Diamond Patents (Class 175/434)
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Patent number: 8113303Abstract: A cutter for a fixed cutter drill bit including a substrate and an ultrahard material layer disposed on an end surface of the substrate, the ultra hard material layer having an upper surface opposite the substrate end surface and a peripheral surface such that the upper surface intersects the peripheral surface along a peripheral edge. The peripheral edge continuously increases and decreases in height as measured from a plane perpendicular to a longitudinal axis of the cutter.Type: GrantFiled: June 8, 2010Date of Patent: February 14, 2012Assignee: Smith International, IncInventors: Youhe Zhang, Yuelin Shen
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Publication number: 20120031674Abstract: A cutting element for an earth-boring tool. The cutting element comprises a substrate base, and a volume of polycrystalline diamond material on an end of the substrate base. The volume of polycrystalline diamond material comprises a generally conical surface, an apex centered about a longitudinal axis extending through a center of the substrate base, a flat cutting surface extending from a first point at least substantially proximate the apex to a second point on the cutting element more proximate a lateral side surface of the substrate base. Another cutting element is disclosed, as are a method of manufacturing and a method of using such cutting elements.Type: ApplicationFiled: August 5, 2011Publication date: February 9, 2012Applicant: BAKER HUGHES INCORPORATEDInventor: Nicholas J. Lyons
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Patent number: 8109350Abstract: A polycrystalline abrasive composite cutter, including a tool body with a top cutting surface and a flank surface. The composite cutter, joined to a substrate, constitute a shear cutter for a PDC bit, roller-cone bit insert, or other tool that can be highly useful for petroleum drilling or other applications. The body of the polycrystalline abrasive composite cutter includes a plurality of polycrystalline abrasive layers (90) and a plurality of arresting layers (100). The polycrystalline abrasive layers (90) and the arresting layers (100) are arranged to alternate throughout the tool body in a direction normal to the top cutting surface (92) and in a direction normal to a flank surface (94).Type: GrantFiled: January 26, 2007Date of Patent: February 7, 2012Assignee: University of Utah Research FoundationInventors: Zhigang Z. Fang, Stephen C. Johnson, Haibo Zhang
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Patent number: 8109349Abstract: In one aspect of the invention, a high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches thickness from the apex to a central region of the cemented metal carbide substrate.Type: GrantFiled: February 12, 2007Date of Patent: February 7, 2012Assignee: Schlumberger Technology CorporationInventors: David R. Hall, Ronald B. Crockett, John D. Bailey, Jeff Jepson, Scott Dahlgren
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Patent number: 8104550Abstract: Earth-boring tools include wear-resistant materials disposed in at least one recess formed in an exterior surface of a body thereof. Exposed surfaces of the wear-resistant material are substantially level with exterior surfaces of the body adjacent the wear-resistant material. In some embodiments, recesses may be formed in formation-engaging surfaces of blades of earth-boring rotary tools, adjacent one or more inserts secured to bodies of earth-boring tools, or adjacent one or more cutting elements secured to bodies of earth-boring tools. Methods of forming earth-boring tools include filling one or more recesses formed in an exterior surface of a body with wear-resistant material and causing exposed surfaces of the wear-resistant material to be substantially level with the exterior surface of the body.Type: GrantFiled: September 28, 2007Date of Patent: January 31, 2012Assignee: Baker Hughes IncorporatedInventors: James L. Overstreet, Michael L. Doster, Mark E. Morris, Kenneth E. Gilmore, Robert M. Welch, Danielle V. Roberts
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Patent number: 8100201Abstract: A rotary drill bit (10) is provided for drilling a hole in a subsurface formation. The bit body (12) includes a plurality of axially extending ribs (16a, b, c and d) and a flow channel between adjacent ribs. A plurality of cutting elements are fixedly mounting on a respective one of the plurality of ribs. A plurality of flow nozzles (20a, b, c and d) direct fluid to a respective one of the plurality of cutting elements to clean and cool the cutting elements.Type: GrantFiled: July 24, 2009Date of Patent: January 24, 2012Assignee: BlueFire Equipment CorporationInventor: Anatoli Borissov
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Patent number: 8100203Abstract: A drill bit that includes a body having a lower end face for engaging a rock formation, the end face having a plurality of raised ribs extending from the face of the bit body and separated by a plurality of channels therebetween; and at least one of the plurality of ribs having a cutting portion of the at least one rib comprising a first diamond impregnated matrix material and at least a portion of a gage surface region thereof comprising a second diamond impregnated matrix material, the gage surface region backed by a third matrix material is disclosed.Type: GrantFiled: May 15, 2008Date of Patent: January 24, 2012Assignee: Smith International, Inc.Inventors: Gregory T. Lockwood, Jonan Fulenchek
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Publication number: 20120012403Abstract: A MAX-phase material is provided for a cutting tool and other applications.Type: ApplicationFiled: July 13, 2011Publication date: January 19, 2012Inventor: L. Pierre de Rochemont
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Patent number: 8083012Abstract: Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element.Type: GrantFiled: October 3, 2008Date of Patent: December 27, 2011Assignee: Smith International, Inc.Inventors: Georgiy Voronin, J. Daniel Belnap, Feng Yu, Benjamin Randall
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Patent number: 8080071Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) comprising a polycrystalline diamond (“PCD”) table including a catalyst material therein that has been implanted with ions (e.g., carbon ions) and/or infiltrated from a host material implanted with carbon ions. In an embodiment, a PDC comprises a substrate and a PCD table bonded to the substrate. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. The PCD table includes an upper surface from which a region inwardly extends. At least a portion of the interstitial regions of the region includes a catalyst material disposed therein. At least a portion of the catalyst material may be at least saturated with carbon.Type: GrantFiled: February 27, 2009Date of Patent: December 20, 2011Assignee: US Synthetic CorporationInventor: Michael A. Vail
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Publication number: 20110303465Abstract: Impregnated drilling tools include elongated structures that provide enhanced properties. The drilling tools contain a diamond-impregnated cutting section that contains elongated structures made from carbon, glass, ceramic, and the like. The elongated structures can comprise tubes, fibers, or rods. In one or more implementations the elongated structures are nano-sized. The elongated structures can control the tensile strength and/or the erosion rate of the drilling tools to optimize the cutting performance of the tools. Additionally, the elongated structures may also weaken the cutting section in one or more implementations; thereby, allowing higher strength binders to be used. Such higher modulus binders can cost less and allow for tailoring of the cutting section to retain the diamonds for the desired amount of time. As the cutting section erodes, the elongated structures may also increase the lubricity at the face of the cutting section.Type: ApplicationFiled: August 24, 2011Publication date: December 15, 2011Applicant: LONGYEAR TM, INC.Inventors: Michael D. Rupp, Cody A. Pearce, Christian M. Lambert, Kristian S. Drivdahl
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Patent number: 8074748Abstract: Embodiments of the invention relate to thermally-stable polycrystalline diamond (“PCD”) elements, polycrystalline diamond compacts (“PDCs”), and methods of fabricating such PCD elements and PDCs. In an embodiment, a PCD element includes a PCD body comprising bonded diamond grains defining a plurality of interstitial regions. The PCD body includes a first volume having a first portion of the interstitial regions and a second volume having a second portion of the interstitial regions. The PCD body further includes an infiltrant that is disposed in the first portion of the interstitial regions and the second portion of the interstitial regions is substantially free of the infiltrant. The infiltrant comprises a glass, a glass-ceramic, silicone, a thermal decomposition reaction product of silicone, a ceramic having a negative coefficient of thermal expansion, or combinations thereof.Type: GrantFiled: February 20, 2009Date of Patent: December 13, 2011Assignee: US Synthetic CorporationInventors: David P. Miess, Craig H. Cooley
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Patent number: 8069935Abstract: According to various aspects of the present invention, a superabrasive element includes a plurality of superabrasive grains (e.g., as diamond grains and/or cubic boron nitride grains). The superabrasive element further includes a binder constituent that bonds at least a portion of the superabrasive grains together. The binder constituent includes predominantly one or more inorganic-compound phases, such as boron or silicon compounds. Applications utilizing such superabrasive elements and methods of fabricating such superabrasive elements are also disclosed.Type: GrantFiled: June 3, 2010Date of Patent: December 6, 2011Assignee: US Synthetic CorporationInventors: David P. Miess, Jiang Qian
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Patent number: 8069937Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table that is substantially free of defects formed due to abnormal grain growth of tungsten carbide grains, and methods of fabricating such PDCs. In an embodiment, a PDC comprises a cemented tungsten carbide substrate including an interfacial surface that is substantially free of tungsten carbide grains exhibiting abnormal grain growth, and a PCD table bonded to the interfacial surface of the cemented tungsten carbide substrate. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a metal-solvent catalyst disposed therein. The PCD table may be substantially free of chromium or the PCD table and the cemented tungsten carbide substrate may each include chromium.Type: GrantFiled: February 26, 2009Date of Patent: December 6, 2011Assignee: US Synthetic CorporationInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Mohammad N. Sani
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Patent number: 8071173Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact includes forming an assembly including an at least partially leached polycrystalline diamond table that includes a plurality of interstitial regions therein and a surface; at least one silicon-containing layer positioned adjacent to the surface of the at least partially leached polycrystalline diamond table; and a substrate positioned at least proximate to the at least partially leached polycrystalline diamond table.Type: GrantFiled: January 30, 2009Date of Patent: December 6, 2011Assignee: US Synthetic CorporationInventor: Mohammad N. Sani
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Patent number: 8069936Abstract: Earth-boring tools and components thereof include a particle-matrix composite material having encapsulated diamond particles embedded within a matrix material. Diamonds in the particles comprise less than about 25% by volume of the composite material, the matrix material comprises less than about 50% by volume of the composite material, and encapsulant material surrounding the diamonds at least substantially comprises a remainder of the volume of the composite material. Methods of forming at least a portion of an earth-boring tool include embedding encapsulated diamond particles in a volume of matrix material to form a particle-matrix composite material. The composite material is formed in such a manner as to cause diamonds to comprise less than about 25% of the composite material, the matrix material to comprise less than about 50% of the composite material, and encapsulant material surrounding the diamonds to at least substantially comprise a remainder of the composite material.Type: GrantFiled: November 20, 2008Date of Patent: December 6, 2011Assignee: Baker Hughes IncorporatedInventors: Danny E. Scott, Wesley D. Fuller
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Patent number: 8066087Abstract: Thermally stable ultra-hard compact constructions comprise a polycrystalline diamond body substantially free of a catalyst material, and a substrate that is joined thereto. The substrate can be ceramic, metallic, cermet and combinations thereof, and can be joined to the body by a braze material or other material that forms an attachment bond at high pressure/high temperature conditions. The body and substrate are specially formed having complementary interfacing surface features to facilitate providing an improved degree of attachment therebetween. The complementary surface features can in the form of openings and projections, e.g., one of the body or substrate can comprise one or more openings, and the other of the body or substrate can comprise one or more projections, disposed within or extending from respective interfacing surfaces. The complementary surface features operate to resist unwanted delamination between the body and substrate, thereby extending effective service life of the construction.Type: GrantFiled: May 8, 2007Date of Patent: November 29, 2011Assignee: Smith International, Inc.Inventors: Anthony Griffo, Madapusi K. Keshavan, Youhe Zhang, Yuelin Shen, Michael Janssen
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Patent number: 8061454Abstract: An ultra-hard and metallic construction comprises an ultra-hard component that is attached to a metallic component via a braze joint. The braze joint is interposed between the ultra-hard component and the metallic component, and comprises a first braze material bonded to a surface of the ultra-hard component. The braze joint includes an intervening layer in direct contact with the first braze material, and that is formed from a rigid material. The braze joint further comprises a second braze material that is interposed between the intervening layer and the metallic component, and that is different from the first braze material.Type: GrantFiled: January 9, 2008Date of Patent: November 22, 2011Assignee: Smith International, Inc.Inventors: Georgiy Voronin, J. Daniel Belnap
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Patent number: 8061458Abstract: A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.Type: GrantFiled: April 25, 2011Date of Patent: November 22, 2011Assignee: US Synthetic CorporationInventors: Kenneth E. Bertagnolli, Michael A. Vail
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Publication number: 20110278075Abstract: A drill bit includes a plurality of continuous segments impregnated with diamond that are each mounted to form a corresponding blade. The regions between the blades define a plurality of fluid passages on the bit face. The blades extend radially outwardly to the gage. The continuous segments may be either straight or spiral in design. Furthermore, the design of the segments supports varying one or more of: diamond content, width, back rake angle and/or relief angle along a length of the segment.Type: ApplicationFiled: July 26, 2011Publication date: November 17, 2011Applicant: Varel International, Ind., L.P.Inventors: Alfazazi Dourfaye, Michel de Reynal
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Patent number: 8057775Abstract: Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to a HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a method includes subjecting a mixture to heat and pressure sufficient to form a PCD material. The mixture comprises a plurality of diamond particles exhibiting a diamond particle size distribution characterized, in part, by a parameter ? that is less than about 1.0, where ? = x 6 · ? , x is the average particle size of the diamond particle size distribution, and ? is the standard deviation of the diamond particle size distribution.Type: GrantFiled: April 22, 2008Date of Patent: November 15, 2011Assignee: US Synthetic CorporationInventors: Michael A. Vail, Kenneth E. Bertagnolli, Jason Wiggins, Jiang Qian, David P. Miess
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Patent number: 8028774Abstract: A high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches from the apex to a central region of the cemented metal carbide substrate. The diamond material comprises a 1 to 5 percent concentration of binding agents by weight.Type: GrantFiled: November 25, 2009Date of Patent: October 4, 2011Assignee: Schlumberger Technology CorporationInventors: David R. Hall, Ronald B. Crockett, Jeff Jepson, Scott Dahlgren, John Bailey
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Patent number: 8028771Abstract: Polycrystalline diamond constructions include a diamond body comprising a matrix phase of bonded together diamond crystals formed at high pressure/high temperature conditions with a catalyst material. The sintered body is treated to remove the catalyst material disposed within interstitial regions, rendering it substantially free of the catalyst material used to initially sinter the body. Accelerating techniques can be used to remove the catalyst material. The body includes an infiltrant material disposed within interstitial regions in a first region of the construction. The body includes a second region adjacent the working surface and that is substantially free of the infiltrant material. The infiltrant material can be a Group VIII material not used to initially sinter the diamond body. A metallic substrate is attached to the diamond body, and can be the same or different from a substrate used as a source of the catalyst material used to initially sinter the diamond body.Type: GrantFiled: February 5, 2008Date of Patent: October 4, 2011Assignee: Smith International, Inc.Inventors: Madapusi K. Keshavan, Anthony Griffo, Yuelin Shen, Youhe Zhang
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Patent number: 8020643Abstract: Ultra-hard constructions include an ultra-hard body having a first region including a polycrystalline matrix first phase and a second phase material interposed therein. The first region is substantially free of a catalyst material used to form the first phase. The body is formed by removing the catalyst material and then replacing it with the second phase material. A second region is disposed within the body and includes the polycrystalline matrix first phase and a catalyst material used to form the first phase. The second phase material has a thermal characteristic that is more closely matched to the matrix first phase than the catalyst material. The body may be joined to a substrate, and the ultra-hard body may consist entirely of the first region. The second phase material can include non-refractory metals, ceramics, silicon, silicon-containing compounds, diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof.Type: GrantFiled: September 12, 2006Date of Patent: September 20, 2011Assignee: Smith International, Inc.Inventors: Monte E. Russell, Scott M. Packer, Russell J. Steel, Ronald K. Eyre
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Patent number: 8020642Abstract: A polycrystalline diamond abrasive element, particularly a cutting element, comprises a table of polycrystalline diamond bonded to a substrate, particularly a cemented carbide substrate, along a non-planar interface. The non-planar interface typically has a cruciform configuration. The polycrystalline diamond has a high wear-resistance, and has a region adjacent the working surface lean in catalysing material and a region rich in catalysing material. The region lean in catalysing material extends to a depth of 40 to 90 microns, which is much shallower than in the prior art. Notwithstanding the shallow region lean in catalysing material, the polycrystalline diamond cutters have a wear resistance, impact strength and cutter life comparable to that of prior art cutters, but requiring only 20% of the treatment times of the prior art cutters.Type: GrantFiled: May 27, 2004Date of Patent: September 20, 2011Inventors: Brett Lancaster, Bronwyn Annette Roberts, Imraan Parker, Klaus Tank, Roy Derrick Achilles, Clement David Van Der Riet
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Patent number: 8020640Abstract: A drill bit that includes a body having a lower end face for engaging a rock formation is disclosed. The end face has a plurality of raised ribs extending from the face of the bit body and separated by a plurality of channels therebetween. At least one of the plurality of ribs has a leading portion and a trailing portion, the leading portion comprising a first matrix material impregnated with super abrasive particles and the trailing portion comprising a second matrix material impregnated with super abrasive particles, wherein the first and second matrix materials differ from each other.Type: GrantFiled: May 16, 2008Date of Patent: September 20, 2011Assignee: Smith International, Inc,Inventors: Gregory T. Lockwood, Jonan Fulenchek
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Patent number: 8020644Abstract: A cutting element is provided including a substrate and a TSP material layer over the substrate. The TSP material layer includes at least a property having a value that varies through the layer.Type: GrantFiled: April 12, 2010Date of Patent: September 20, 2011Assignee: Smith International Inc.Inventor: Madapusi K. Keshavan
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Patent number: 8020641Abstract: A method of optimizing drill bit design and an optimized drill bit for drilling a well into an earth formation comprising a bit body; a number of blades spaced around the bit body, each blade having a curved outer edge and a forward face; a first row of cutter pockets recessed into the face along the outer edge of each blade; a second group of cutter pockets recessed into the face of each blade offset from the first row; and a plurality of cutting elements, each cutting element being brazed into a different one of the cutter pockets.Type: GrantFiled: October 13, 2008Date of Patent: September 20, 2011Assignee: Baker Hughes IncorporatedInventors: Robert M. Welch, Eric E. McClain, L. Allen Sinor
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Patent number: 8020645Abstract: Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm3/grams (“G·cm3/g”) or less. Other embodiments are directed to polycrystalline diamond compacts (“PDCs”) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.Type: GrantFiled: August 18, 2010Date of Patent: September 20, 2011Assignee: US Synthetic CorporationInventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael Vail, Debkumar Mukhopadhyay
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Patent number: 8002859Abstract: A method of forming a thermally stable cutting element that includes disposing at least a portion of a polycrystalline abrasive body containing a catalyzing material to be leached into a leaching agent; and subjecting the polycrystalline abrasive object to an elevated temperature and pressure is disclosed. Thermally stable cutting elements and systems and other methods for forming thermally stable cutting elements are also disclosed.Type: GrantFiled: February 5, 2008Date of Patent: August 23, 2011Assignee: Smith International, Inc.Inventors: Anthony Griffo, Madapusi K. Keshavan
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Publication number: 20110180331Abstract: The present invention provides a rock bit which enables a reduction in surface pressure from a well wall and which allows possible vibration to be suppressed. A first of the present invention provides a rock bit including a bit body with a journal portion, a cone portion configured to be rotatable with respect to the bit body, a bearing portion located between the cone portion and the journal portion, and a seal provided between the cone portion and the journal portion to seal the bearing portion, wherein the cone portion includes a gauge surface that contacts a side wall of a well, and a diamond composite material is preferably disposed extensively and smoothly on the gauge surface. In a second aspect of the present invention, a ring bit is provided at an outer peripheral portion of a bit body. Furthermore, a cone portion of a tri-cone bit includes no gauge tip or surface chip that contacts the side wall of the well but only cemented carbide tips that contact a bottom of the well.Type: ApplicationFiled: March 22, 2010Publication date: July 28, 2011Applicant: TIX CorporationInventor: Nobuhiro Kuribayashi
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Publication number: 20110174550Abstract: A block of dense material is made up of hard particles, of the same or different nature, dispersed in a binder phase. The material has a solidus temperature Ts above which the binder phase is liquid. There is deposited on at least a portion of the surface of the block of dense material an active coating composed of a material capable of reacting chemically with the dense material when the assembly is heated to beyond a minimum reaction temperature Tr. The block coated with the active coating is subjected to a heat treatment comprising heating, then maintenance for a time tm at a maintenance temperature Tm greater than or equal to the minimum reaction temperature Tr, followed by cooling to ambient temperature.Type: ApplicationFiled: October 7, 2009Publication date: July 21, 2011Applicant: VAREL INTERNATIONAL, IND., L.P.Inventors: Christophe Colin, Elodie Sorlier, Alfazazi Dourfaye
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Patent number: 7963348Abstract: A tool for enlarging a borehole that includes an elongated tubular body; at least one movable arm affixed to the tubular body, the at least one movable arm comprising an outer surface formed of at least one of a matrix material and an abrasive material; and at least one actuating member for expanding at least one movable arm from the collapsed state to an expanded state is disclosed.Type: GrantFiled: October 11, 2007Date of Patent: June 21, 2011Assignee: Smith International, Inc.Inventors: Tommy Laird, Navish Makkar
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Cutting elements configured for casing component drillout and earth boring drill bits including same
Patent number: 7954570Abstract: A drill bit includes a bit body having a face on which two different types of cutting elements are disposed, the first type being cutting elements suitable for drilling at least one subterranean formation and the second type being cutting elements suitable for drilling through a casing bit disposed at an end of a casing or liner string and cementing equipment or other components, if such are disposed within the casing or liner string, as well as cement inside as well as exterior to the casing or liner string. The second type of cutting elements exhibits a relatively greater exposure than the first type of cutting elements, so as to engage the interior of the casing bit and, if present, cementing equipment components and cement to drill therethrough, after which the second type of cutting elements quickly wears upon engagement with the subterranean formation material exterior to the casing bit, and the first type of cutting elements continues to drill the subterranean formation.Type: GrantFiled: September 20, 2006Date of Patent: June 7, 2011Assignee: Baker Hughes IncorporatedInventors: Eric E. McClain, John C. Thomas, Sarvesh Tyagi, Jack T. Oldham, Lester I. Clark, William Heuser -
Patent number: 7950477Abstract: A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.Type: GrantFiled: November 6, 2009Date of Patent: May 31, 2011Assignee: US Synthetic CorporationInventors: Kenneth E. Bertagnolli, Michael A. Vail
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Patent number: 7946362Abstract: A matrix drill bit and method of manufacturing a matrix bit having back raked cutting elements is disclosed. In one aspect, a matrix drill bit for well drilling includes a matrix bit body that has a front area in a direction of drilling and two or more diamond impregnated cutting blades protruding from the front area of the matrix bit body. The cutting blades each have a front external surface protruding from the front area of the matrix bit body and present a plurality of back raked downhole interface surfaces in the direction of drilling. The downhole interface surfaces span a leading face and a trailing face where the leading face extends to a first height and the trailing face extends to a second height and the first height is greater than the second height.Type: GrantFiled: March 16, 2007Date of Patent: May 24, 2011Assignee: Halliburton Energy Services, Inc.Inventors: Nuno Da Silva, Valérie Sillen, Nicolas Luyckx
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Patent number: 7946363Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.Type: GrantFiled: March 18, 2009Date of Patent: May 24, 2011Assignee: Smith International, Inc.Inventors: Youhe Zhang, Yuelin Shen, Madapusi K. Keshavan, Michael G. Azar
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Patent number: 7942219Abstract: PCD constructions include a PCD body comprising a polycrystalline matrix region, a first region that includes a replacement material positioned remote from a body surface, and a second region that is substantially free of the replacement material and that extends a depth from the body surface. The PCD construction can further include a substrate that is attached to the body. The PCD body is formed by removing a solvent catalyst material used to form the body, replacing the removed solvent catalyst material with a replacement material, and then removing the replacement material from a region of the body to thereby form the second region. The replacement material can be introduced into the PCD body during a HPHT process, and the substrate may or may not be the source of the noncatalyzing material.Type: GrantFiled: March 21, 2007Date of Patent: May 17, 2011Assignee: Smith International, Inc.Inventors: Madapusi K. Keshavan, Ronald K. Eyre, Anthony Griffo, Peter Thomas Cariveau
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Publication number: 20110083909Abstract: Diamond bonded construction comprise a diamond body attached to a support. In one embodiment, an initial substrate used to sinter the body is interposed between the body and support, and is thinned to less than 5 times the body thickness, or to less than the body thickness, prior to attachment to the support to relieve stress in the body. In another embodiment, the substrate is removed after sintering, and the body is attached to the support. The support has a material construction different from that of the initial substrate, wherein the initial substrate is selected for infiltration and the support for end use properties. The substrate and support include a hard material with a volume content that may be the same or different. Interfaces between the body, substrate, and/or support may be nonplanar. The body may be thermally stable, and may include a replacement material disposed therein.Type: ApplicationFiled: October 12, 2010Publication date: April 14, 2011Applicant: SMITH INTERNATIONAL, INC.Inventors: Yuelin Shen, Youhe Zhang
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Patent number: 7918293Abstract: Methods of evaluating a superabrasive volume or a superabrasive compact are disclosed. One method may comprise exposing a superabrasive volume to beta particles and detecting a quantity of scattered beta particles. Further, a boundary may be perceived between a first region and a second region of the superabrasive volume in response to detecting the quantity of scattered beta particles. In another embodiment, a boundary between a catalyst-containing region and a catalyst-diminished region of a polycrystalline diamond volume may be perceived. In a further embodiment, a boundary may be perceived between a catalyst-containing region and a catalyst-diminished region of a polycrystalline diamond compact. Additionally, a depth to which a catalyst-diminished region extends within a polycrystalline diamond volume of a polycrystalline diamond compact may be measured in response to detecting a quantity of scattered beta particles. A system configured to evaluate a superabrasive volume is disclosed.Type: GrantFiled: March 8, 2006Date of Patent: April 5, 2011Assignee: US Synthetic CorporationInventor: Michael A. Vail
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Publication number: 20110067930Abstract: A cutting structure for a drill bit includes a diamond table affixed to one end of a first substrate. A second substrate is affixed to the other end of the first substrate. The second substrate is made from a different material than the first substrate. The first and second substrates are substantially coaxial.Type: ApplicationFiled: September 20, 2010Publication date: March 24, 2011Inventor: Timothy P. Beaton
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Publication number: 20110067924Abstract: Implementations of the present invention include impregnated drill bits having a plurality of relatively large abrasive cutting media, such as polycrystalline diamonds, embedded therein. According to some implementations of the present invention, the relatively large abrasive cutting media can be dispersed in an unorganized arrangement throughout at least a portion of the crown. Additionally, one or more implementations can include a second plurality of relatively small abrasive cutting media. Implementations of the present invention also include drilling systems including impregnated drill bits having a plurality of relatively large abrasive cutting media embedded therein, methods of using such impregnated drill bits, and methods of forming such impregnated drill bits.Type: ApplicationFiled: September 17, 2010Publication date: March 24, 2011Applicant: LONGYEAR TM, INC.Inventors: Christian M. Lambert, Michael D. Rupp
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Patent number: 7909121Abstract: Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device.Type: GrantFiled: January 9, 2008Date of Patent: March 22, 2011Assignee: Smith International, Inc.Inventors: Georgiy Voronin, Nephi M. Mourik, J. Daniel Belnap
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Publication number: 20110061945Abstract: An apparatus for downhole operation. The apparatus comprising a support body having a surface located in a borehole and a coating on an at least a portion of the surface of the support body. The coating is an inert material selected for reducing friction and corrosion.Type: ApplicationFiled: February 6, 2009Publication date: March 17, 2011Inventors: Richard Saenger, Jean Desroches, Natalia Quisel
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Publication number: 20110042150Abstract: In one aspect of the invention a rotary mine roof drilling apparatus has an arm attached to and intermediate a drill bit and a platform. The apparatus also has a thrusting mechanism adapted to push the drill bit into a mine roof. The drill bit has a bit body intermediate a shank and a working surface. The working surface has a cutting element with a carbide substrate bonded to a diamond working end with a pointed geometry; and the diamond working end has a 0.050-0.200 inch apex radius.Type: ApplicationFiled: October 29, 2010Publication date: February 24, 2011Inventors: DAVID R. HALL, RONALD CROCKETT
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Publication number: 20110036640Abstract: A drill bit includes a crown defining a central axis. The crown includes at least one segment. The segment includes a planar portion and a plurality of surface features continuous with and extending away from the planar portion. The surface features are discontinuous within the segment with respect to a first arced path defined at a first radial distance from the central axis.Type: ApplicationFiled: August 16, 2010Publication date: February 17, 2011Applicant: LONGYEAR TM, INC.Inventors: Christian M. Lambert, Michael D. Rupp
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Publication number: 20110036643Abstract: Thermally stable polycrystalline constructions comprise a diamond body joined with a substrate, and may have a nonplanar interface. The construction may include an interlayer interposed between the diamond body and substrate. The diamond body preferably has a thickness greater than about 1.5 mm, and comprises a matrix phase of bonded together diamond crystals and interstitial regions disposed therebetween that are substantially free of a catalyst material used to sinter the diamond body. A replacement material is disposed within the interstitial regions. A population of the interstitial regions may include non-solvent catalyst material and/or an infiltrant aid disposed therein. The diamond body comprises two regions; namely, a first region comprising diamond grains that may be sized smaller than diamond grains in a second region, and/or the first region may comprise a diamond volume that is greater than that in the second region.Type: ApplicationFiled: August 6, 2010Publication date: February 17, 2011Inventors: J. Daniel Belnap, Yi Fang, Guojiang Fan, Peter T. Cariveau, Georgiy Voronin, Yuelin Shen, Youhe Zhang, Feng Yu, Yahua Bao, Ronald K. Eyre
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Publication number: 20110031030Abstract: A cutter for a drill bit used for drilling wells in a geological formation includes an ultra hard working surface and a chamfer along an edge of the working surface, wherein the chamfer has a varied geometry along the edge. The average geometry of the chamfer varies with cutting depth. A depression in the shaped working surface is oriented with the varied chamfer and facilitates forming the varied chamfer. A non-planar interface has depressions oriented with depressions in the shaped working surface to provide support to loads on the working surface of the cutter when used.Type: ApplicationFiled: May 28, 2010Publication date: February 10, 2011Inventors: YUELIN SHEN, Youhe Zhang, Steffen S. Kristiansen
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Publication number: 20110031037Abstract: A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 80% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 50% by weight of the plurality of metallic phases is disclosed.Type: ApplicationFiled: August 6, 2010Publication date: February 10, 2011Applicant: SMITH INTERNATIONAL, INC.Inventors: Federico Bellin, Yi Fang, Michael Stewart, Nephi A. Mourik, Peter Cariveau
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Publication number: 20110024194Abstract: A drilling assembly for simultaneous hole enlargement operations comprises a drill bit, an adjustable diameter reamer, and a hole opener. The reamer is coupled with, and positioned uphole from the drill bit. The reamer is adjustable between a first diameter and a second diameter that is larger than the first diameter. The hole opener is coupled with, and positioned uphole from the reamer.Type: ApplicationFiled: March 27, 2009Publication date: February 3, 2011Inventors: Luk Servaes, Stefano Mancini