Cutting elements, bearings, and earth-boring tools including multiple substrates attached to one another

Patent metadata

Field	Value
Publication number	US-9650838-B2
Application number	US-201414537434-A
Country	US
Kind code	B2
Filing date	Nov 10, 2014
Priority date	Mar 4, 2011
Publication date	May 16, 2017
Grant date	May 16, 2017

Abstract

Cutting elements for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed. The portion of the first substrate may exhibit a thickness less than a thickness of the first substrate before a remainder of the first substrate was removed to form the portion of the first substrate. Another substrate may be attached to the portion of the first substrate, the portion of the first substrate being interposed between the polycrystalline table and the other substrate. Earth-boring tools may include such cutting elements secured to bodies of the earth-boring tools. Bearings for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed, the polycrystalline table defining a contact surface. Another substrate may be attached to the portion of the first substrate.

First claim

What is claimed is:

1. A cutting element for an earth-boring tool, comprising:
a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed, the portion of the first substrate comprising first hard, carbide, nitride, oxide, and/or boride particles within a first metal or metal alloy matrix material; and
another substrate attached to the portion of the first substrate, the other substrate comprising second hard, carbide, nitride, oxide, and/or boride particles within a second metal or metal alloy matrix material, the portion of the first substrate being interposed between the polycrystalline table and the other substrate;
wherein the portion of the first substrate comprises a first volume percentage of the first metal or metal alloy matrix material and the other substrate comprises a second, lesser volume percentage of the second metal or metal alloy matrix material, and wherein at least one of an end of the portion of the first substrate and a facing end of the another substrate comprises a rough-ground surface.

2. The cutting element of claim 1 , wherein the portion of the first substrate comprises an annular member bounding a central recess attached at a periphery of the polycrystalline table and the another substrate comprises a protrusion located in the central recess of the portion of the first substrate.

3. The cutting element of claim 1 , wherein at least a portion of the polycrystalline table is free of catalyst material.

4. The cutting element of claim 1 , further comprising at least one of a catalyst material, a braze material, an inert reinfiltrant material, an organic adhesive, and an organo-metallic adhesive attaching the portion of the first substrate to the other substrate.

5. The cutting element of claim 1 , wherein a first average particle size of the first hard, carbide, nitride, oxide, and/or boride particles is greater than a second average particle size of the second hard, carbide, nitride, oxide, and/or boride particles.

6. The cutting element of claim 5 , wherein the first average particle size is at least two times greater than the second average particle size.

7. The cutting element of claim 1 , wherein a thickness of the portion of the first substrate is less than 1 mm.

8. An earth-boring tool, comprising:
a body; and
a cutting element secured to the body, the cutting element comprising:
a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed, the portion of the first substrate comprising first hard, carbide, nitride, oxide, and/or boride particles within a first metal or metal alloy matrix material; and
another substrate attached to the portion of the first substrate, the other substrate comprising second hard, carbide, nitride, oxide, and/or boride particles within a second metal or metal alloy matrix material, the portion of the first substrate being interposed between the polycrystalline table and the other substrate;
wherein the portion of the first substrate comprises a first volume percentage of the first metal or metal alloy matrix material and the other substrate comprises a second, lesser volume percentage of the second metal or metal alloy matrix material, and wherein at least one of an end of the portion of the first substrate and a facing end of the another substrate comprises a rough-ground surface.

9. The earth-boring tool of claim 8 , wherein the portion of the first substrate comprises an annular member bounding a central recess attached at a periphery of the polycrystalline table and the another substrate comprises a protrusion located in the central recess of the portion of the first substrate.

10. The earth-boring tool of claim 8 , wherein a first average particle size of the first hard, carbide, nitride, oxide, and/or boride particles is greater than a second average particle size of the second hard, carbide, nitride, oxide, and/or boride particles.

11. The earth-boring tool of claim 10 , wherein the first average particle size is at least two times greater than the second average particle size.

12. The earth-boring tool of claim 8 , wherein a thickness of the portion of the first substrate is less than 1 mm.

Assignees

• Baker Hughes Inc

Inventors

• Digiovanni Anthony A
• Lyons Nicholas J
• Nelms Derek L
• Scott Danny E

Classifications

• C22C29/14

  based on borides · CPC title

• E21B10/5735 Primary

  Interface between the substrate and the cutting element · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title

• C22C1/051

  Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor · CPC title

• B22F3/14

  simultaneously · CPC title