Laser-Polished Superabrasive Cutting Elements for Lower Wear

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Solution Overview

Problem

Earth-boring tools experience premature failure due to imperfections in cutting structures made from superhard or superabrasive materials, leading to increased wear and costs in drilling operations.

Innovation Solution

A method involving the formation of cutting elements with a polycrystalline cutting table, where the cutting surface is treated using laser pulsing to remove micro-anomalies and improve smoothness, reducing wear and extending the tool's lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If cutting structures are made from superhard materials, then hardness and cutting capability are improved, but micro-anomalies and imperfections in the material cause higher wear rates and premature failure

Engineering Contradiction:

ImprovehardnessVSAvoidwear resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies laser treatment to the cutting surface before the cutting element is put into service. This preliminary action removes micro-anomalies and imperfections from the superhard material surface, preventing them from causing premature failure during operation. The laser treatment is performed as a pre-processing step that eliminates potential failure points before the cutting element experiences stress loads and heat during drilling operations.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If traditional manufacturing methods are used for cutting elements, then production is simpler, but micro-anomalies remain on the cutting surface leading to premature failure

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsurface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical polishing and grinding methods with laser treatment. Instead of using mechanical abrasives to remove material and smooth the cutting surface, a laser beam is used to selectively remove micro-anomalies and imperfections. This substitution provides superior surface quality control while maintaining manufacturing efficiency, as the laser process can precisely target and remove defects without the limitations of mechanical contact methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The laser treatment process enhances the durability and efficiency of cutting elements by minimizing microcracks and imperfections, resulting in reduced wear rates and extended service life of earth-boring tools.

Implementation Method 1

treating a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12168266B2Methods of making a cutting element for an earth-boring tool, methods of reprocessing cutting elements, and associated cutting elements

Publication Date: 2024.12.17 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A method of making a cutting element for use on an earth-boring tool may include forming the cutting element including a cutting table formed from a superabrasive polycrystalline material. The method may further include polishing a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table. The cutting element may include a superabrasive polycrystalline cutting table including a cutting surface substantially free of micro-anomalies in the superabrasive material.