803 results about "Superhard material" patented technology

Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure / high temperature process.

The present invention discloses a CMP pad dresser which has a plurality of uniformly spaced abrasive particles protruding therefrom. The abrasive particles are super hard materials, and are typically diamond, polycrystalline diamond (PCD), cubic boron nitride (cBN), or polycrystalline cubic boron nitride(PcBN). The abrasive particles are brazed to a substrate which may be then coated with an additional anti-corrosive layer. The anti-corrosive layer is usually a diamond or diamond-like carbon which is coated over the surface of the disk to prevent erosion of the brazing alloy by the chemical slurry used in conjunction with the CMP pad. This immunity to chemical attack allows the CMP pad dresser to dress the pad while it is polishing a workpiece. In addition to even spacing on the substrate, the abrasive particles extend for a uniform distance away from the substrate, allowing for even grooming or dressing of a CMP pad both in vertical and horizontal directions. A method of producing such a CMP pad dresser is also disclosed.

Cutting elements of this invention include an ultra hard body joined with a metallic substrate. The body includes an uppermost layer comprising a plurality of bonded ultra hard crystals and interstitial regions, and that defines a body working surface. The uppermost layer includes an outer region that is relatively more thermally stable than a remaining portion of the uppermost layer. The body further includes an intermediate layer joined to the uppermost layer, comprising a plurality of bonded ultra hard crystals, and having a wear resistance less than that of the uppermost layer remaining region. The body may additionally include a lowermost PCD layer that is interposed between and attached to the intermediate layer and the substrate.

Cutting elements of this invention include an ultra hard body joined with a metallic substrate. The body includes an uppermost layer comprising a plurality of bonded ultra hard crystals and interstitial regions, and that defines a body working surface. The uppermost layer includes an outer region that is relatively more thermally stable than a remaining portion of the uppermost layer. The body further includes an intermediate layer joined to the uppermost layer, comprising a plurality of bonded ultra hard crystals, and having a wear resistance less than that of the uppermost layer remaining region. The body may additionally include a lowermost PCD layer that is interposed between and attached to the intermediate layer and the substrate.

Thermally stable ultra-hard compact constructions comprise a polycrystalline diamond body substantially free of a catalyst material, and a substrate that is joined thereto. The substrate can be ceramic, metallic, cermet and combinations thereof, and can be joined to the body by a braze material or other material that forms an attachment bond at high pressure / high temperature conditions. The body and substrate are specially formed having complementary interfacing surface features to facilitate providing an improved degree of attachment therebetween. The complementary surface features can in the form of openings and projections, e.g., one of the body or substrate can comprise one or more openings, and the other of the body or substrate can comprise one or more projections, disposed within or extending from respective interfacing surfaces. The complementary surface features operate to resist unwanted delamination between the body and substrate, thereby extending effective service life of the construction.

A non-uniform interface is formed between a polycrystalline ultra hard material layer and a cemented tungsten carbide substrate, or a polycrystalline ultra hard material layer and a transition layer, or a transition layer and a substrate of a cutting element. A first sheet made from an intermediate material is formed and embossed on one face forming a non-uniform pattern raised in relief on the face. The embossed sheet is placed on a face of a presintered substrate. An ultra hard material sheet is formed and embossed, forming a non-uniform face complementary to the non-uniform face on the sheet of intermediate material. The ultra hard material sheet is placed over the intermediate material sheet so that the complementary faces are adjacent to each other. The assembly of substrate and sheets is sintered in a HPHT process. The sintering process causes the first sheet to become integral with the substrate and results in a substrate having a non-uniform cutting face onto which is bonded a polycrystalline ultra hard material layer. Embossed transition material sheets may be employed between the ultra hard material sheet and the first sheet to form transition layers with uniform or non-uniform interfaces.

Cutting elements having coarse grain substrates and ultra hard material layers are provided. The substrates are formed from coarse grain size particles of tungsten carbide. A method of forming such cutting elements and a drag bit incorporating such cutting elements are also provided.

The present invention discloses a CMP pad dresser which has a plurality of uniformly spaced abrasive particles protruding therefrom. The abrasive particles are super hard materials, and are typically diamond, polycrystalline diamond (PCD), cubic boron nitride (cBN), or polycrystalline cubic boron nitride(PcBN). The abrasive particles are brazed to a substrate which may be then coated with an additional anti-corrosive layer. The anti-corrosive layer is usually a diamond or diamond-like carbon which is coated over the surface of the disk to prevent erosion of the brazing alloy by the chemical slurry used in conjunction with the CMP pad. This immunity to chemical attack allows the CMP pad dresser to dress the pad while it is polishing a workpiece. In addition to even spacing on the substrate, the abrasive particles extend for a uniform distance away from the substrate, allowing for even grooming or dressing of a CMP pad both in vertical and horizontal directions. A method of producing such a CMP pad dresser is also disclosed.

In one aspect of the present invention, a high impact resistant tool, having a super hard material is bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide segment. A stem is formed in the base end of the carbide segment opposite the front end and the carbide stem is press fitted into bore of a steel body.

In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to an interfacial surface of the base. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.

In one aspect of the present invention, a high impact resistant tool has a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide segment. A stem formed in the base end of the carbide segment opposite the front end is press fit into a bore of a steel body. The steel body is rotationally fixed to a drum adapted to rotate about its axis.

A cutting device comprises a base having a working side that is oriented to face a workpiece from which material is to be removed. A plurality of individual cutting elements are arranged on the working side of the base, with each cutting element having a peak that comprises at least one cutting edge that is formed from a polycrystalline superhard material. The peaks of the cutting elements are aligned in a common plane.

In one aspect of the present invention, a high impact wear resistant tool has a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a thickness of at least 0.100 inch and forms an included angle of 35 to 55 degrees. The superhard material has a plurality of substantially distinct diamond layers. Each layer of the plurality of layers has a different catalyzing material concentration. A diamond layer adjacent the substrate of the superhard material has a higher catalyzing material concentration than a diamond layer at a distal end of the superhard material.

A high impact resistant pick in a holder having a super hard material bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. A bore is formed in a base end of the carbide bolster generally opposed to the front end. A steel shank being fitted into the bore of the bolster at a bolster end of the shank, and a portion of the shank is disposed within a bore of the holder at a holder end of the shank.

In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to an interfacial surface of the base. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.

An earth-boring bit has a bit body and at least one cantilevered bearing shaft depending inwardly and downwardly from the bit body. A cutter is mounted for rotation on the bearing shaft and includes a plurality of cutting elements. At least one of the cutting elements has a generally cylindrical body formed of hard metal with a convex cutting end. A plurality of recesses extend longitudinally from the apex to the junction. The recesses are shallow grooves symmetrically spaced about the axis. A layer of super-hard material is formed on the cutting end of the body and overlays the recesses formed thereon.

A weldable ultrahard insert can include an ultrahard working layer and a weldable metal layer metallically bonded with the working layer. The ultrahard working layer can be any ultrahard material such as PCD, PCBN, metal carbide, ceramic, diamond, or the like. The weldable ultrahard inserts can be formed by charging a reaction vessel with ultrahard materials, including precursors thereof, and placing a weldable metal layer in the reaction vessel with an optional intermediate layer. The assembly can be subjected to a pressure and a temperature sufficient to metallically bond the weldable metal layer to the ultrahard material. The weldable layer is formed as part of the insert in situ which facilitates subsequent welding of the insert to a tool substrate without risking damage to the ultrahard material.

The present invention generally provides an insert for a clamping device or gripping apparatus for conducting translational forces and / or torque into a moveable object, such as a tubular, casing, liner, pipe, expandable tubular, tubing, drill pipe. In one aspect, the insert comprises a base material and a plurality of gripping elements forming an object gripping surface. Gripping elements are at least partially embedded in the base material. The gripping elements in one embodiment are curved to correspond to an outer circumference of an object to be gripped. In one embodiment, the gripping elements are inclined relative to a longitudinal axis of the insert. In another aspect, the gripping elements may comprise grains or particles of a hardened or super-hard material. The present invention also provides a method of making the insert and using the insert in a gripping apparatus.

In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface.

The invention relates to an injection molding formula for a ceramic bond superhard material grinding tool. The injection molding formula comprises following components: 100wt% of total amount of ceramic system, 5-30wt% of the ceramic system of macromolecule system, and 5-8wt% of the ceramic system of wetting agent. An injection molding method comprises steps of burdening, mixing materials, molding, degreasing and sintering. Due to the formula and additive amount of macromolecule bonder, friction force in molding is improved, the fluidity of the molding material is guaranteed, and the ceramic superhard material grinding tool product with good tissue homogeneity and high quality stability is prepared through injection molding without mixing and prilling.

In one aspect of the present invention, a high impact resistant excavation pick having a super hard material is bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide frustum. A tapered bore is formed in the base end of the carbide frustum opposite the front end and a steel shank with a tapered interface is fitted into the tapered bore.

In one aspect of the invention, a pick comprises a carbide bolster disposed intermediate an impact tip and a shank assembly. The impact tip comprises a superhard material bonded to a carbide substrate, and the tip is bonded to the bolster opposing a base of the bolster. The shank assembly comprises a central axis, a first end that protrudes into a cavity formed in the base of the bolster, and also an inducible attachment mechanism disposed proximate the first end. The inducible attachment mechanism is adapted to attach the shank assembly to the carbide bolster and restrict movement of the shank assembly with respect to the carbide bolster. The attachment mechanism may restrict movement of the shank assembly in a direction parallel to the central axis.

A high-impact resistant pick having a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. A bore formed in a base end of the carbide bolster is generally opposed to the front end. A steel body has a shaft extending distally from a shelf, and which shaft is fitted into the bore of the bolster at an interface. A shank adapted for connection to a driving mechanism extends proximally from the steel body opposite the shaft. A washer is disposed intermediate the base end of the carbide bolster and the shelf of the steel body.

Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

A cutting tool for use in impinging earth strata includes a cutting tool body having a head portion at an axial forward end, a collar portion axially rearward of the head portion, and a shank portion axially rearward of the collar portion at an axial rearward end, wherein the cutting tool body contains a first socket at the axial forward end thereof. The shank portion generally tapers in the axial rearward direction. The cutting tool also includes a hard cutting member affixed to the cutting tool body within the first socket. The hard cutting member includes an axial forward end and an axial rearward end. The hard cutting member also includes a superhard axial forward portion of the axial forward end thereof, wherein the superhard axial forward portion comprises a substrate and a layer of superhard material adhered to the substrate.

The invention discloses a low-temperature high-strength microcrystalline glass vitrified bond used for preparing grinding tools made of superhard material diamond and cubic boron nitride. The components and the weight percentage are that SiO2 takes 40-70%, B2O3 takes 5-25%, Al2O3 takes 2-5%, Na2O takes 2-15%, K2O takes 2-5%, MgO takes 2-4%, CaO takes 2-4%, Li2O takes 1-10%, ZrO2 takes 2-5% and Sb2O3 takes 2-5%. The microcrystalline glass is abtaind by sintering the powder, the temperature of sintering-crystallization is 700-900 DEG C, the thermal expansion coefficient is 4-10*10-6 / DEG C and the bending strength can reach 160-200MPa. The grinding tool prepared by the combination of the microcrystalline glass and the powders of diamond and cubic boron nitride can satisfy the using speed of 160m / s or more. The invention has the advantages of low sintering temperature of the bond, low thermal expansion coefficient and high strength.