Segmented Superabrasive Compacts for Rotary Drill Bit Repair
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Solution Overview
Problem
Conventional polycrystalline diamond compacts (PDCs) lack improved toughness, wear resistance, and thermal stability, which limits their operational lifetime in applications like rotary drill bits and machining equipment.
Innovation Solution
The development of superabrasive compacts with multiple superabrasive cutting portions bonded to a cemented carbide substrate, where one cutting portion can be used when the other is worn, and the use of a metal-solvent catalyst to enhance bonding and thermal stability, along with leaching to remove catalyst for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single PDC cutting element is used in a rotary drill bit, then the initial cutting performance is good, but the operational lifetime is limited due to wear
Solution Approach 1:
The PDC assembly is segmented into multiple cutting portions (first superabrasive cutting portion and second superabrasive cutting portion) bonded to opposite surfaces of a single cemented carbide substrate. This segmentation allows one cutting portion to be used when the other is worn, effectively doubling the operational lifetime while maintaining consistent cutting performance throughout the service life.
2Reliability
If conventional HPHT process is used to fabricate PDCs, then the diamond particles bond to form a matrix, but the thermal stability and wear resistance are insufficient
Solution Approach 1:
The HPHT fabrication parameters are optimized to create a denser, more thermally stable diamond matrix. Additionally, the use of cemented carbide substrates with specific compositions and the controlled infiltration of metal-solvent catalysts during HPHT processing enhance the thermal stability and wear resistance of the final PDC structure.
Solution Approach 2:
The PDC assembly uses a composite structure combining cemented carbide substrate with superabrasive diamond cutting portions. This composite material approach leverages the high strength and thermal stability of cemented carbide while incorporating the extreme wear resistance of diamond, achieving superior overall performance.
3Reliability
If metal-solvent catalyst is used during HPHT process, then diamond particle intergrowth is promoted, but the catalyst remains in interstitial regions reducing performance
Solution Approach 1:
The metal-solvent catalyst is intentionally left in the interstitial regions during HPHT processing to promote diamond particle bonding, then subsequently removed through leaching or other extraction methods. This two-stage approach first utilizes the catalyst for its bonding function, then eliminates it to prevent performance degradation from catalyst presence in the final product.
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
This design extends the operational lifetime of superabrasive compacts by allowing the use of a non-worn cutting portion when one is worn, and enhances thermal stability and wear resistance, making them suitable for demanding applications like rotary drill bits and machining equipment.
Implementation Method 1
The substrate(s) and volume(s) of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains
Implementation Method 2
The diamond table is formed and bonded to a substrate using a high-pressure/high-temperature ('HPHT') process
Implementation Method 3
leaching to remove catalyst for improved performance
Data Source
AI summary
Embodiments of the invention relate to superabrasive compacts including multiple superabrasive cutting portions and methods of repairing a rotary drill bit that employs at least one of such superabrasive compacts.