IP Library › Granted Patent US 9,447,642
Granted Patent B2
US 9,447,642 · App. 14/076,431 · Granted Sep 20, 2016

Polycrystalline diamond material with high toughness and high wear resistance

Inventors: Federico Bellin (The Woodlands, TX); Yi Fang (Orem, UT); Michael Stewart (Provo, UT); Nephi A. Mourik (Provo, UT); Peter T. Cariveau (Draper, UT)
Assignee: Smith International, Inc.
E21B10/567C22C26/00E21B10/55E21B10/5735B22F2999/00C22C2204/00
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Quick Facts
Patent No.
US 9,447,642
App. No.
14/076,431
Granted
Sep 20, 2016
Kind
B2
Abstract

A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 85% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 35% by weight of the plurality of metallic phases is disclosed.

Claims (41)

1. A cutting element, comprising:

a substrate; and

an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material comprises:

a plurality of interconnected diamond particles; and

a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles;

wherein the plurality of interconnected diamond particles form at least about 60 to at most about 85% by weight of the polycrystalline diamond material; and

wherein the plurality of metal carbide phases represent at least 35% by weight of the plurality of metallic phases.

2. The cutting element of claim 1 , wherein the plurality of interconnected diamond particles form at least about 60 to at most about 68% by weight of the polycrystalline diamond material.

3. The cutting element of claim 1 , wherein the plurality of interconnected diamond particles form at least about 68 to at most about 72% by weight of the polycrystalline diamond material.

4. The cutting element of claim 1 , wherein the plurality of metal binder phases represent at least 12% by weight of the plurality of metallic phases.

5. The cutting element of claim 4 , wherein the plurality of metal binder phases represent at least 25% by weight of the plurality of metallic phases.

6. The cutting element of claim 1 , wherein the average size of the diamond particles is greater than the average size of the metal carbide phases.

7. The cutting element of claim 1 , wherein the polycrystalline diamond material has a hardness of at least 3000 HV.

8. The cutting element of claim 1 , wherein the polycrystalline diamond material has a hardness of at least 3500 HV.

9. The cutting element of claim 1 , wherein an average distance between the bonded diamond particles is less than an average particle size of the diamond particles.

10. The cutting element of claim 1 , further comprising at least one transition layer disposed between the substrate and the outer layer, wherein the at least one transition layer comprises diamond particles, metal carbide, and a metal binder.

11. The cutting element of claim 10 , wherein the at least one transition layer has a diamond content less than a diamond content of the outer layer.

12. The cutting element of claim 10 , wherein the at least one transition layer has a metal carbide content greater than a metal carbide content of the outer layer.

13. A cutting element, comprising:

a substrate; and

an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material comprising:

a plurality of interconnected diamond particles; and

a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles;

wherein the plurality of interconnected diamond particles form at least about 60% by weight of the polycrystalline diamond material; and

wherein the plurality of metal carbide phases represent about 7 to 35% by weight of the polycrystalline diamond material, and wherein the plurality of metal carbide phases represent at least 35% by weight of the plurality of metallic phases.

14. The cutting element of claim 13 , wherein the plurality of metal carbide phases represent at least 50% by weight of the plurality of metallic phases.

15. The cutting element of claim 13 , wherein the plurality of metal binder phases represent at least 12% by weight of the plurality of metallic phases.

16. The cutting element of claim 15 , wherein the plurality of metal binder phases represent at least 25% by weight of the plurality of metallic phases.

17. The cutting element of claim 13 , wherein the plurality of interconnected diamond particles form at least about 75% by weight of the polycrystalline diamond material.

18. The cutting element of claim 13 , wherein the plurality of interconnected diamond particles form no more than about 85% by weight of the polycrystalline diamond material.

19. The cutting element of claim 13 , further comprising at least one transition layer disposed between the substrate and the outer layer, wherein the at least one transition layer comprises diamond particles, metal carbide, and a metal binder.

20. The cutting element of claim 19 , wherein the at least one transition layer has a diamond content less than a diamond content of the outer layer.

21. The cutting element of claim 19 , wherein the at least one transition layer has a metal carbide content greater than a metal carbide content of the outer layer.

22. A drill bit, comprising:

a tool body, and at least one cutting element, the cutting element comprising:

a substrate; and

an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material comprising:

a plurality of interconnected diamond particles; and

a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles;

wherein the plurality of interconnected diamond particles form at least about 60% by weight of the polycrystalline diamond material; and

wherein the plurality of metal carbide phases represent at least 35% by weight of the plurality of metallic phases.

Continuity (3)
Continuation 12851677 · Aug 6, 2010
Provisional Application 61232134 · Aug 7, 2009
Related Publication 20140060938A1 · Mar 6, 2014