CA2556052A1 - Polycrystalline diamond composite constructions comprising thermally stable diamond volume - Google Patents

Polycrystalline diamond composite constructions comprising thermally stable diamond volume Download PDF

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Publication number
CA2556052A1
CA2556052A1 CA002556052A CA2556052A CA2556052A1 CA 2556052 A1 CA2556052 A1 CA 2556052A1 CA 002556052 A CA002556052 A CA 002556052A CA 2556052 A CA2556052 A CA 2556052A CA 2556052 A1 CA2556052 A1 CA 2556052A1
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CA
Canada
Prior art keywords
diamond
region
bonded
thermally stable
volume
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.)
Granted
Application number
CA002556052A
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French (fr)
Other versions
CA2556052C (en
Inventor
Stewart N. Middlemiss
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Smith International Inc
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Smith International Inc
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Filing date
Publication date
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Publication of CA2556052A1 publication Critical patent/CA2556052A1/en
Application granted granted Critical
Publication of CA2556052C publication Critical patent/CA2556052C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

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
    • E21B10/573—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
    • E21B10/5735—Interface between the substrate and the cutting element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

PCD composite constructions comprise a diamond body bonded to a substrate.
The diamond body comprises a thermally stable diamond bonded region that is made up of a single phase of diamond crystals bonded together. The diamond body includes a PCD region bonded to the thermally stable region and that comprises bonded together diamond crystals and interstitial regions interposed between the diamond crystals. The PCD
composite is prepared by combining a first volume of PCD with a second volume of diamond crystal-containing material consisting essentially of a single phase of bonded together diamond crystals.
A substrate is positioned adjacent to or joined to the first volume. The first and second volumes are subjected to high pressure/high temperature process conditions, during process the first and second volumes form a diamond bonded body that is attached to the substrate, and the second volume forms the thermally stable diamond bonded region.

Claims (26)

1. A PCD composite compact comprising:
a diamond bonded body comprising;
a thermally stable region extending a distance below a diamond bonded body surface, the thermally stable region having a material microstructure consisting essentially of a single phase of diamond crystals that are bonded together;
a polycrystalline diamond region extending a depth from the thermally stable region and bonded thereto, the polycrystalline diamond region comprising bonded together diamond crystals and interstitial regions interposed between the diamond crystals, wherein a metal solvent catalyst material is disposed within the interstitial regions; and a substrate attached to the diamond bonded body.
2. The PCD composite compact as recited in claim 1 wherein the thermally stable region has a diamond volume density of approximately 100 percent.
3. The PCD composite compact as recited in claim 1 wherein the thermally stable region extends a depth of less than about 0.1 mm from the working surface.
4. The PCD composite compact as recited in claim 1 wherein the thermally stable region extends a depth of greater than about 0.1 mm from the working surface.
5. The PCD composite compact as recited in claim 1 wherein the polycrystalline diamond region has a thickness of at least about 50 micrometers.
6. The PCD composite compact as recited in claim 1 wherein the polycrystalline diamond region has a thickness in the range of from about 100 to 5,000 micrometers.
7. The PCD composite compact as recited in claim 1 wherein the substrate is integrally joined to the polycrystalline diamond region of the diamond body.
8. The PCD composite compact as recited in claim 1 wherein the polycrystalline diamond region comprises a volume content of diamond crystals that changes with location within the polycrystalline diamond region.
9. A drill bit used for drilling subterranean formations comprising a body and a number of cutting elements attached to the body, the cutting elements being formed from the PCD composite compact as recited in claim 1.
10. A PCD composite compact made by the process of:
combining:
a first volume of diamond crystal-containing material comprising bonded together diamond crystals and interstitial regions interposed between the diamond crystals, wherein a metal solvent catalyst material is disposed within the interstitial regions; with a second volume of diamond crystal-containing material consisting essentially of a single phase of bonded together diamond crystals;
wherein the first volume of diamond crystal-containing material is in contact with a substrate, and wherein the first volume of diamond-containing material, the second volume of diamond-containing material, and the substrate comprise an assembly; and subjecting the assembly to high pressure/high temperature conditions to form a diamond bonded body that is attached to the substrate and that comprises a polycrystalline diamond region formed from the first diamond crystal-containing material, and a thermally stable diamond bonded region that is formed from the second diamond-containing material, wherein the polycrystalline diamond region and the thermally stable diamond bonded region are integrally joined together, and wherein the thermally stable diamond bonded region is positioned along a working surface of the compact.
11. The PCD composite compact as recited in claim 10 wherein the second volume of diamond crystal-containing material is formed by processes selected from the group consisting of chemical vapor deposition and plasma vapor deposition.
12. The PCD composite compact as recited in claim 10 wherein the second volume of diamond crystal-containing material has a diamond volume content of 100 percent.
13. The PCD composite compact as recited in claim 10 wherein the thermally stable diamond bonded region of the diamond bonded body extends a depth from the working surface of less than about 0.1 mm.
14. The PCD composite compact as recited in claim 10 wherein the thermally stable diamond bonded region of the diamond bonded body extends a depth from the working surface of greater than about 0.1 mm.
15. The PCD composite compact as recited in claim 10 wherein the polycrystalline diamond region has a thickness of greater than about 50 microns.
16. The PCD composite compact as recited in claim 10 wherein the polycrystalline diamond region has a thickness in the range of from about 100 microns to 5,000 microns.
17. A PCD composite compact made by the process of:
combining:
a volume of diamond powder; with a substrate, wherein at least one of the diamond powder and the substrate includes a solvent metal catalyst;
subjecting the volume of diamond powder and the substrate to a first high pressure/high temperature condition to consolidate and sinter the diamond powder to form a polycrystalline diamond region, and to join the polycrystalline diamond region to the substrate to form an assembly;
combining the assembly with a volume of thermally stable diamond bonded material consisting essentially of bonded together diamond crystals, wherein the volume of thermally stable diamond bonded material is positioned adjacent the polycrystalline diamond region; and subjecting the assembly and the volume of thermally stable diamond bonded material to a second high pressure/high temperature condition to consolidate the volume of thermally stable diamond bonded material to form a thermally stable diamond bonded region, and bond the thermally stable diamond bonded region to the polycrystalline diamond region to form a diamond bonded body, wherein the diamond bonded body comprises the polycrystalline diamond region interposed between the substrate and the thermally stable diamond bonded region.
18. The PCD composite compact as recited in claim 17 wherein the volume of diamond powder comprises diamond grains having an average particle size in the range of from about 0.1 micrometers to 200 micrometers.
19. The PCD composite compact as recited in claim 17 wherein the volume of thermally stable diamond bonded material is formed by processes selected from the group consisting of chemical vapor deposition and plasma vapor deposition.
20. The PCD composite compact as recited in claim 17 wherein the volume of thermally stable diamond bonded material has a diamond volume content of approximately 100 percent.
21. The PCD composite compact as recited in claim 17 wherein the thermally stable diamond bonded region extends a depth from the a working surface of the diamond body of less than about 0.1 mm.
22. The PCD composite compact as recited in claim 17 wherein the thermally stable diamond bonded region extends a depth from a working surface of the diamond body of greater than about 0.1 mm.
23. The PCD composite compact as recited in claim 17 wherein the polycrystalline diamond region has a thickness of greater than about 50 microns.
24. The PCD composite compact as recited in claim 17 wherein the polycrystalline diamond region has a thickness in the range of from about 100 microns to 5,000 microns.
25. A method of making a PCD composite compact comprising the steps of:
combining:
a construction comprising a volume of polycrystalline diamond integrally joined to a metallic substrate, wherein the polycrystalline diamond comprises bonded together diamond crystals and a solvent metal catalyst disposed within interstitial regions interposed between the diamond crystals; with a volume of thermally stable diamond bonded material formed by chemical vapor deposition, wherein the volume of thermally stable diamond bonded material consists essentially of bonded together diamond crystals, wherein the volume of thermally stable diamond bonded material is positioned adjacent a surface of the volume of polycrystalline diamond; and subjecting the combined construction of the volume of polycrystalline diamond, the substrate, and the volume of thermally stable diamond bonded material to a high pressure/high temperature condition to form a diamond bonded body comprising a thermally stable diamond bonded region formed from the volume of thermally stable diamond bonded material, and a polycrystalline diamond region that is bonded to the thermally stable diamond bonded region and that is interposed between the substrate and the thermally stable diamond bonded region, wherein the thermally stable diamond bonded region forms at least a portion of a working surface of the diamond bonded body.
26. A diamond bonded composite construction comprising:
a diamond bonded body including:
a polycrystalline diamond region comprising a plurality of bonded together diamond crystals and interstitial regions interposed between the diamond crystals, wherein the polycrystalline diamond region has a diamond volume content of less than about 99 percent;
a thermally stable diamond bonded region comprising a diamond volume content of approximately 100 percent, the thermally stable diamond bonded region being bonded to the polycrystalline diamond region; and a substrate bonded to the diamond body.
CA2556052A 2005-08-03 2006-08-02 Polycrystalline diamond composite constructions comprising thermally stable diamond volume Expired - Fee Related CA2556052C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/197,120 US7462003B2 (en) 2005-08-03 2005-08-03 Polycrystalline diamond composite constructions comprising thermally stable diamond volume
US11/197,120 2005-08-03

Publications (2)

Publication Number Publication Date
CA2556052A1 true CA2556052A1 (en) 2007-02-03
CA2556052C CA2556052C (en) 2012-09-25

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US (2) US7462003B2 (en)
EP (1) EP1760165A3 (en)
CA (1) CA2556052C (en)

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US7462003B2 (en) 2008-12-09
US20070029114A1 (en) 2007-02-08

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