Pdc cutter with unique microstructure

Patent metadata

Field	Value
Publication number	US-2024425736-A1
Application number	US-202418826879-A
Country	US
Kind code	A1
Filing date	Sep 6, 2024
Priority date	Mar 14, 2022
Publication date	Dec 26, 2024
Grant date	—

Abstract

A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a diamond table and a substrate. The diamond table may be attached to the substrate. The diamond table may include bonded diamond grains defining interstitial channels. The interstitial channels may be filled with non-catalytic binder materials in some regions. The interstitial channels in some other regions may be filled with catalytic materials from the substrate.

First claim

We claims:

1 . A superabrasive compact, comprising:
a substrate; and a superabrasive volume attached to the substrate, wherein the superabrasive volume has a plurality of polycrystalline diamond particles and a non-catalytic binder (NCB), wherein the polycrystalline diamond particles bonded in part by the non-catalytic binder.

2 . The superabrasive compact of claim 1 , wherein the non-catalytic binder comprises at least one of Titanium, MgCO 3 , CaCO 3 , Boron, Tantalum, Cr 2 AlC, or Niobium.

3 . The superabrasive compact of claim 1 , wherein the plurality of polycrystalline diamond particles comprise a first plurality of polycrystalline diamond particles with a size ranging from about 1 to about 10 μm.

4 . The superabrasive compact of the claim 3 , wherein the plurality of polycrystalline diamond particles comprise a second plurality of polycrystalline diamond particles with a size ranging from about 10 nm to about 5 μm.

5 . The superabrasive compact of the claim 4 , wherein the plurality of polycrystalline diamond particles comprise a third plurality of polycrystalline diamond particles with a size ranging from about 10 μm to 100 μm.

6 . The superabrasive compact of claim 5 , wherein the non-catalytic binder is about 1% to about 5% of diamond particles.

7 . The superabrasive compact of claim 5 , wherein the non-catalytic binder disperses and adheres to the third plurality of polycrystalline diamond particles and the first plurality of polycrystalline diamond particles.

8 . The superabrasive compact of claim 5 , wherein the non-catalytic binder segregates to form a pool.

9 . The superabrasive compact of claim 5 , wherein the non-catalytic binder is in bonding between the second plurality of diamonds.

10 . A superabrasive compact, comprising:
a superabrasive volume, wherein the superabrasive volume has a plurality of polycrystalline diamond particles and a non-catalytic binder (NCB), wherein the polycrystalline diamond particles bonded in part by the non-catalytic binder, wherein the non-catalytic binder comprises at least one of Titanium, MgCO 3 , CaCO 3 , Boron, Tantalum, Cr 2 AlC, or Niobium.

11 . The superabrasive compact of claim 10 , wherein the plurality of polycrystalline diamond particles comprise a first plurality of polycrystalline diamond particles with a size ranging from about 1 to about 10 μm.

12 . The superabrasive compact of the claim 11 , wherein the plurality of polycrystalline diamond particles comprise a second plurality of polycrystalline diamond particles with a size ranging from about 10 nm to about 5 μm.

13 . The superabrasive compact of the claim 12 , wherein the plurality of polycrystalline diamond particles comprise a third plurality of polycrystalline diamond particles with a size ranging from about 10 μm to 100 μm.

14 . The superabrasive compact of claim 13 , wherein the non-catalytic binder is about 1% to about 5% of diamond particles.

15 . The superabrasive compact of claim 13 , wherein the non-catalytic binder disperses and adheres to the third plurality of polycrystalline diamond particles and the first plurality of polycrystalline diamond particles.

16 . A superabrasive compact, comprising:
a superabrasive volume, wherein the superabrasive volume has a first plurality of polycrystalline diamond particles with a size ranging from about 1 to about 10 μm; a second plurality of polycrystalline diamond particles with a size ranging from about 10 nm to about 5 μm.

17 . The superabrasive compact of the claim 16 , wherein the plurality of polycrystalline diamond particles comprise a third plurality of polycrystalline diamond particles with a size ranging from about 10 μm to 100 μm.

18 . The superabrasive compact of the claim 16 further comprises a non-catalytic binder (NCB), wherein the polycrystalline diamond particles bonded in part by the non-catalytic binder, wherein the non-catalytic binder comprises at least one of Titanium, MgCO 3 , CaCO 3 , Boron, Tantalum, Cr 2 AlC, or Niobium.

19 . The superabrasive compact of claim 16 , wherein the non-catalytic binder is about 1% to about 5% of diamond particles.

20 . The superabrasive compact of claim 18 , wherein the non-catalytic binder disperses and adheres to the third plurality of polycrystalline diamond particles and the first plurality of polycrystalline diamond particles.

Assignees

• Cnpc Usa Corp
• Beijing Huamei Inc
• China Nat Petroleum Corp

Inventors

• Zhang Kai
• Cheng Chris
• Feng Xiao
• Peng Qi
• Yang Xiongwen

Classifications

• B24D11/003 Primary

  without embedded abrasive particles (B24D11/005 takes precedence) · CPC title

• B24D99/005

  Segments of abrasive wheels · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• C09K3/1436 Primary

  Composite particles, e.g. coated particles · CPC title