Method for forming a cutting element and downhole tools incorporating the same

Patent metadata

Field	Value
Publication number	US-2016047171-A1
Application number	US-201514921040-A
Country	US
Kind code	A1
Filing date	Oct 23, 2015
Priority date	Dec 9, 2011
Publication date	Feb 18, 2016
Grant date	—

Abstract

Cutting elements include an ultrahard material body formed at high pressure and high temperature conditions in the absence of catalyzing material to provide a material microstructure comprising a matrix phase of bonded together ultrahard material particles and interstitial regions disposed throughout the matrix phase providing porosity of less than about 6 volume percent. The body may include a substrate attached thereto, and may include an infiltrant material disposed in a population of the interstitial regions. The body may have regions with different porosities, e.g., with a higher porosity region located adjacent a substrate interface and/or along a central region. The body may include more than one infiltrant, each located in different regions. The infiltrant may be introduced into the body during a separate high pressure/high temperature process. The body may include a region which extends a depth from a working surface that is substantially free of any infiltrant.

First claim

What is claimed is:

1 . A bit for drilling earthen formations comprising:
a bit body; and one or more cutting elements attached thereto, wherein one or more of the cutting elements are prepared by:
subjecting a material comprising a plurality of ultrahard material particles to a sufficiently high pressure/high temperature condition to form a sintered ultrahard material body, wherein the ultrahard material body has a material microstructure comprising a matrix phase of bonded together ultrahard material particles and interstitial regions disposed throughout the matrix phase providing a porosity in the range from about 1 to 6% volume, based on the total volume of the ultrahard material body;
removing the sintered ultrahard material body from the high pressure and temperature conditions; and
introducing an infiltrant material into the interstitial regions of the ultrahard material body subsequent by subjecting the ultrahard material body and an infiltrant material to a second high pressure/high pressure condition.

2 . The bit of claim 1 , further comprising one or more fixed blades projecting outwardly from the bit body and having one or more cutting elements disposed thereon.

3 . The bit of claim 1 , further comprising one or more legs extending from the bit body, each leg comprising a journal having a cone rotatably attached thereto, wherein one or more cutting elements are disposed thereon.

4 . The bit of claim 1 , wherein the porosity of the ultrahard material body after the step of subjecting is in the range of from about 2 to 5 volume %, based on the total volume of the ultrahard material body.

5 . The bit of claim 1 , wherein at least a portion of the ultrahard material particles comprise diamond particles.

6 . The bit of claim 1 , wherein the infiltrant material is selected from Group VIII metals, combinations, and alloys thereof.

7 . The bit of claim 1 , wherein the infiltrant material is selected from Groups IIA, IB, IIB metals, combinations, and alloys thereof.

8 . The bit of claim 1 , wherein the infiltrant material is selected from the group consisting of Si, Ti, Ge, combinations, and alloys thereof.

9 . The bit of claim 1 , wherein the infiltrant material is selected from carbonates of Group IA or IIA metals, their combinations or compounds which include them.

10 . The bit of claim 1 , wherein during the step of introducing, controlling introduction of infiltrant material to provide a first region in the ultrahard material body comprising the infiltrant material, and a second region that is substantially free of the infiltrant material.

11 . The bit of claim 14 , wherein the second region extends a depth from a working surface of the ultrahard material body.

12 . The bit of claim 1 , wherein the ultrahard material body produced during the step of subjecting comprises a first region having a porosity that is different from a second region.

13 . A method of making a bit for drilling earthen formations comprising operatively connecting one or more cutting elements to a bit body, wherein one or more of the cutting elements have been prepared by:
subjecting a material comprising a plurality of ultrahard material particles to a first high pressure/high temperature condition to form a sintered ultrahard material body in the substantial absence of a catalyzing material, wherein the ultrahard material body has a material microstructure comprising a matrix phase of bonded together ultrahard material particles and interstitial regions disposed throughout the matrix phase providing a porosity in the range from about 1 to 6 volume percent based on the total volume of the ultrahard material body; removing the ultrahard material body from the first high pressure/high temperature condition; and introducing an infiltrant material into at least a portion of the interstitial regions of the ultrahard material body during a second high pressure/high temperature condition.

14 . The method of claim 13 , wherein after the step of removing, a material containing the infiltrant material is positioned adjacent a surface of the ultrahard material body.

15 . The method of claim 14 , wherein during the step of introducing, the high pressure/high temperature condition is sufficient to melt the infiltrant material and cause it to infiltrate into at least a portion of the interstitial regions of the ultrahard material body.

16 . The method of claim 14 wherein during the temperature during the step of subjecting is higher than the melting temperature of the infiltrant material during the step of introducing.

17 . The method of claim 13 , further comprising treating the ultrahard material body to remove a portion of the infiltrant material from a region extending a depth from a working surface of the ultrahard material body, wherein the infiltrant material remains in another region of the body.

18 . The method of claim 13 , wherein during the step of introducing, controlling introduction of infiltrant material to provide a first region in the ultrahard material body comprising the infiltrant material, and a second region that is substantially free of the infiltrant material.

19 . The method of claim 18 , wherein the second region extends a depth from a working surface of the ultrahard material body.

20 . The method of claim 13 , wherein the ultrahard material body produced during the step of subjecting comprises a first region having a porosity that is different from a second region.

Assignees

• Smith International

Inventors

• Voronin Georgiy

Classifications

• B24D18/0009

  using moulds or presses · CPC title

• B24D3/02

  the constituent being used as bonding agent · CPC title

• B24D18/00

  Manufacture of grinding tools {or other grinding devices}, e.g. wheels, not otherwise provided for · CPC title

• B24D99/005

  Segments of abrasive wheels · CPC title

• E21B10/55

  with preformed cutting elements · CPC title