Polycrystalline diamond compact with fiber-reinforced substrate

Patent metadata

Field	Value
Publication number	US-10465449-B2
Application number	US-201515580728-A
Country	US
Kind code	B2
Filing date	Jul 8, 2015
Priority date	Jul 8, 2015
Publication date	Nov 5, 2019
Grant date	Nov 5, 2019

Abstract

The present disclosure relates to a polycrystalline diamond compact (PDC) with a fiber-reinforces substrate. The disclosure further relates to method of forming such a PDC.

First claim

The invention claimed is:

1. A polycrystalline diamond compact (PDC) comprising:
a polycrystalline diamond table; and
a substrate comprising:
a cemented material;
a binder; and
a plurality of fibers having an average aspect ratio of at least a critical aspect ratio, A c , wherein A c =σ f /(2T c ), wherein σ f is ultimate tensile strength of the fibers and T c is shear bond strength between the fiber and the binder.

2. The PDC of claim 1 , wherein at least a portion of the plurality of fibers are bonded to the polycrystalline diamond table.

3. The PDC of claim 1 , wherein the plurality of fibers are present in an area of the substrate and not present in another area of the substrate.

4. The PDC of claim 1 , wherein the plurality of fibers are uniformly distributed in the substrate.

5. The PDC of claim 1 , wherein the plurality of fibers decrease in concentration with distance from the polycrystalline diamond table.

6. The PDC of claim 1 , wherein the plurality of fibers are oriented so that their longer dimension on average is at a 70 degree angle with respect to an interface between the polycrystalline diamond table and the substrate.

7. The PDC of claim 1 , wherein the plurality of fibers includes fibers comprising tungsten (W) molybdenum (Mo), titanium (Ti), chromium (Cr), manganese (Mn), yttrium (Yt), zirconium (Zr), niobium (Nb), Hafnium (Hf), Tantalum (Ta), nickel (Ni), carbon (C), any refractory ceramic, or any combinations, mixtures, or alloys thereof.

8. The PDC of claim 1 , wherein the fibers are distinguishable from the cemented material and binder in the substrate.

9. An earth-boring drill bit comprising:
a bit body; and
a polycrystalline diamond compact (PDC) comprising:
a polycrystalline diamond table; and
a substrate comprising:
a cemented material;
a binder; and
a plurality of fibers having an average aspect ratio of at least a critical aspect ratio, A c , wherein A c =σ f /(2T c ), wherein σ f is ultimate tensile strength of the fibers and T c is shear bond strength between the fiber and the binder.

10. The earth-boring drill bit of claim 9 , wherein at least a portion of the plurality of fibers are bonded to the polycrystalline diamond table.

11. The earth-boring drill bit of claim 9 , wherein the plurality of fibers are present in an area of the substrate and not present in another area of the substrate.

12. The earth-boring drill bit of claim 9 , wherein the plurality of fibers are uniformly distributed in the substrate.

13. The earth-boring drill bit of claim 9 , wherein the plurality of fibers decrease in concentration with distance from the polycrystalline diamond table.

14. The earth-boring drill bit of claim 9 , wherein the plurality of fibers are oriented so that their longer dimension on average is at a 70 degree angle with respect to an interface between the polycrystalline diamond table and the substrate.

15. The earth-boring drill bit of claim 9 , wherein the plurality of fibers includes fibers comprising tungsten (W) molybdenum (Mo), titanium (Ti), chromium (Cr), manganese (Mn), yttrium (Yt), zirconium (Zr), niobium (Nb), Hafnium (Hf), Tantalum (Ta), nickel (Ni), carbon (C), any refractory ceramic, or any combinations, mixtures, or alloys thereof.

16. The PDC of claim 1 , wherein the fibers are distinguishable from the cemented material and binder in the substrate.

17. A method of forming a polycrystalline diamond compact (PDC) comprising:
forming an assembly comprising:
a mold;
a polycrystalline diamond table or polycrystalline diamond table precursor in the mold; and
a substrate precursor in the mold, the substrate precursor comprising:
a cemented material;
a binder having a highest melting point; and
a plurality of fibers having a lowest melting point having an average aspect ratio of at least a critical aspect ratio, A c , wherein A c =σ f /(2T c ), wherein σ f is ultimate tensile strength of the fibers and T c is shear bond strength between the fiber and the binder; and

heating the assembly to a temperature higher than the highest melting point of the binder and lower than the lowest melting point of the plurality of fibers.

18. The method of claim 17 , wherein the assembly comprises a polycrystalline diamond table precursor and heating further comprises heating the assembly to a temperature above a temperature at which the polycrystalline diamond table precursor forms a polycrystalline diamond table.

19. The method of claim 17 , wherein at least a portion of the plurality of fibers is ferromagnetic, further comprising applying a magnetic field to the assembly to orient the ferromagnetic portion of the plurality of fibers.

20. The method of claim 17 , further comprising bonding the fibers to the polycrystalline diamond table.

Assignees

• Halliburton Energy Services Inc

Inventors

• Saini Gagan

Classifications

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title

• B22F2202/05

  Use of magnetic field · CPC title

• B22F2005/001

  Cutting tools, earth boring or grinding tool other than table ware · CPC title

• B22F2302/406

  Diamond · CPC title

• C22C47/14 Primary

  by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments · CPC title