CA2132284A1 - Diamond drag bit cutting elements - Google Patents
Diamond drag bit cutting elementsInfo
- Publication number
- CA2132284A1 CA2132284A1 CA002132284A CA2132284A CA2132284A1 CA 2132284 A1 CA2132284 A1 CA 2132284A1 CA 002132284 A CA002132284 A CA 002132284A CA 2132284 A CA2132284 A CA 2132284A CA 2132284 A1 CA2132284 A1 CA 2132284A1
- Authority
- CA
- Canada
- Prior art keywords
- cutter
- set forth
- diamond
- stud
- insert stud
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 79
- 239000010432 diamond Substances 0.000 title claims abstract description 79
- 238000005520 cutting process Methods 0.000 title abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 25
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims abstract description 23
- 230000008569 process Effects 0.000 claims abstract description 16
- 239000002245 particle Substances 0.000 claims description 13
- 238000005245 sintering Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 4
- 230000007704 transition Effects 0.000 claims description 4
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 239000011435 rock Substances 0.000 claims description 3
- 239000002131 composite material Substances 0.000 abstract description 13
- 238000010345 tape casting Methods 0.000 abstract description 5
- 238000005219 brazing Methods 0.000 abstract description 2
- 238000010276 construction Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 36
- 239000000758 substrate Substances 0.000 description 10
- 230000015572 biosynthetic process Effects 0.000 description 7
- 239000011230 binding agent Substances 0.000 description 6
- 238000003786 synthesis reaction Methods 0.000 description 6
- 230000008901 benefit Effects 0.000 description 4
- 238000005553 drilling Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 238000005056 compaction Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 235000010980 cellulose Nutrition 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 235000019441 ethanol Nutrition 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009659 non-destructive testing Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
Abstract
DIAMOND DRAG BIT CUTTING ELEMENTS
Abstract of the Disclosure A unitized polycrystalline composite diamond stud type drag bit cutter has no high temperature braze of a PDC wafer to a cemented tungsten carbide stud, The diamond cutting surface may be planar, convex, curved or a truncated cone.
The polycrystalline diamond layer is applied to the surface of a carbide stud bya tape casting process. The unitized construction of the cutter eliminates the problems associated with the high temperature brazing of a PDC wafer to a carbide stud.
Abstract of the Disclosure A unitized polycrystalline composite diamond stud type drag bit cutter has no high temperature braze of a PDC wafer to a cemented tungsten carbide stud, The diamond cutting surface may be planar, convex, curved or a truncated cone.
The polycrystalline diamond layer is applied to the surface of a carbide stud bya tape casting process. The unitized construction of the cutter eliminates the problems associated with the high temperature brazing of a PDC wafer to a carbide stud.
Description
r~ ~? r, ~ ~
, ~ -DIAMOND DRAG BIT CUTTING ELEMENTS
Backqround The present invention relates to diamond drag bits. More particularly, this invention relates to diamond cutting elements for diamond drag bits.
Polycrystalline diamond compacts (PDC) have been effectively used for cutters on drag bits while drilling soft earthen formations in petroleum and mining exploration for more than a decade. The most common cutter type used in PDC
drag bits is classified in the drilling industry as a "stud" type PDC. For example, a typical stud type PDC cutter is illustrated in Figure 6 and Figure 7 of U.S. ~ :~
Patent No. 4,776,411.
Practically all stud-type PDC cutters used to date have been manufactured ~ r;
as two piece units. A thin layer ~approximately 0.7 to 1 mm) of polycrystalline diamond is chemically/metallurgically bonded to a face of a much thicker (approximately 4 to 5 mm) right cylinder wafer of cobalt cemeni:ed tungsten carbide. This integral diamond/carbide compact is then brazed to a cobalt cemented tungsten carbide modified cylindrical stud or post at an angle of ~ ~ ~
between 15 to 20 from the axis of the stud. The top surface of the stud is ' typically radiused to conform to the diamond/carbide wafer cylindrical surface and relieved rearwardly normal to the diamond surface.
Although PDC stud type cutters, as currently manufactured, serve a very :
useful purpose, there are several disadvantages in their manufacture and application. The flat on the stud to which the PDC wafer is brazed and the carbide side of the PDC wafer must have extremely fine ground surfaces to effect ~ -a braze of necessary strength. These grinding operations are time consuming and costly.
_1_ '~ ,~ ;,.. ~:
- ,` ,J ,~
. ! .
The bonding of the PDC wafer to the carbide stud is fraught with many variables that are difficult to control. The braze temperature is significantly higher than the thermal degradation temperature of the diamond layer and the bond interface of the diamond and carbide. Therefore, the diamond has to be protected by a complicated heat sink apparatus that is difficult to control during the braze cycle. A high reject ratio is inherent in this process, lowering output and driving up costs.
The actual braze quality is difficult to determine even with the most sophisticated non-destructive testing equipmentavailable. An undesirable level of less than good brazes go undetected and wind up as PDC cutter failures in thefield. The brazing process can also cause incipient and premature failure of thebond of the diamond layer to the carbide wafer which also will show up as a PDC
cutter failure in the field. It is also difficult to braze a PDC cutter wafer that has two or more carbide particle/diamond particle transition layers that have a highcobalt level because the high differential in thermal expansion causes the PDC
layer to crack during the braze cycle.
It would be desirable to provide a stud type PDC cutter that does not require a braze of a PDC wafer to a tungsten carbide stud. The new stud type PDC cutter disclosed herein eliminates the need to braze a PDC wafer to a tungsten carbide stud, thereby obviating the problems and inadequacies described above in current PDC stud design and processes.
Summarv of the Invention The present invention comprises a diamond insert stud cutter for a rock bit. Each cylindrical stud cutter is preferably formed with a cemented tungsten carbide body having a first cylindrical base end and a second cutter end having at least one diamond layer directly bonded to a pre-formed surface formed by thesecond cutter end. The diamond layer is formed by a high pressure, high temperature sintering process. The pre-formed surface may be angled negatively with respect to an axis of the stud body 5 to 30 with a preferred angle of 20 .
Brief DescriDtion of the Drawincs The above-noted features and advantages of the present invention will be more fully understood upon a study of the following description in conjunction 35 with the detailed drawings wherein:
FIGURE 1 is a partial cross-section of a prior art cylindrical stud type polycrystalline diamond compact drag bit cutter;
, ~ -DIAMOND DRAG BIT CUTTING ELEMENTS
Backqround The present invention relates to diamond drag bits. More particularly, this invention relates to diamond cutting elements for diamond drag bits.
Polycrystalline diamond compacts (PDC) have been effectively used for cutters on drag bits while drilling soft earthen formations in petroleum and mining exploration for more than a decade. The most common cutter type used in PDC
drag bits is classified in the drilling industry as a "stud" type PDC. For example, a typical stud type PDC cutter is illustrated in Figure 6 and Figure 7 of U.S. ~ :~
Patent No. 4,776,411.
Practically all stud-type PDC cutters used to date have been manufactured ~ r;
as two piece units. A thin layer ~approximately 0.7 to 1 mm) of polycrystalline diamond is chemically/metallurgically bonded to a face of a much thicker (approximately 4 to 5 mm) right cylinder wafer of cobalt cemeni:ed tungsten carbide. This integral diamond/carbide compact is then brazed to a cobalt cemented tungsten carbide modified cylindrical stud or post at an angle of ~ ~ ~
between 15 to 20 from the axis of the stud. The top surface of the stud is ' typically radiused to conform to the diamond/carbide wafer cylindrical surface and relieved rearwardly normal to the diamond surface.
Although PDC stud type cutters, as currently manufactured, serve a very :
useful purpose, there are several disadvantages in their manufacture and application. The flat on the stud to which the PDC wafer is brazed and the carbide side of the PDC wafer must have extremely fine ground surfaces to effect ~ -a braze of necessary strength. These grinding operations are time consuming and costly.
_1_ '~ ,~ ;,.. ~:
- ,` ,J ,~
. ! .
The bonding of the PDC wafer to the carbide stud is fraught with many variables that are difficult to control. The braze temperature is significantly higher than the thermal degradation temperature of the diamond layer and the bond interface of the diamond and carbide. Therefore, the diamond has to be protected by a complicated heat sink apparatus that is difficult to control during the braze cycle. A high reject ratio is inherent in this process, lowering output and driving up costs.
The actual braze quality is difficult to determine even with the most sophisticated non-destructive testing equipmentavailable. An undesirable level of less than good brazes go undetected and wind up as PDC cutter failures in thefield. The brazing process can also cause incipient and premature failure of thebond of the diamond layer to the carbide wafer which also will show up as a PDC
cutter failure in the field. It is also difficult to braze a PDC cutter wafer that has two or more carbide particle/diamond particle transition layers that have a highcobalt level because the high differential in thermal expansion causes the PDC
layer to crack during the braze cycle.
It would be desirable to provide a stud type PDC cutter that does not require a braze of a PDC wafer to a tungsten carbide stud. The new stud type PDC cutter disclosed herein eliminates the need to braze a PDC wafer to a tungsten carbide stud, thereby obviating the problems and inadequacies described above in current PDC stud design and processes.
Summarv of the Invention The present invention comprises a diamond insert stud cutter for a rock bit. Each cylindrical stud cutter is preferably formed with a cemented tungsten carbide body having a first cylindrical base end and a second cutter end having at least one diamond layer directly bonded to a pre-formed surface formed by thesecond cutter end. The diamond layer is formed by a high pressure, high temperature sintering process. The pre-formed surface may be angled negatively with respect to an axis of the stud body 5 to 30 with a preferred angle of 20 .
Brief DescriDtion of the Drawincs The above-noted features and advantages of the present invention will be more fully understood upon a study of the following description in conjunction 35 with the detailed drawings wherein:
FIGURE 1 is a partial cross-section of a prior art cylindrical stud type polycrystalline diamond compact drag bit cutter;
r~
FIGURE 2 is a partial cross-section of an embodiment of the present invention illustrating an ultra-hard planar composite layer of polycrystalline diamond directly bonded to a flat surface formed on a cylindrical tungsten carbide stud;
FIGURE 3 is a frontal view of the stud of Figure 2 showing a polycrystalline diamond layer bonded to a flat surface formed on a cylindrical carbide stud;
FIGURE 4 is a side view of an embodiment of the present invention which is an oblique or skewed cylinder having a thin composite layer of polycrystalline diamond bonded to a curved frontal surface formed on the tungsten carbide stud;
FIGURE 5 is a top view of the stud of Figure 4 showing a curved polycrystalline diamond layer bonded to a curved frontal surface of an essentially cylindrical tungsten carbide stud;
FIGURE 6 is a partial cross-section of an embodiment of the present invention showing a cylindrical tungsten carbide stud having a truncated conicalcutting end with a composite polycrystalline diamond layer bonded to the conicalsurface; and FIGURE 7 is an isometric view of the stud of Figure 6 showing a diamond layer bonded to the truncated conical surface of the tungsten carbide stud.
Descrir tion Prior art Figure 1, a partial cross section of an insert cutter generally designated as 10, illustrates a polycrystalline diamond stud type cutter for drag type drill bits. A thin composite cutting layer 14 of polycrystalline diamond ischemically and metallurgically bonded to a cylindrical tungsten carbide substrate 16 under high pressure/high temperature diamond synthesis conditions.
Subsequently, the rearward side 23 of the substrate 16 is ground to a flat polished surface and is then attached by a high temperature braze 18 to a groundflat surface 22 on a carbide stud 24 which is formed at a rearward angle of from15 to 20 relative to the axis 26 of the carbide stud 24. The preferred rearward angle is 20.
Figure 2 is a partial cross section of a diamond drag bit cutter and is an embodiment of the present invention which is generally designated as 30. A
cylindrical tungsten carbide stud 32 has a pre-formed flat 34 that is rearwardlyinclined 5 to 30 from a stud axis 33 ~angle A). The top surface 35 of stud 32 forms, for example, a radius which becomes tangent to the side edges of the flatsurface 34. A thin planar composite diamond cutting layer 36 is formed on the ~ ?
~,~ ,""~ ,"-,-- ,,,~, ~.,.
flat surface 34 of the stud using high pressure/high temperature diamond synthesis conditions. This creates diamond to diamond bonding and bonding of the diamond composite layer to the carbide stud flat surface.
As shown in exploded view 2a of Figure 2, it is generally desirable to form, by diamond tape cast methods, a composite diamond layer 36 as a gradient of diamond and pre-cemented tungsten carbide particles. For example, an outer layer 40 comprises 90 to 100% diamond particles. A middle layer 41 comprises approximately 50% diamond and 50% carbide particles. An inner layer 42 compromises 90 to 100% carbide particles. This produces a composite diamond `
layer 36 with very low residual stresses coupled with a very hard and wear resistant outer surface 40 as an integral part of a cutter having no brazed joint.
The layers are applied by the techniques and processes commonly referred to as "tape casting" in conjunction with high pressure/high temperature ~HP/HT) diamond synthesis technology. Tape casting technology is commonly used in the electronics industry to fabricate ceramic coatings, substrates and multilayer structures. Tapes of various materials can be produced by a doctor blade castingprocess or by high shear compaction process, a proprietary process by Ragan Technologies, a division of Wallace Technical Ceramics, Inc., San Diego, California .
The two tape processes have been successfully used to produce products.
Some of the basic advantages of the high shear compaction process over the doctor blade process are as follows: (1 ) uniform density; ~2) higher green density;
(3) process flexibility in controlling thickness, surface finish; and (4) higherreliability and flexibility. -Diamond layers and composites are also beneficially made by tape casting methods. Fine diamond powder is mixed with a temporary binder. The binder can be natural or synthetic high molecular weight substances such as starches, alcohols, celluloses and polymers. The diamond powder/binder mixture is milled to a homogeneous mass then rolled into strips (tapes) of the desired thickness and width, then dried to remove volatile carriers. The green tape is strong and flexible enough to be handled. The tape may be cut into the necessary shapes to conform to a tungsten carbide substrate geometry where it is temporarily glued. This assembly is then placed in a refractory metal HT/HP reaction mold and heated in a vacuum to drive off the temporary binder. The mold assembly is placed in a conventional HT/HP diamond synthesis apparatus to sinter the diamond grains together and bond the diamond mass to the carbide substrate.
~ ~ ~ j ~ ! 3 Figure 3 is a front view of the insert of Figure 2 and shows the planar composite diamond layer 36 chemically and metallurgically bonded to the pre-formed but not necessarily precision ground flat 34 of the stud.
Figure 4, another embodiment of the present invention generally designated as 50, is an oblique Of skewed cemented carbide cylinder 52. A pre-formed curved frontal surface 56, which slopes rearwardly 5 to 30 in reference to stud axis 58, has a relatively thin (0.25 to 1.5 mm) non-planar polycrystalline diamond layer 54 bonded thereto under high pressure/high temperature diamond synthesis conditions. The composite diamond layer 54 is preferably fabricated 1 n by using diamond tape cast methods. This produces a cutter 50 having very low residual stresses and an ultra-hard and wear resistant cutting surface 54 without the use of an undesirable braze.
Figure 5 is a top view of the insert of Figure 4 showing a curved polycrystalline diamond surface 54 bonded to a pre-formed curved oblique surface 56 of the tungsten carbide stud. The diamond layer 54 is inclined rearwardly in relation to the stud axis 58, terminating at an apex 55. The top surface 57 of the carbide stud body is formed essentially perpendicular to the curved surface 56 and intersects the edges of the diamond layer 54. This forms a heel clearance for the diamond cutting layer while the cutter works in a borehole.
Figures 6 and 7, another embodiment of the present invention, illustrate a drag bit cutter 60 having a cylindrical tungsten carbide body 62 and a truncated conical cutting surface 64. The cylindrical cutter body 62 has a truncated conical surface 66 to which a thin layer of polycrystalline diamond 64 has been chemically and metallurgically bonded using tape casting and high pressure/high temperature diamond synthesis techniques. This forms an integral unit with the carbide body 62. The angled surface 68 is formed by directing an EDM cut through the conical surface layer 64 about 90 to the surface. This creates the desired leading cutting edge 65 and the top trailing edge surface 68. The angledsurface 68 is at an oblique angle to an axis of the cylindrical body, giving thecutting edge 65 heel clearance while drilling. The cutter so formed has very lowresidual stresses and requires no potentially deleterious braze. While the diamond layer 64 on the trailing conical surface of cutter 60 plays no part in the drilling action, bonding of a composite diamond layer 64 to the entire conical surface 66before the truncation procedure simplifies the manufacturing process. It also produces superior diamond layer properties.
..
It should be noted that a single layer or multiple layers of diamond may be utilized in fabricating the above described embodiments to meet the needs for field application or for ease of manufacture.
An advantage of the present invention is that it provides a more rigid carbide backing for greater strength as the carbide stud is continuous with no braze interruption. Another advantage of the present invention over the prior art is multiple transition layers of varying percentages of diamond and tungsten carbide particles may be directly bonded to a carbide stud surface to provide superior impact strength of the diamond layer and the bond line.
It should also be understood ~hat other ultra-hard materials, such as cubic boron nitride particles, may be used in lieu of diamond particles to form the ultra-hard cutting layers of all the above embodiments.
For certain applications or cutter geometries, it may be advantageous to use other means than tape cast processes to bond an ultra-hard material mass to a carbide substrate surface to form a brazeless cutter. For example, a methodmay be injection molding of diamond, cubic boron nitride or other ultra-hard particles admixed with a binder into a mold cavity containing a pre-formed carbide substrate. This assembly is then sintered under high pressure/high temperature conditions to form a brazeless cutter. Another method may be extrusion of a hard particle/binder mass into a pre-form for subsequent high pressure/high temperature sintering to a carbide substrate. Another method may be the placing of loose ultra-hard particles into a mold cavity containing a pre-formed carbide substrate for subsequent high pressure/high temperature sinteringto the carbide substrate.
It will, of course, also be realized that various other modifications can be made in the design and operation of the present invention without departing fromthe spirit thereof. Thus, it should be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
FIGURE 2 is a partial cross-section of an embodiment of the present invention illustrating an ultra-hard planar composite layer of polycrystalline diamond directly bonded to a flat surface formed on a cylindrical tungsten carbide stud;
FIGURE 3 is a frontal view of the stud of Figure 2 showing a polycrystalline diamond layer bonded to a flat surface formed on a cylindrical carbide stud;
FIGURE 4 is a side view of an embodiment of the present invention which is an oblique or skewed cylinder having a thin composite layer of polycrystalline diamond bonded to a curved frontal surface formed on the tungsten carbide stud;
FIGURE 5 is a top view of the stud of Figure 4 showing a curved polycrystalline diamond layer bonded to a curved frontal surface of an essentially cylindrical tungsten carbide stud;
FIGURE 6 is a partial cross-section of an embodiment of the present invention showing a cylindrical tungsten carbide stud having a truncated conicalcutting end with a composite polycrystalline diamond layer bonded to the conicalsurface; and FIGURE 7 is an isometric view of the stud of Figure 6 showing a diamond layer bonded to the truncated conical surface of the tungsten carbide stud.
Descrir tion Prior art Figure 1, a partial cross section of an insert cutter generally designated as 10, illustrates a polycrystalline diamond stud type cutter for drag type drill bits. A thin composite cutting layer 14 of polycrystalline diamond ischemically and metallurgically bonded to a cylindrical tungsten carbide substrate 16 under high pressure/high temperature diamond synthesis conditions.
Subsequently, the rearward side 23 of the substrate 16 is ground to a flat polished surface and is then attached by a high temperature braze 18 to a groundflat surface 22 on a carbide stud 24 which is formed at a rearward angle of from15 to 20 relative to the axis 26 of the carbide stud 24. The preferred rearward angle is 20.
Figure 2 is a partial cross section of a diamond drag bit cutter and is an embodiment of the present invention which is generally designated as 30. A
cylindrical tungsten carbide stud 32 has a pre-formed flat 34 that is rearwardlyinclined 5 to 30 from a stud axis 33 ~angle A). The top surface 35 of stud 32 forms, for example, a radius which becomes tangent to the side edges of the flatsurface 34. A thin planar composite diamond cutting layer 36 is formed on the ~ ?
~,~ ,""~ ,"-,-- ,,,~, ~.,.
flat surface 34 of the stud using high pressure/high temperature diamond synthesis conditions. This creates diamond to diamond bonding and bonding of the diamond composite layer to the carbide stud flat surface.
As shown in exploded view 2a of Figure 2, it is generally desirable to form, by diamond tape cast methods, a composite diamond layer 36 as a gradient of diamond and pre-cemented tungsten carbide particles. For example, an outer layer 40 comprises 90 to 100% diamond particles. A middle layer 41 comprises approximately 50% diamond and 50% carbide particles. An inner layer 42 compromises 90 to 100% carbide particles. This produces a composite diamond `
layer 36 with very low residual stresses coupled with a very hard and wear resistant outer surface 40 as an integral part of a cutter having no brazed joint.
The layers are applied by the techniques and processes commonly referred to as "tape casting" in conjunction with high pressure/high temperature ~HP/HT) diamond synthesis technology. Tape casting technology is commonly used in the electronics industry to fabricate ceramic coatings, substrates and multilayer structures. Tapes of various materials can be produced by a doctor blade castingprocess or by high shear compaction process, a proprietary process by Ragan Technologies, a division of Wallace Technical Ceramics, Inc., San Diego, California .
The two tape processes have been successfully used to produce products.
Some of the basic advantages of the high shear compaction process over the doctor blade process are as follows: (1 ) uniform density; ~2) higher green density;
(3) process flexibility in controlling thickness, surface finish; and (4) higherreliability and flexibility. -Diamond layers and composites are also beneficially made by tape casting methods. Fine diamond powder is mixed with a temporary binder. The binder can be natural or synthetic high molecular weight substances such as starches, alcohols, celluloses and polymers. The diamond powder/binder mixture is milled to a homogeneous mass then rolled into strips (tapes) of the desired thickness and width, then dried to remove volatile carriers. The green tape is strong and flexible enough to be handled. The tape may be cut into the necessary shapes to conform to a tungsten carbide substrate geometry where it is temporarily glued. This assembly is then placed in a refractory metal HT/HP reaction mold and heated in a vacuum to drive off the temporary binder. The mold assembly is placed in a conventional HT/HP diamond synthesis apparatus to sinter the diamond grains together and bond the diamond mass to the carbide substrate.
~ ~ ~ j ~ ! 3 Figure 3 is a front view of the insert of Figure 2 and shows the planar composite diamond layer 36 chemically and metallurgically bonded to the pre-formed but not necessarily precision ground flat 34 of the stud.
Figure 4, another embodiment of the present invention generally designated as 50, is an oblique Of skewed cemented carbide cylinder 52. A pre-formed curved frontal surface 56, which slopes rearwardly 5 to 30 in reference to stud axis 58, has a relatively thin (0.25 to 1.5 mm) non-planar polycrystalline diamond layer 54 bonded thereto under high pressure/high temperature diamond synthesis conditions. The composite diamond layer 54 is preferably fabricated 1 n by using diamond tape cast methods. This produces a cutter 50 having very low residual stresses and an ultra-hard and wear resistant cutting surface 54 without the use of an undesirable braze.
Figure 5 is a top view of the insert of Figure 4 showing a curved polycrystalline diamond surface 54 bonded to a pre-formed curved oblique surface 56 of the tungsten carbide stud. The diamond layer 54 is inclined rearwardly in relation to the stud axis 58, terminating at an apex 55. The top surface 57 of the carbide stud body is formed essentially perpendicular to the curved surface 56 and intersects the edges of the diamond layer 54. This forms a heel clearance for the diamond cutting layer while the cutter works in a borehole.
Figures 6 and 7, another embodiment of the present invention, illustrate a drag bit cutter 60 having a cylindrical tungsten carbide body 62 and a truncated conical cutting surface 64. The cylindrical cutter body 62 has a truncated conical surface 66 to which a thin layer of polycrystalline diamond 64 has been chemically and metallurgically bonded using tape casting and high pressure/high temperature diamond synthesis techniques. This forms an integral unit with the carbide body 62. The angled surface 68 is formed by directing an EDM cut through the conical surface layer 64 about 90 to the surface. This creates the desired leading cutting edge 65 and the top trailing edge surface 68. The angledsurface 68 is at an oblique angle to an axis of the cylindrical body, giving thecutting edge 65 heel clearance while drilling. The cutter so formed has very lowresidual stresses and requires no potentially deleterious braze. While the diamond layer 64 on the trailing conical surface of cutter 60 plays no part in the drilling action, bonding of a composite diamond layer 64 to the entire conical surface 66before the truncation procedure simplifies the manufacturing process. It also produces superior diamond layer properties.
..
It should be noted that a single layer or multiple layers of diamond may be utilized in fabricating the above described embodiments to meet the needs for field application or for ease of manufacture.
An advantage of the present invention is that it provides a more rigid carbide backing for greater strength as the carbide stud is continuous with no braze interruption. Another advantage of the present invention over the prior art is multiple transition layers of varying percentages of diamond and tungsten carbide particles may be directly bonded to a carbide stud surface to provide superior impact strength of the diamond layer and the bond line.
It should also be understood ~hat other ultra-hard materials, such as cubic boron nitride particles, may be used in lieu of diamond particles to form the ultra-hard cutting layers of all the above embodiments.
For certain applications or cutter geometries, it may be advantageous to use other means than tape cast processes to bond an ultra-hard material mass to a carbide substrate surface to form a brazeless cutter. For example, a methodmay be injection molding of diamond, cubic boron nitride or other ultra-hard particles admixed with a binder into a mold cavity containing a pre-formed carbide substrate. This assembly is then sintered under high pressure/high temperature conditions to form a brazeless cutter. Another method may be extrusion of a hard particle/binder mass into a pre-form for subsequent high pressure/high temperature sintering to a carbide substrate. Another method may be the placing of loose ultra-hard particles into a mold cavity containing a pre-formed carbide substrate for subsequent high pressure/high temperature sinteringto the carbide substrate.
It will, of course, also be realized that various other modifications can be made in the design and operation of the present invention without departing fromthe spirit thereof. Thus, it should be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
Claims (21)
1. An insert stud cutter comprising:
a tungsten carbide cylindrical body, said body having a first cylindrical base end and a second cutter end, said second cutter end having at least one ultra-hard layer directly bonded to a pre-formed surface on said second cutter end by a tape cast method.
a tungsten carbide cylindrical body, said body having a first cylindrical base end and a second cutter end, said second cutter end having at least one ultra-hard layer directly bonded to a pre-formed surface on said second cutter end by a tape cast method.
2. An insert stud cutter as set forth in Claim 1 wherein said pre-formed surface is planar.
3. An insert stud cutter as set forth in Claim 1 wherein said pre-formed surface is curved.
4. An insert stud cutter as set forth in any one of Claims 1, 2 or 3 wherein said curved surface is convex.
5. An insert stud cutter as set forth in Claim 4 wherein said pre-formed surface is a truncated cone.
6. An insert stud cutter as set forth in any one of claims 1, 2 or 3 wherein said ultra-hard surface is polycrystalline diamond.
7. An insert stud cutter as set forth in Claim 6 wherein said polycrystalline diamond surface contains at least one transition layer of mixed diamond and tungsten carbide.
8. An insert stud cutter as set forth in any one of claims 1, 2 or 3 wherein said ultra-hard layer is of a relatively constant thickness across said pre-formed surface.
9. An insert stud cutter as set forth in claim 8 wherein said ultra-hard layer is bonded to said second cutter end of said cylindrical body by a high pressure, high temperature sintering process.
10. An insert stud cutter as set forth in any one of claims 1, 2 or 3 wherein said pre-formed surface is angled negatively with respect to an axis of said stud body in the range of from 5° to 30°.
11. An insert stud cutter as set forth in Claim 10 wherein the negative angle is 20°.
12. A diamond insert stud cutter for a rock bit comprising;
a tungsten carbide cylindrical body, said body forming a first cylindrical base end, and a second cutter end, said second cutter end having at least one polycrystalline diamond layer directly bonded to a pre-formed surface formed by said second cutter end by a high pressure, high temperature sintering process, said pre-formed surface being angled negatively with respect to an axis of said stud body in the range of from 5° to 30°.
a tungsten carbide cylindrical body, said body forming a first cylindrical base end, and a second cutter end, said second cutter end having at least one polycrystalline diamond layer directly bonded to a pre-formed surface formed by said second cutter end by a high pressure, high temperature sintering process, said pre-formed surface being angled negatively with respect to an axis of said stud body in the range of from 5° to 30°.
13. An insert stud cutter as set forth in Claim 12 wherein the negative angle is 20°.
14. An insert stud cutter as set forth in either one of Claims 12 or 13 wherein said pre-formed surface is planar.
15. An insert stud cutter as set forth in either one of Claims 12 or 13 wherein said pre-formed surface is curved.
16. An insert stud cutter as set forth in Claim 15 wherein said curved surface is convex.
17. An insert stud cutter as set forth in Claim 16 wherein said pre-formed surface is a truncated cone.
18. An insert stud cutter as set forth in any one of Claims 12 or 13 wherein the polycrystalline diamond contains at least one transition layer comprising diamond and tungsten carbide particles.
19. An insert stud cutter as set forth in any one of Claims 12 or 13 wherein said diamond may comprise one or more layers of diamond tape cast material sintered to said pre-formed surface.
20. An insert stud cutter for rock bits comprising;
a tungsten carbide cylindrical body, said body having a first cylindrical base end and a second cutter end, said second cutter end having at least one layer of cubic boron nitride directly bonded to a pre-formed surface on said second cutter end by a high pressure, high temperature sintering process, said pre-formed surface being angled negatively with respect to an axis of said stud body 5° to 30°.
a tungsten carbide cylindrical body, said body having a first cylindrical base end and a second cutter end, said second cutter end having at least one layer of cubic boron nitride directly bonded to a pre-formed surface on said second cutter end by a high pressure, high temperature sintering process, said pre-formed surface being angled negatively with respect to an axis of said stud body 5° to 30°.
21. An insert stud cutter as set forth in Claim 20 wherein said negative angle is 20°.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/124,892 | 1993-09-20 | ||
| US08/124,892 US5379853A (en) | 1993-09-20 | 1993-09-20 | Diamond drag bit cutting elements |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2132284A1 true CA2132284A1 (en) | 1995-03-21 |
Family
ID=22417303
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002132284A Abandoned CA2132284A1 (en) | 1993-09-20 | 1994-09-16 | Diamond drag bit cutting elements |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US5379853A (en) |
| CA (1) | CA2132284A1 (en) |
| GB (1) | GB2282166B (en) |
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1993
- 1993-09-20 US US08/124,892 patent/US5379853A/en not_active Expired - Fee Related
-
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- 1994-09-16 CA CA002132284A patent/CA2132284A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| GB2282166A (en) | 1995-03-29 |
| GB9418471D0 (en) | 1994-11-02 |
| GB2282166B (en) | 1997-11-12 |
| US5379853A (en) | 1995-01-10 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |