Drill bit compact and method including graphene

Patent metadata

Field	Value
Publication number	US-12584199-B2
Application number	US-202117906235-A
Country	US
Kind code	B2
Filing date	Mar 12, 2021
Priority date	Mar 13, 2020
Publication date	Mar 24, 2026
Grant date	Mar 24, 2026

Abstract

A polycrystalline composite tool component and associated methods are disclosed. In one example plurality of diamond particles are coated with a conforming catalyst metal coating and a plurality of graphene particles. Various asymmetric distributions of graphene particles are shown that provide a variety of material properties.

First claim

The invention claimed is:

1 . A composite tool component, comprising:
a plurality of diamond particles; a plurality of graphene particles located within the plurality of diamond particles; and a conforming catalyst metal coating the diamond particles and the graphene particles, separately from each other, with a consistent thickness of continuous metal about both the diamond particles and the graphene particles to provide improved reaction and sintering between the plurality of diamond particles and the plurality of graphene particles as a result of more predictable reactions at contact points between particles.

2 . The composite tool component of claim 1 , wherein the catalyst metal includes cobalt.

3 . The composite tool component of claim 1 , wherein the catalyst metal includes a group VIII element.

4 . The composite tool component of claim 1 , wherein the plurality of diamond particles include polycrystalline diamond particles.

5 . The composite tool component of claim 1 , wherein the plurality of diamond particles include diamond particles of grain size between 0.05 μm and 3.00 μm.

6 . The composite tool component of claim 1 , wherein the plurality of diamond particles include diamond particles of grain size between 2.0 μm and 60.0 μm.

7 . The composite tool component of claim 1 , wherein the plurality of graphene particles include 99 percent single layer graphene particles.

8 . The composite tool component of claim 1 , wherein the plurality of graphene particles include multiple layer graphene particles.

9 . A polycrystalline diamond compact (PDC), comprising:
a substrate; a polycrystalline diamond layer on one or more surface of the substrate, the polycrystalline diamond layer including: a plurality of diamond particles; a plurality of graphene particles located within the plurality of diamond particles; and a catalyst metal coating the diamond particles and the graphene particles, separately from each other, with a consistent thickness of continuous metal about both the diamond particles and the graphene particles to provide improved reaction and sintering between the plurality of diamond particles and the plurality of graphene particles as a result of more predictable reactions at contact points between particles.

10 . The polycrystalline diamond compact of claim 9 , wherein the substrate includes tungsten carbide.

11 . The polycrystalline diamond compact of claim 9 , wherein a bond between the polycrystalline diamond layer and the substrate includes a gradient of diffused cobalt from the substrate into the polycrystalline diamond layer.

12 . A method of forming a composite tool, comprising:
coating a plurality of diamond particles with a catalyst metal to form coated diamond particles including a consistent thickness of continuous metal; coating a plurality of graphene particles with the catalyst metal to form coated graphene particles including a consistent thickness of continuous metal; mixing the coated diamond particles with the graphene particles, wherein mixing the coated diamond particles with coated graphene particles includes mixing the coated diamond particles with coated 3D graphene particles; and sintering the coated diamond particles and coated graphene particles to bind the coated diamond particles and coated graphene particles together, wherein the catalyst coating provides improved reaction and sintering between the coated diamond particles and the coated graphene particles as a result of more predictable reactions at contact points between particles.

13 . The method of claim 12 , further including leaching one or more outer surfaces of the composite tool after binding the coated diamond particles and coated graphene particles together.

14 . The method of claim 12 , wherein coating a plurality of diamond particles and a plurality of graphene particles includes coating from one or more precursor liquids.

Assignees

• Nat Oilwell Varco Lp

Inventors

• Kumar Biju P
• Rivera Jr Richard
• Roberts Tom Scott
• Ivie Brad
• Jordan Richard

Classifications

• C22C1/101

  by coating · CPC title

• E21B10/5676

  having a cutting face with different segments, e.g. mosaic-type inserts · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title

• B22F2302/406

  Diamond · CPC title