laser is oriented at an angle of less than 5° to the tangent.

[0093] In some embodiments, the substantially tangential laser machining of the diamond threads in the diamond limits and / or prevents a heat-affected zone and limits and / or prevents graphitization in the heat-affected zone. However, in some embodiments, some graphitization and / or thermal strain may occur in the diamond microstructure. In some embodiments, blasting of the diamond threads after laser machining removes graphitized carbon and / or releases thermal strain in the diamond before the diamond threads mate with the base threads, as in any of the embodiments described herein. In some embodiments, blasting includes blasting the diamond threads with a silicon carbide abrasive.

[0094] While this disclosure describes a method for creating threads in a diamond needle body, it should be understood that at least some of the embodiments described herein can be used to create threads in other large-size diamond blanks, such as diamond anvils, diamond nozzles, diamond cutting elements, and other diamond elements that are coupled to non-diamond bases.

[0095] As described herein, the processing of diamond materials is challenging and resource-intensive. In some embodiments, manufacturing and / or machining diamond into the geometry and / or dimensions of a throttle valve is expensive or impossible with a given sintering machine. In some embodiments, the throttle valve includes a needle body and / or a valve seat having multiple integral diamond blanks as corner segments. Although the corner segments are described herein as part of the needle body, it should be understood that this description applies to the corner segments of the valve seat.

[0096] In some embodiments, each corner segment is itself a diamond blank. For example, each corner segment may be a large-size diamond blank having the material properties described herein and sintered according to the methods described herein. In some embodiments, the corner segments are positioned to form the needle body segmentally around its axial direction. The corner segments are combined to form the needle body circumferentially around its axial direction. In some embodiments, the needle body includes at least two corner segments. In some embodiments, the needle body includes a total of six segments, with three corner segments shown in a cross-sectional view. In some embodiments, the corner segments allow for easier fabrication of pressure balancing holes by machining grooves in each of the corner segments, which form pressure balancing holes when assembled in the needle body.

[0097] In some embodiments, the corner segments have an arc length relative to the axial direction. For example, the arc length can be measured in degrees and / or percentages around a circumference perpendicular to the axial direction. In some embodiments, the arc lengths of each of the plurality of corner segments are equal. In some embodiments, the arc length of at least one corner segment is different from the arc length of a second corner segment.

[0098] In some embodiments, the corner segments contact each other at the interface surface at the corner interface. In some embodiments, the corner interface is radially oriented relative to the axial direction. In such embodiments, radial compression from the base (e.g., due to different CTEs as described herein) creates compression between the corner segments at the corner interface.

[0099] In some embodiments, the interface surfaces of adjacent corner segments are in direct contact with each other, with no other material between them. In some embodiments, the interface surfaces are ground, overlapped, or otherwise machined to produce a smooth interface surface and a fluid-sealed corner interface. In some embodiments, the interface surfaces have surface textures, surface features, or sintered articles that create one or more voids at the corner interface between the corner segments. In some embodiments, radial compression of the corner segments at the corner interface deforms the interface surface to create a fluid-sealed interface. In some embodiments, voids or other spaces between the corner segments allow fluid to flow through them in the axial direction, eliminating the need for pressure balancing orifices.

[0100] In some embodiments, the needle body having multiple corner segments is radially compressed by the base. In some embodiments, the needle body including multiple corner segments includes threads. For example, diamond threads may be formed in the corner segments, wherein at least a portion of the threads are present in each of the corner segments. The threads may be formed in the outer surface of the corner segments such that at least one thread is continuous between adjacent corner segments.

[0101] In some embodiments, the additional material may be located between at least two of the corner segments. For example, an adhesive or other filler material may be positioned on one or both interface surfaces at the corner interface. In some embodiments, the adhesive may promote microstructural bonding between the corner segments. In some embodiments, the adhesive may adhere to the corner segments. In some embodiments, a filler material fills at least one gap between the corner segments to seal the corner interface. Such an adhesive or filler material may limit and / or prevent leakage through the corner interface and through the needle body.

[0102] In some embodiments, the throttle valve has a seal at the longitudinal end of the needle body. The seal can be formed by deformation of the gasket material or the base material itself. In some embodiments, the diamond thread and the base thread cooperate to apply a force in the axial direction. The axial force applies compressive force in the axial direction between the chamfer, bent edge, or other angled edge of the needle body and the circumferential edge of the base. In some embodiments, the circumferential edge is located near a pressure balancing cavity or other void in the base (e.g., a pressure balancing cavity as described herein). In some embodiments, the compressive force causes the diamond of the needle body to deform the base material at the circumferential edge to create a fluid-tight seal and ensure that any fluid flows through a planned channel (e.g., a pressure balancing orifice).

[0103] In some embodiments, the throttle valve further includes a gasket that is compressible in the axial direction between the needle body and the base to further seal the threaded portion and limit and / or prevent leakage. In some embodiments, the gasket comprises a polymer material. In some embodiments, the gasket comprises a malleably deformable metal. In some embodiments, the gasket is adhered to the needle body. In some embodiments, the gasket is adhered to the base.

[0104] In some embodiments, the throttle valve has a tapered (i.e., gradually tapering) needle-shaped threaded portion to form a seal longitudinally within the threaded portion. For example, the needle body gradually tapers in the axial direction through at least a portion of diamond threads. In some embodiments, the needle body and the base gradually taper in the axial direction through at least a portion of diamond threads and base threads, respectively. In some embodiments, the tapered (i.e., gradually tapering) threaded portion of the needle body generates a radially oriented compressive force between the diamond threads and the base threads to concentrate the compressive force and further promote deformation of the base threads. In some embodiments, the base is tapered (gradually tapering) in the base threaded portion (e.g., the female box) to concentrate the compressive force and further promote deformation of the base threads.

[0105] In some embodiments, the throttle valve has cut surfaces on the needle body and / or base that cut or deform the contact surfaces to form a seal. In some embodiments, the shoulder surface of the base and the flange surface of the needle body contact each other to restrict and / or prevent fluid flow therebetween. In some embodiments, the fluid flow therebetween is further restricted by cut structures located on or in the flange surface. When the needle body is screwed into or otherwise pressed into the base, the cut structures cut into the shoulder surface of the base and / or apply force thereto. The cut structures can plastically or elastically deform the shoulder surface to form a fluid seal on the shoulder surface. In some embodiments, the cut structures are continuous around the circumference of the flange surface. In some embodiments, the flange surface has a plurality of discrete cut elements that plastically or elastically deform the shoulder surface to form a fluid seal on the shoulder surface.

[0106] In at least one embodiment of this disclosure, the throttle valve (including a needle body and / or seat made of large-size diamond blank, and / or a needle body and / or seat made of segments of large-size diamond blank) has a longer operating life and provides a longer uptime compared to conventional steel throttle valves.

[0107] This disclosure relates to systems and methods for attaching large-size diamond blanks to non-diamond bases according to any of the following:

[0108] Item 1. An apparatus comprising: a needle body including an integral diamond blank having a tapered surface facing distally; and a base comprising a non-diamond material positioned in an axial direction around a proximal portion of the needle body opposite to the distal end and applying a compressive force to the proximal portion of the needle body.

[0109] Item 2. The apparatus according to Clause 1, wherein the monolithic diamond blank has at least one dimension greater than 10 millimeters.

[0110] Item 3. The device according to Clause 1, wherein the integral diamond blank has a diameter greater than 10 mm relative to the axial direction.

[0111] Item 4. The apparatus according to Clause 1, wherein the coefficient of thermal expansion of the base is greater than the coefficient of thermal expansion of the diamond blank.

[0112] Item 5. The device according to Clause 1, wherein the needle body includes a deflecting surface adjacent to the tapered surface in the axial direction.

[0113] Item 6. The device according to Clause 1 further includes a spacer between the conical surface and the base, wherein the spacer is at least 10% of the length of the needle body.

[0114] Item 7. The device according to Clause 1, wherein the proximal portion is at least 25% of the length of the needle body.

[0115] Item 8. The device according to Clause 1 further includes a pressure balancing cavity between at least a portion of the needle body and at least a portion of the base.

[0116] Item 9. The device according to Clause 8 further includes a pressure balancing port extending from the distal end through the needle body to the pressure balancing chamber.

[0117] Item 10. The device according to Clause 1, wherein the distal end is truncated.

[0118] Item 11. The apparatus according to Clause 1, wherein the diamond material has a flexural strength greater than 800 MPa and a fracture toughness greater than 8 MPa, and a diamond volume fraction greater than 90%.

[0119] Item 12. The apparatus according to Clause 1, wherein the diamond material has been stress-relieving treated.

[0120] Item 13. The device according to Clause 1, wherein the needle body includes a plurality of angular segments relative to the axial direction.

[0121] Item 14. The apparatus as described in Clause 13, wherein the corner segments of the plurality of corner segments have a consistent arc length.

[0122] Item 15. The apparatus as described in Clause 13, wherein at least two of the plurality of corner segments are in direct contact with each other at the interface.

[0123] Item 16. An apparatus comprising: a needle body including an integral diamond blank having distal and proximal portions; a base comprising a non-diamond material; a diamond thread positioned in an axial direction on the proximal portion of the needle body opposite the distal portion; and a base thread positioned on the base and complementaryly engaging with the diamond thread.

[0124] Item 17. The device according to Clause 16 further includes a pressure balancing cavity between at least a portion of the needle body and at least a portion of the base.

[0125] Item 18. The device according to Clause 17 further includes a pressure balancing hole extending from the distal end to the pressure balancing chamber through the needle body.

[0126] Item 19. The device according to Clause 16, wherein the base thread exhibits a cold-forged microstructure when mating with the diamond thread.

[0127] Item 20. The apparatus according to Clause 16, wherein the diamond thread has a diamond radius of curvature, the diamond radius of curvature being at least 10% of the diamond thread depth.

[0128] Item 21. The device according to Clause 16, wherein the non-diamond material is an iron-containing material.

[0129] Item 22. The apparatus according to Clause 16, wherein the diamond material has a flexural strength greater than 800 MPa, a fracture toughness greater than 8 MPa, and a diamond volume fraction greater than 90%.

[0130] Item 23. The apparatus according to Clause 16, wherein the diamond material has been stress-relieving treated.

[0131] Item 24. The device according to Clause 16, wherein the needle body includes a plurality of angular segments relative to the axial direction.

[0132] Item 25. The apparatus according to Clause 24, wherein the corner segments of the plurality of corner segments have a consistent arc length.

[0133] Item 26. The apparatus as described in Clause 24, wherein at least two of the plurality of corner segments are in direct contact with each other at the interface.

[0134] Item 27. A method for joining diamonds, the method comprising: machining diamond threads in a large-size diamond blank; forming base threads in a base; and screwing the diamond threads into the base threads.

[0135] Item 28. The method according to Clause 27 further includes deforming the base thread with the diamond thread to complementarily engage with the base thread.

[0136] Item 29. The method according to Clause 28, wherein, prior to deforming the base thread, the base thread has a base thread depth greater than the diamond thread depth.

[0137] Item 30. The method according to Clause 29, wherein the diamond thread has a diamond radius of curvature that is greater than the base radius of curvature before deforming the base thread.

[0138] Item 31. The method according to Clause 27, wherein machining the diamond thread includes laser machining the diamond thread.

[0139] Item 32. The method according to Clause 31 further includes sandblasting the diamond threads after laser processing.

[0140] Item 33. The method according to Clause 32, wherein the sandblasting comprises sandblasting the diamond threads with silicon carbide.

[0141] Item 34. The method according to Article 31, wherein laser processing of the diamond thread comprises laser processing the diamond thread at an angle substantially tangential to the surface of the large-size diamond blank.

[0142] Item 35. The method according to Item 34, wherein the fundamental tangent angle is an angle of less than 20° with respect to the tangent to the surface of the large-size diamond blank.

[0143] Item 36. The method according to Article 27, wherein the diamond material of the large-size diamond blank has a flexural strength greater than 800 MPa and a fracture toughness greater than 8 MPa, and a diamond volume fraction greater than 90%.

[0144] Item 37. The method as described in Item 27, wherein the diamond material of the large-size diamond blank has been subjected to stress-relieving treatment.

[0145] Item 38. A method of joining diamonds, the method comprising: machining diamond threads in a diamond needle body comprising a plurality of corner segments, wherein at least a portion of the diamond threads is provided on each of the plurality of corner segments; forming base threads in a base; and screwing the diamond threads into the base threads.

[0146] Item 39. The method according to Clause 38 further includes deforming the base thread with the diamond thread to complementarily engage with the base thread.

[0147] Item 40. The method according to Clause 39, wherein, prior to deforming the base thread, the base thread has a base thread depth greater than the diamond thread depth.

[0148] Item 41. The method according to Clause 40, wherein the diamond thread has a diamond radius of curvature, and the diamond radius of curvature is greater than the base radius of curvature before the base thread is deformed.

[0149] Item 42. The method according to Clause 38, wherein machining the diamond thread includes laser machining the diamond thread.

[0150] Item 43. The method according to Clause 42 further includes sandblasting the diamond threads after laser processing.

[0151] Item 44. The method according to Clause 43, wherein the sandblasting comprises sandblasting the diamond threads with silicon carbide.

[0152] Item 45. The method according to Clause 42, wherein laser processing of the diamond thread comprises laser processing the diamond thread at an angle substantially tangential to the surface of the diamond needle body comprising a plurality of corner segments.

[0153] Item 46. The method according to Clause 45, wherein the substantially tangent angle is an angle of less than 20° with the tangent to the surface of the diamond needle body comprising a plurality of angular segments.

[0154] Item 47. The method according to Clause 38, wherein the diamond material of each corner segment of the diamond needle body has a flexural strength greater than 800 MPa and a fracture toughness greater than 8 MPa, and a diamond volume fraction greater than 90%.

[0155] Item 48. The method according to Clause 38, wherein the diamond material of each corner segment of the diamond needle body has undergone stress-relieving treatment.

[0156] It should be understood that references to "one embodiment" or "embodiment" in this disclosure are not intended to exclude the existence of additional embodiments that also include the described features. For example, any element described with respect to embodiments herein may be combined with any element of any other embodiment described herein, provided that such features are not described as mutually exclusive. Numbers, percentages, ratios, or other values ​​used herein are intended to include that value, as well as other values ​​that are "about," "substantially," or "approximately" said values, as will be understood by one of ordinary skill in the art as covered by embodiments of this disclosure. Therefore, the values ​​should be interpreted broadly enough to cover values ​​that are at least sufficiently close to the value to perform the desired function or achieve the desired result. The values ​​include at least the variation expected in a suitable manufacturing or production process and may include values ​​within 5%, 1%, 0.1%, or 0.01% of the stated value.

[0157] As used herein, the terms “approximately,” “about,” and “substantially” mean quantities close to the stated amount, which are within standard manufacturing or process tolerances, or which still perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” and “substantially” can refer to quantities less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount. Furthermore, it should be understood that any directions or frames of reference described above are only relative directions or movements. For example, any references to “up” and “down,” or “above” or “below”, describe only the relative position or movement of the relevant element.

[0158] In view of this disclosure, those skilled in the art should recognize that equivalent constructions do not depart from the spirit and scope of this disclosure, and various changes, substitutions, and modifications can be made to the embodiments disclosed herein without departing from the spirit and scope of this disclosure. Equivalent constructions including the functional "device plus function" clause are intended to cover structures described herein as performing the stated function, including structural equivalents operating in the same manner and equivalent structures providing the same function. The applicant expressly states that no claim refers to a device plus function or other functional claims except those claims that use the word "device" in conjunction with the relevant function. Every addition, deletion, and modification to the embodiments falling within the meaning and scope of the claims will be covered by the claims. Therefore, the described embodiments are considered illustrative rather than restrictive, and the scope of this disclosure is indicated by the appended claims rather than the foregoing description.

Claims

1. An apparatus comprising: A needle body having a tapered surface toward a distal end and a proximal portion opposite the distal end in an axial direction, wherein the surface of the needle body comprises polycrystalline diamond. and A base comprising a non-diamond material positioned around the proximal portion, wherein the base is press-fitted to the proximal portion of the needle body.

2. The apparatus according to claim 1, wherein, The needle body comprises a monolithic diamond blank.

3. The apparatus according to claim 2, wherein, The monolithic diamond blank is a large-size diamond blank with at least one dimension greater than 10 mm.

4. The apparatus according to claim 1, wherein, The press fit is an interference fit.

5. The apparatus according to claim 1, wherein, The compression fit is a contraction fit.

6. The device of claim 1, wherein the needle body comprises a plurality of angular segments relative to the axial direction.

7. The apparatus according to claim 6, wherein, The corner segments among the plurality of corner segments have a consistent arc length.

8. The apparatus of claim 1 further includes a diamond valve seat configured to receive the tapered surface of the needle body.

9. An apparatus comprising: A needle body having a tapered surface toward a distal end and a proximal portion opposite the distal end in an axial direction, wherein the surface of the needle body comprises polycrystalline diamond. The base comprises a non-diamond material; Diamond threads are located in the surface comprising polycrystalline diamond on the proximal portion of the needle body; and A base thread, which is positioned on the base and complementarily engages with the diamond thread.

10. The apparatus of claim 9, further comprising a pressure balancing cavity between at least a portion of the needle body and at least a portion of the base.

11. The apparatus of claim 10, further comprising a pressure balancing hole extending from the distal end through the pressure balancing chamber into the needle body.

12. The apparatus according to claim 9, wherein, When mates with the diamond thread, the base thread exhibits a cold-forged microstructure.

13. The apparatus of claim 9, wherein the diamond thread has a diamond radius of curvature, the diamond radius of curvature being at least 10% of the diamond thread depth.

14. The device of claim 9, wherein the needle body comprises a plurality of angular segments relative to the axial direction.

15. The apparatus according to claim 14, wherein, The corner segments among the plurality of corner segments have a consistent arc length.

16. A method for bonding diamonds, the method comprising: Machining diamond threads in a monolithic diamond blank; A base thread is formed in the base; and The diamond thread is screwed into the base thread.

17. The method of claim 16, further comprising using the diamond thread to deform the base thread to complementarily engage with the base thread.

18. The method according to claim 17, wherein, Before deforming the base thread, the base thread has a base thread depth greater than that of the diamond thread.

19. The method of claim 17, wherein, The diamond thread has a diamond radius of curvature, which is greater than the base radius of curvature before the base thread is deformed.

20. The method of claim 16, wherein, Machining the diamond thread includes laser machining of the diamond thread.

21. The method according to claim 16, wherein, The monolithic diamond blank is the first corner segment among multiple corner segments of the diamond needle body, and The method further includes: Diamond threads are machined in the second corner segment of the plurality of corner segments to form a continuous diamond thread between the first corner segment and the second corner segment.

22. A method for bonding diamonds, the method comprising: The proximal portion of the diamond blank is inserted into the base such that at least a portion of the base circumferentially surrounds the proximal portion; and The base is used to compress the proximal portion of the diamond blank.

23. The method according to claim 22, wherein the method comprises: A tapered surface is machined in the distal portion of the diamond blank.

24. The method of claim 23, wherein the method comprises: The base is heated before the proximal portion of the diamond blank is inserted into the base; and The base is cooled to produce thermal shrinkage of the base.

Images