Shear-Resistant Joint Between Superabrasive Body and Substrate

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Superabrasive compacts used in drilling tools face issues with cracking and delamination due to mismatched coefficients of thermal expansion and residual stresses between the superabrasive body and the substrate, leading to reduced durability and performance.

Innovation Solution

Incorporating a metallic member between the superabrasive body and the substrate, which is deformed to conform to complementary surface features, forming a shear-resistant joint without requiring high-pressure/high-temperature processing or brazing, thereby reducing stresses and enhancing bonding strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the superabrasive body is directly bonded to the substrate using HPHT process or brazing, then strong bonding is achieved, but cracking and delamination occur due to mismatched coefficients of thermal expansion and residual stresses

Engineering Contradiction:

Improvebonding strengthVSAvoiddurability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A metallic member is introduced as an intermediary between the superabrasive body and the substrate. This metallic member has a coefficient of thermal expansion that is intermediate between those of the superabrasive body and the substrate, thereby reducing thermal stress and preventing cracking and delamination while maintaining bonding strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The joint structure comprises a composite assembly of three different materials: the superabrasive body, the metallic member, and the substrate. This composite structure allows each material to contribute its favorable properties, with the metallic member specifically addressing the thermal expansion mismatch issue.

Inventive Principle:

Principle #40Composite materials

2Strength

If a metallic member is deformed to conform to surface features to form a shear-resistant joint, then bonding strength and shear resistance are improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveshear resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Surface features are pre-formed on both the superabrasive body and the substrate before assembly. The metallic member is then deformed to conform to these pre-established surface features, creating a shear-resistant mechanical interlock. This preliminary preparation of surfaces simplifies the overall manufacturing process compared to attempting to create the interlocking features during assembly.

Inventive Principle:

Principle #10Preliminary action

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 solution provides superior performance by reducing cracking and breakage, allowing for thicker superabrasive bodies and eliminating liquid metal embrittlement, resulting in improved durability and reliability of the superabrasive compacts in drilling applications.

Implementation Method 1

The metallic member deformed to substantially conform to the surface feature of the bonding surface and the substrate surface feature of the interfacial surface

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10087685B1Shear-resistant joint between a superabrasive body and a substrate

Publication Date: 2018.10.02 US SYNTHETIC CORP

AI summary

Embodiments disclosed herein relate to superabrasive compacts having a metallic member disposed between a superabrasive body and a substrate; and drill bits and methods of making the same.