Braze joints with a dispersed particulate microstructure

Patent metadata

Field	Value
Publication number	US-2017191315-A1
Application number	US-201515105218-A
Country	US
Kind code	A1
Filing date	Jun 25, 2015
Priority date	Jun 25, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

The microstructure of braze joints in polycrystalline diamond compact (PDC) cutters may be tailored to increase the shear strength of the braze joint, for example, by increasing the amount of a dispersed particulate microstructure therein. A method for forming a dispersed particulate microstructure may include brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 5° C. above a solidus temperature of the braze alloy and 200° C. above a liquidus temperature of the braze alloy; and forming a braze joint between the polycrystalline diamond table and the hard composite substrate that comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 μm to 2.0 μm and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

First claim

1 . A method comprising:
brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 1° C. above a solidus temperature of the braze alloy and 200° C. above a liquidus temperature of the braze alloy; and cooling the braze alloy to form a dispersed particulate microstructure in a braze joint between the polycrystalline diamond table and the hard composite substrate, wherein the braze joint comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 μm to 2.0 μm and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

2 . The method of claim 1 , wherein the braze temperature is between 1° C. above a solidus temperature of the braze alloy and 100° C. above a liquidus temperature of the braze alloy.

3 . The method of claim 1 , wherein the braze temperature is between 1° C. above a solidus temperature of the braze alloy and 50° C. above a liquidus temperature of the braze alloy.

4 . The method of claim 1 , wherein the braze temperature is between 1° C. above a solidus temperature of the braze alloy and a liquidus temperature of the braze alloy.

5 . The method of claim 1 , wherein brazing involves: holding at the braze temperature for 1 second to 30 minutes.

6 . The method of claim 1 , wherein brazing involves: holding at the braze temperature for 1 second to 5 minutes.

7 . The method of claim 1 , wherein brazing involves: holding at the braze temperature for 1 second to 1 minute.

8 . The method of claim 1 , wherein brazing involves: heating the braze alloy to a first temperature, holding at the first temperature for 1 second to 30 minutes, and continuing to heat the braze alloy to the braze temperature.

9 . The method of claim 1 , wherein the braze joint comprises at least 50% by volume of the dispersed particulate microstructure.

10 . The method of claim 1 , wherein the braze joint comprises at least 70% by volume of the dispersed particulate microstructure.

11 . The method of claim 1 , wherein the braze joint comprises at least 90% by volume of the dispersed particulate microstructure.

12 . The method of claim 1 , wherein the braze alloy comprises particulates dispersed in a base alloy, the particulates comprising metallic particulates, ceramic particulates, or a combination thereof and having a diameter of 0.1 μm to 5.0 μm and an aspect ratio of 1 to 10.

13 . A polycrystalline diamond compact cutter comprising:
a polycrystalline diamond table bound to a hard composite substrate at a braze joint that comprises at least 40% by volume of a microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 μm to 2.0 μm and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

14 . The polycrystalline diamond compact cutter of claim 13 , wherein the braze joint comprises at least 50% by volume of the dispersed particulate microstructure.

15 . The polycrystalline diamond compact cutter of claim 13 , wherein the braze joint comprises at least 70% by volume of the dispersed particulate microstructure.

16 . The polycrystalline diamond compact cutter of claim 13 , wherein the braze joint further comprises particulates dispersed in the ductile matrix, the particulates comprising metallic particulates, ceramic particulates, or a combination thereof and having a diameter of 0.1 μm to 5.0 μm and an aspect ratio of 1 to 10.

17 . A drilling assembly comprising:
a drill string extending into a wellbore; a pump fluidly connected to the drill string and configured to circulate a drilling fluid into the drill string and through the wellbore; and a drill bit attached to an end of the drill string, the drill bit having a matrix bit body and a plurality of polycrystalline diamond compact cutters coupled to an exterior portion of the matrix bit body, wherein at least one of the polycrystalline diamond compact cutters comprises a polycrystalline diamond table bound to a hard composite substrate at a braze joint that comprises at least 40% by volume of a microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 μm to 2.0 μm and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

18 . The drilling assembly cutter of claim 17 , wherein the braze joint comprises at least 50% by volume of the dispersed particulate microstructure.

19 . The drilling assembly cutter of claim 17 , wherein the braze joint comprises at least 70% by volume of the dispersed particulate microstructure.

20 . The drilling assembly cutter of claim 17 , wherein the braze joint further comprises particulates dispersed in the ductile matrix, the particulates comprising metallic particulates, ceramic particulates, or a combination thereof and having a diameter of 0.1 μm to 5.0 μm and an aspect ratio of 1 to 10.

Assignees

• Halliburton Energy Services Inc

Inventors

• Saini Gagan
• Atkins William Brian

Classifications

• E21B10/567

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

• E21B10/46 Primary

  characterised by wear resisting parts, e.g. diamond inserts · CPC title

• B23P15/28

  cutting tools (sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00) · CPC title

• E21B10/42

  Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits (characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62) · CPC title

• B23K2101/00

  Articles made by soldering, welding or cutting · CPC title