PDC Cutter With Chemical Addition for Enhanced Abrasion Resistance

Patent metadata

Field	Value
Publication number	US-2016008955-A1
Application number	US-201414582562-A
Country	US
Kind code	A1
Filing date	Dec 24, 2014
Priority date	Jun 25, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

A superabrasive cutter and a method of making the superabrasive cutter are disclosed. The superabrasive cutter may comprise a plurality of polycrystalline superabrasive particles and about 0.01% to about 4% by weight of the superabrasive particles of a dopant as evaluated prior to a high pressure/high temperature process. The dopant may be immiscible with a catalyst for forming the polycrystalline superabrasive particles.

First claim

What is claimed is:

1 . A superabrasive cutter comprising:
a substrate; a polycrystalline superabrasive composite bonded to the substrate, the polycrystalline superabrasive composite comprising: a plurality of polycrystalline superabrasive particles that are sintered to form the polycrystalline superabrasive composite in a high pressure/high temperature process; a catalyst that promotes sintering between the superabrasive particles; and about 0.01% to about 4% by weight of the superabrasive particles of a dopant evaluated prior to the high pressure/high temperature process, wherein the dopant is substantially immiscible with the catalyst,
wherein:
the polycrystalline superabrasive compsite comprises a first polycrystalline superabrasive zone that is substantially free of the catalyst and that is positioned distally from the substrate and a second polycrystalline superabrasive zone that is rich in the catalyst material and that is positioned proximally to the substrate.

2 . The superabrasive cutter of claim 1 , wherein a wear rate of the superabrasive cutter evaluated after the second polycrystalline superabrasive zone is exposed in a wear scar is within about one standard deviation of the wear rate of the superabrasive cutter evaluated prior to second polycrystalline superabrasive zone being exposed.

3 . The superabrasive cutter of claim 2 , wherein the wear rate of the superabrasive cutter evaluated after the second polycrystalline superabrasive zone is exposed in the wear scar is within about two standard deviations of the wear rate of the superabrasive cutter evaluated prior to the second polycrystalline superabrasive zone being exposed.

4 . The superabrasive cutter of claim 1 , wherein a wear rate of the superabrasive cutter evaluated after the second polycrystalline superabrasive zone is exposed in a wear scar is within about 10% of the wear rate of the superabrasive cutter evaluated prior to second polycrystalline superabrasive zone being exposed.

5 . The superabrasive cutter of claim 1 , wherein subjecting the superabrasive cutter to abrasion introduces a wear scar to the superabrasive cutter.

6 . The superabrasive cutter of claim 1 , wherein the dopant comprises at least one of copper, gallium, lead, tin, or alloys thereof.

7 . The superabrasive cutter of claim 1 , wherein the dopant has a lower melting temperature than the catalyst.

8 . The superabrasive cutter of the claim 1 , wherein the dopant is present in an amount by weight of the superabrasive particles of less than about 1.0% evaluated prior to the high pressure/high temperature process.

9 . The superabrasive cutter of the claim 1 , wherein the dopant is present in an amount by weight of the superabrasive particles in a range from about 1.0% to about 2.0% evaluated prior to the high pressure/high temperature process.

10 . The superabrasive cutter of the claim 9 , wherein the dopant is present in an amount by weight of the superabrasive particles of less than about 1.5% evaluated prior to the high pressure/high temperature process.

11 . The superabrasive cutter of claim 1 , wherein dopant is present in the polycrystalline superabrasive composite following the high pressure/high temperature process.

12 . The superabrasive cutter of claim 1 , wherein dopant and catalyst are present in the first polycrystalline superabrasive zone in interstitial regions between adjacent superabrasive particles.

13 . The superabrasive cutter of claim 1 , wherein a concentration of the dopant following the high pressure/high temperature process is less than the concentration of the dopant prior to the high pressure/high temperature process.

14 . The superabrasive cutter of claim 1 , wherein a concentration of the dopant following the high pressure/high temperature process is less than a concentration of the catalyst as evaluated in the second polycrystalline superabrasive zone.

15 . The superabrasive cutter of claim 1 , wherein a concentration of catalyst in the substrate prior to the high pressure/high temperature process is less than about 9.5 wt %.

16 . A method of making a superabrasive cutter, comprising:
mixing a dopant with a plurality of superabrasive particles; positioning the mixture of the plurality of superabrasive particles and the dopant proximate to a substrate that comprises a catalyst that promotes sintering between the superabrasive particles, wherein the dopant is substantially immiscible with the catalyst; subjecting the substrate, the plurality of superabrasive particles, and the dopant to conditions of elevated temperature and pressure suitable for producing a polycrystalline superabrasive composite; and introducing acid to the polycrystalline superabrasive composite to leach at least a portion of the catalyst from the polycrystalline superabrasive composite,
wherein the superabrasivecutter comprises a first polycrystalline superabrasive zone that is substantially free of the catalyst and that is positioned distally from the substrate and a second polycrystalline superabrasive zone that is rich in the catalyst material and that is positioned proximally to the substrate.

17 . The method of claim 16 , wherein a wear rate of the superabrasive cutter evaluated after the second polycrystalline superabrasive zone is exposed in a wear scar is within about one standard deviation of the wear rate of the superabrasive cutter evaluated prior to second polycrystalline superabrasive zone being exposed.

18 . The method of claim 16 , wherein the dopant comprises at least one of copper, gallium, lead, tin, or alloys thereof.

19 . The superabrasive cutter of the claim 16 , wherein the dopant is present in an amount by weight of the superabrasive particles of less than about 1.0% evaluated prior to the high pressure/high temperature process.

20 . The superabrasive cutter of the claim 16 , wherein the dopant is present in an amount by weight of the superabrasive particles in a range from about 1.0% to about 2.0% evaluated prior to the high pressure/high temperature process.

21 . The superabrasive cutter of the claim 16 , wherein the dopant is present in an amount by weight of the superabrasive particles of less than about 1.5% evaluated prior to the high pressure/high temperature process.

Assignees

• Diamond Innovations Inc

Inventors

• Gledhill Andrew
• Long Christopher Allen

Classifications

• B24D3/06 Primary

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• E21B10/56

  Button-type inserts (E21B10/52 takes precedence) · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• E21B10/567 Primary

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title