Self-sharpening cutting elements, earth-boring tools including such cutting elements, and methods of forming such cutting elements

Patent metadata

Field	Value
Publication number	US-9359828-B2
Application number	US-201313794187-A
Country	US
Kind code	B2
Filing date	Mar 11, 2013
Priority date	Mar 21, 2012
Publication date	Jun 7, 2016
Grant date	Jun 7, 2016

Abstract

Cutting elements for earth-boring tools comprise a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, and Ti. A polycrystalline superabrasive material may be attached to the substrate. Earth-boring tools comprise a body. At least one cutting element is attached to the body. The at least one cutting element comprises a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, and Ti. A polycrystalline superabrasive material may be attached to the substrate. Methods of forming cutting elements for earth-boring tools comprise disposing a substrate including at least one material selected from the group consisting of CoCr, CoCrMo, CoCrW, and Ti in a container. Particles of superabrasive material may be disposed in the container. The particles of superabrasive material may be sintered with the substrate in the container to form a polycrystalline superabrasive material attached to the substrate.

First claim

What is claimed is:

1. A cutting element for an earth-boring tool, comprising:
a cutting table comprising a polycrystalline superabrasive material, the cutting table comprising an at least substantially planar cutting face; and
a substrate attached to the cutting table, the substrate comprising at least one metal or metal alloy material selected from the group consisting of CoCr, CoCrMo, CoCrW, wherein a wear rate of the substrate is faster than a wear rate of a similarly configured substrate comprising cobalt-cemented tungsten carbide, and wherein the substrate is at least substantially free of particle-matrix composite material.

2. The cutting element of claim 1 , further comprising an intermediate material interposed between the substrate and the cutting table.

3. The cutting element of claim 2 , wherein the intermediate material comprises at least one of Ta and W.

4. The cutting element of claim 1 , wherein the cutting table is attached directly to the substrate.

5. The cutting element of claim 1 , wherein the substrate at least substantially comprises the metal or metal alloy material selected from the group consisting of CoCr, CoCrMo, CoCrW.

6. The cutting element of claim 5 , wherein the substrate is at least substantially free of tungsten carbide.

7. The cutting element of claim 1 , wherein an interface between the cutting table and the substrate is nonplanar.

8. The cutting element of claim 1 , wherein at least a portion of the cutting table at and proximate the cutting face is at least substantially free of catalyst material used to form the cutting table.

9. An earth-boring tool, comprising:
a body; and
at least one cutting element attached to the body, the at least one cutting element comprising:
a cutting table comprising a polycrystalline superabrasive material, the cutting table comprising an at least substantially planar cutting face; and
a substrate attached to the cutting table, the substrate comprising at least one metal or metal alloy material selected from the group consisting of CoCr, CoCrMo, CoCrW, wherein a wear rate of the substrate is faster than a wear rate of a similarly configured substrate comprising cobalt-cemented tungsten carbide, and wherein the substrate is at least substantially free of composite material.

10. The earth-boring tool of claim 9 , wherein the polycrystalline superabrasive material is at least substantially free of particle-matrix composite material.

11. The earth-boring tool of claim 9 , wherein at least a portion of the cutting table at and proximate the cutting face is at least substantially free of catalyst material used to form the cutting table.

12. The earth-boring tool of claim 9 , wherein the body comprises steel and wherein the at least one cutting element is welded to the body.

13. A method of forming a cutting element for an earth-boring tool, comprising:
disposing a substrate comprising at least one metal or metal alloy material selected from the group consisting of CoCr, CoCrMo, CoCrW in a container;
disposing particles of superabrasive material in the container; and
sintering the particles of superabrasive material with the substrate in the container to form a cutting table comprising a polycrystalline superabrasive material, the cutting table comprising an at least substantially planar cutting face, the cutting table attached to the substrate, wherein a wear rate of the substrate is faster than a wear rate of a similarly configured substrate comprising cobalt-cemented tungsten carbide, and wherein the substrate is at least substantially free of particle-matrix composite material.

14. The method of claim 13 , further comprising disposing an intermediate material between the substrate and the particles of superabrasive material in the container.

15. The method of claim 14 , further comprising selecting the intermediate material to comprise at least one of Ta and W.

16. The method of claim 13 , wherein sintering the particles of superabrasive material with the substrate in the container to form the polycrystalline superabrasive material attached to the substrate comprises attaching the polycrystalline superabrasive material directly to the substrate.

17. The method of claim 13 , further comprising selecting the substrate to substantially comprise the metal or metal alloy material selected from the group consisting of CoCr, CoCrMo, CoCrW.

18. The method of claim 13 , further comprising removing catalyst material used to form the cutting table from at least a portion of the cutting table at and proximate the cutting face.

19. The method of claim 13 , wherein sintering the particles of superabrasive material with the substrate in the container comprises exposing the particles of superabrasive material with the substrate in the container to a temperature of at least 1350° C. and a pressure of at least 5 GPa.

20. The method of claim 13 , wherein sintering the particles of superabrasive material with the substrate in the container comprises sweeping a catalyst material from the substrate among at least some particles of the particles of superabrasive material.

21. The method of claim 13 , further comprising dispersing a catalyst material among the particles of superabrasive material in the container.

Assignees

• Baker Hughes Inc

Inventors

• Scott Danny E

Classifications

• E21B10/573 Primary

  characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element · CPC title

• E21B10/006

  providing a cutting edge which is self-renewable during drilling · CPC title