Abstract: A polycrystalline diamond cutting element for earth boring drill bits presents at least three regions of different abrasion resistance to the earthen formation when in operation. The cutting element has an end working surface and the regions, which are substantially free of catalyzing material, form a series of at least three layers. In operation, these layers wear at different rates causing a series of protruding lips. The end working surface may be substantially planar or frusto-conical in form.

Abstract: A rotary drag bit exhibiting enhanced cutting efficiency and extended life is provided. The rotary drag bit comprises a bit body having a face surface, and a plurality of cutters coupled to the face surface of the bit body. The plurality of cutters comprises at least one pilot cutter and a rotationally trailing larger, primary cutter at substantially the same radius and, optionally of slightly less exposure. The pilot cutter is sized and positioned to pre-fracture the formation and perform an initial cut, while the primary cutter removes weakened, remaining formation material along the same rotational path. A method to pre-fracture subterranean formations using a rotary drag bit having a pilot cutter configuration is also provided.

Abstract: In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to an interfacial surface of the base. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.

Abstract: In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to an interfacial surface of the base. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.

Abstract: Cutting elements of this invention include an ultra hard body joined with a metallic substrate. The body includes an uppermost layer comprising a plurality of bonded ultra hard crystals and interstitial regions, and that defines a body working surface. The uppermost layer includes an outer region that is relatively more thermally stable than a remaining portion of the uppermost layer. The body further includes an intermediate layer joined to the uppermost layer, comprising a plurality of bonded ultra hard crystals, and having a wear resistance less than that of the uppermost layer remaining region. The body may additionally include a lowermost PCD layer that is interposed between and attached to the intermediate layer and the substrate.

Abstract: A sintered body for cutting tools that includes hard particle phase comprising a plurality of hard particles, wherein at least a portion of the hard phase particles comprise a coating deposited by atomic layer deposition disposed thereon; and a binder phase is disclosed. The hard particles that may be included in the sintered bodies may include tungsten carbide, diamond, and boron nitride particles.

Abstract: In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to an interfacial surface of the base. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.

Abstract: 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.

Abstract: Superabrasive elements, methods of fabricating such elements, and applications utilizing such elements. In one embodiment, a superabrasive element includes a mass of polycrystalline diamond including ultra-dispersed diamond grain structures present in an amount greater than zero weight percent and less than about 75 weight percent of the mass of polycrystalline diamond. Various structures and apparatuses that utilize the superabrasive elements, such as polycrystalline diamond compacts (PDCs) and drill bits are disclosed. Methods of manufacture are also disclosed.

Abstract: A polycrystalline superabrasive composite tool can be produced using high pressure high temperature processes allowing for increased thermal resistance, wear resistance and toughness of abrasive tools, and additionally allowing for increased effective thickness of abrasive tools. A polycrystalline superabrasive compact can include a support substrate and a superabrasive polycrystalline layer having a diffusion bridge embedded therein that includes a carbide former. Additionally, a working layer can be attached adjacent to the superabrasive polycrystalline layer and opposite the support substrate to form a drill bit sandwich segment. The diffusion bridge matrix of the present invention allows for a new welding phase at each interface between the superabrasive polycrystalline layer and support substrate and between the polycrystalline layer and the metal working layer, thus eliminating delamination failure at the interfaces.

Abstract: Improved cutter design as well as an improved design for downhole cutters, such as mandrel cutters and rotary cutter mills. A cutter is described with a rectangular, rounded “lozenge” shape. The cutter presents a cross-sectional cutting area having a pair of curvilinear end sections and an elongated central section. Preferably, the overall length of the cutter is 1.5 times the width. The cutter may also include a raised cutter edge for chip breaking during cutting.

Abstract: An earth-boring bit has a mechanical face seal assembly with PCD faces. The bit has a bearing shaft with a cone rotatably mounted on the bearing shaft. The seal locates between the bearing shaft and the cone for sealing lubricant therein. The seal includes at least one rigid seal ring having a cemented carbide body and an annular PCD face located on it. The mating face may also be of a PCD material. The cemented carbide body contains a binder that migrates into the PCD face while the PCD face is being formed. A binder-free region is leached on the surface of the PCD face.

Abstract: A modular fixed cutter earth-boring bit body includes a blade support piece and at least one blade piece fastened to the blade support piece. A modular fixed cutter earth-boring bit and methods of making modular fixed cutter earth-boring bit bodies and bits also are disclosed.

Abstract: A rotary drag bit including an inverted cone geometry proximate the longitudinal axis thereof is disclosed. The inverted cone region may include a central region, the central region including a plurality of cutting structures affixed thereto and arranged along at least one spiral path. The at least one spiral path may encircle its center of revolution at least once within the inverted cone region. A cone region displacement and a method for manufacturing a rotary drag bit therewith are disclosed. At least one groove may be formed within the cone region displacement along a respective at least one spiral path, the at least one spiral path encircling its center of revolution at least once. A plurality of cutting structures may be placed within the at least one groove and the cone region displacement may be placed within a mold for filling with an infiltratable powder and infiltrating with a hardenable infiltrant.

Abstract: A down hole cutting tool includes a cutting element support structure. The cutting element support structure has at least one cavity formed therein. A cutting element is disposed in the cavity. Braze alloy is also disposed in the cavity between the cutting element and the cutting element support structure. The braze alloy comprises between about 0.5% and about 10% by weight of at least one selected from the group of gallium (Ga), indium (In), thallium (Tl). Methods for building a down hole tool using the braze alloy are also disclosed.

Abstract: A cutting element for a rotary drill bit that has a superabrasive member joined to a substrate at a three-dimensional interface is disclosed. The interface of the cutting element preferably incorporates a first ring pattern comprising a plurality of circumferentially arranged raised sections which are separated by a plurality of radially extending grooves. Also, the interface configuration may include at least a second ring pattern comprising a plurality of circumferentially arranged raised sections which are separated by a plurality of radially extending grooves. Radially adjacent ring patterns may substantially circumferentially overlap with one another. An interface of a cutting element including at least one ring pattern having an odd number of sections is also disclosed. Further, rotary drill bits including at least one such cutting element are disclosed.

Abstract: Composite constructions comprise a plurality of granules that are arranged together in a randomly-oriented manner. The granules each comprise an ordered arrangement of a first material phase and a second material phase, wherein the first and second material phases are each continuous, and each occupy different and distinct regions of the granule. At least a portion of the first and second material phases of each granule are in contact with one another. The first material phase comprises a material selected from the group consisting of cermet materials, polycrystalline diamond, polycrystalline cubic boron nitride, and mixtures thereof. The second material phase comprises a material that is relatively softer, e.g., more ductile, than the first material phase.

Abstract: An earth-boring bit has a seal assembly with a seal face having a DLC coating. The seal assembly locates between a bearing pin and a cone of the bit. The seal assembly has at least one rigid ring that rotates against a mating surface. The DLC coating is diamond-like carbon that may be coated by different processes onto either the ring, the mating surface, or both.

Abstract: An insert for a drill bit which includes a diamond impregnated body, and a shearing portion disposed on said body is shown. In addition, a method for forming a drill bit that includes (a) forming a shearing portion on a diamond-impregnated insert body to form a cutting insert, (b) forming a bit body having a plurality of sockets sized to receive a plurality of the cutting inserts, and (c) mounting the plurality of cutting inserts in the bit body and affixing the plurality of cutting inserts to the bit body; wherein steps (a)–(c) are carried out such that a total exposure of the diamond-impregnated insert to temperatures above 1000° F. is greater than a total exposure of the shearing portion to temperatures above 1000° F.

Abstract: The side tracking system includes a window mill having a full diameter cutting surface and a reduced diameter tapered cutting surface and a whipstock having a ramp engaging the reduced diameter cutting surface. The materials of the whipstock have a first cutablity and the materials of the casing have a second cutability. The reduced diameter cutting surface contacts the whipstock ramp at a first contact area and the full diameter cutting surface contacts the wall of the casing at a second contact area. As weight is applied to the mill, there is a first contact stress at the first contact area and a second contact stress at the second contact area. A cutability ratio is the first cutability divided by the second cutability and a contact stress ratio is the first contact stress divided by the second contact stress. The mill cuts the casing rather than the whipstock by maintaining the product of the cutability ratio and the contact stress ratio less than one.

Abstract: A superabrasive cutting element including a diamond or other superabrasive material table having a peripheral cutting edge defined by at least two adjacent chamfers having an arcuate surface substantially tangent to each of the at least two chamfers interposed therebetween. Methods of producing such superabrasive cutting elements and drill bits equipped with such superabrasive cutting elements are also disclosed.

Abstract: A superabrasive cutting element for use with a drill bit for drilling subterranean formations and having a superabrasive table, or cutting face, in which a conglomerate of superabrasive particles is dispersed and bonded, or sintered, and in which at least one exposed cutting region of the superabrasive table develops a rough, asperital surface for improving the cutting efficiency of the drill bit, particularly in but not limited to relatively hard, relatively nonabrasive formations. The superabrasive table may include superabrasive particles of substantially differing size, or quality or a combination of differing size and quality. A rotary drill bit including cutting elements embodying the present invention is also disclosed.

Abstract: Cutting elements having coarse grain substrates and ultra hard material layers are provided. The substrates are formed from coarse grain size particles of tungsten carbide. A method of forming such cutting elements and a drag bit incorporating such cutting elements are also provided.

Abstract: A drill bit with rolling cone cutters for drilling a borehole in an earthen formation. The bit has a bit body, at least one leg depending from the bit body, a rolling cone rotatably mounted on the leg, the cone having a plurality of adjacent rows of cutters thereupon, at least one hole formed within the cone, the hole having a cylindrical wall, and a cutting element partially disposed within the hole, the cutting element having a cylindrical base which fits within the cylindrical wall of said hole, a shoulder which extends outward from the base of the cutting element, and an exposed cutting end extending from the shoulder, the cutting end being substantially symmetrical about a longitudinal axis of the cutting element.

Abstract: A drilling tool having an expandable bladder and a method for using the same are provided. The drilling tool includes a tool body having an interior cavity, a plurality of extendable arms coupled with the tool body, and an expandable bladder at least partially disposed within the interior cavity of the tool body. The expandable is operable to deploy the extendable arms from a retracted position relative to the exterior surface of the tool body to an extended position relative to the exterior surface of the tool body.

Abstract: A superabrasive cutting element including a diamond or other superabrasive material table having a peripheral cutting edge defined by at least two adjacent chamfers having an arcuate surface substantially tangent to each of the at least two chamfers interposed therebetween. Methods of producing such superabrasive cutting elements and drill bits equipped with such superabrasive cutting elements are also disclosed.

Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: A cutting element and bit incorporating the cutting element is provided, as well as a method for forming the same. The cutting element includes an ultra hard material layer including chromium and carbon and exhibiting increased abrasion resistance without sacrificing toughness. The method for manufacturing the cutting element includes providing a layer of ultra hard material particles and chromium carbide over the substrate, and then sintering to form the cutting element.

Abstract: A cutting element for a drag-type drill bit comprises a cutter body having a generally cylindrical base section adapted for snug-fitting engagement in a socket of a drill bit body. The cutter body is secured to the bit body by brazing or other conventional attachment techniques. The cutter body further has a generally cylindrical cutting section integral with the base section. The cutting section has at least one inclined surface extending from a top surface of the cutting section partially along the length of the generally cylindrical cutting section. The cutter body may comprise a sintered tungsten carbide and the top surface may comprise a layer of super hard material.

Abstract: A non-uniform interface is formed between a polycrystalline ultra hard material layer and a cemented tungsten carbide substrate, or a polycrystalline ultra hard material layer and a transition layer, or a transition layer and a substrate of a cutting element. A first sheet made from an intermediate material is formed and embossed on one face forming a non-uniform pattern raised in relief on the face. The embossed sheet is placed on a face of a presintered substrate. An ultra hard material sheet is formed and embossed, forming a non-uniform face complementary to the non-uniform face on the sheet of intermediate material. The ultra hard material sheet is placed over the intermediate material sheet so that the complementary faces are adjacent to each other. The assembly of substrate and sheets is sintered in a HPHT process.

Abstract: A drill bit employing a plurality of discrete, post-like, abrasive, particulate-impregnated cutting structures extending upwardly from abrasive, particulate-impregnated blades defining a plurality of fluid passages therebetween on the bit face. Additional cutting elements may be placed in the cone of the bit surrounding the centerline thereof. The blades may extend radially in a linear fashion, or be curved and spiral outwardly to the gage to provide increased blade length and enhanced cutting structure redundancy. Additionally, discrete protrusions may extend outwardly from at least some of the plurality of cutting structures. The discrete protrusions may be formed of a thermally stable diamond product and may exhibit a generally triangular cross-sectional geometry relative to the direction of intended bit rotation.

Abstract: In one embodiment, composite constructions of the invention are in the form of a plurality of coated fibers bundled together to produce a fibrous composite construction in the form of a rod. Each fiber has a core formed from a hard phase material, that is surrounded by a shell formed from a binder phase material. In another embodiment of the invention, monolithic sheets of the hard phase material and the binder phase material are stacked and arranged to produce a swirled composite in the form of a rod. In still another embodiment of the invention, sheets formed from coated fibers are arranged to produce a swirled composite. Inserts for use in such drilling applications as roller cone rock bits and percussion hammer bits, and shear cutters for use in such drilling applications as drag bits, that are manufactured using conventional methods from these composite constructions exhibit increased fracture toughness due to the continuous binder phase around the hard phase of the composites.

Abstract: A superabrasive cutting element for use with a drill bit for drilling subterranean formations and having a superabrasive table, or cutting face, in which a conglomerate of superabrasive particles are dispersed and bonded, or sintered, and in which at least one exposed cutting region of the superabrasive table develops a rough, asperital surface for improving the cutting efficiency of the drill bit, particularly in but not limited to relatively hard, relatively nonabrasive formations. The superabrasive table may include superabasive particles of substantially differing size, quality or a combination of differing size and quality. A rotary drill bit including cutting elements embodying the present invention is also disclosed.

Abstract: A method for forming a drill bit body is disclosed which comprises infiltrating powdered tungsten carbide with a binder alloy in a mold. The mold has therein at least one displacement adapted to form a mounting pad for a cutting element. The displacement comprises a substantially cylindrical body having a diameter selected to substantially conform to a radius of the cutting element and a projection adapted to form a relief groove under a position of a diamond table in the cutting element when the cutting element is mounted on the pad. The width of the relief groove is selected so that the relief groove extends back from an outer surface of the bit body at least about 40 percent of that portion of a thickness of the diamond table which does not extend past the outer surface.

Abstract: A variety of large diameter PDC cutters for use in drill bits are disclosed. Specifically, various PDC cutters having a diameter between 19.0 mm and 25.0 mm are disclosed. The various PDC cutters disclosed include an elliptical PDC cutter, wherein a major diameter of the elliptical cutter is selected from a range of 19.0 mm to 25.0 mm, a circular PDC cutter, wherein a diameter of the circular cutter falls between 19.0 mm and 25.0 mm, and a non-planar substrate cutter, wherein a diameter of the non-planar cutter falls between 19.0 mm and 25.0 mm. Additionally, the thickness of the diamond table is increased as compared to prior art PDC cutters. The increase in diamond table thickness results in improved durability and performance.

Abstract: An insert for a drill bit which includes a diamond impregnated body, and a shearing portion disposed on said body is shown. In addition, a method for forming a drill bit that includes (a) forming a shearing portion on a diamond-impregnated insert body to form a cutting insert, (b) forming a bit body having a plurality of sockets sized to receive a plurality of the cutting inserts, and (c) mounting the plurality of cutting inserts in the bit body and affixing the plurality of cutting inserts to the bit body; wherein steps (a)-(c) are carried out such that a total exposure of the diamond-impregnated insert to temperatures above 1000° F. is greater than a total exposure of the shearing portion to temperatures above 1000° F.

Abstract: The present invention provides a bit with cutting structures or inserts that include diamond particles, in which the diamond-impregnated inserts are surrounded by substantially diamond-free support members. The diamond-impregnated inserts are manufactured separately from the bit body. Once formed, the diamond-impregnated inserts are affixed to the substantially diamond-free support members on bit body by brazing or other means of attachment. The total thermal exposure of the diamond particles during manufacture in accordance with the present invention is significantly lower than the total manufacturing-related thermal exposure in previously known diamond-impregnated cutting structures. Furthermore, the substantially diamond-free support members allow the bit to continue cutting through a formation without an increased contact area, as experienced by bits with diamond-impregnated ribs. Thus, the operating life of the cutting structures, and therefore the life of the bit itself, is increased.

Abstract: Fracture and wear resistant cutting elements are provided. Examples include a cutting element formed of a wear resistant material having a binder composition and a coarse grain size such that the portion of the cutting element formed of the wear resistant material has a fracture toughness of at least about 18 ksi(in)0.5 and a wear number of at least about 1.8. In a particular example, the wear resistant material has a fracture toughness of at least about 20 ksi(in)0.5. A down hole cutting tool incorporating such cutting elements is also provided.

Abstract: A rotary-cutter Earth-penetrating bit in which a given track of bottom hole is attacked by inserts of two different types, e.g. chisel-shaped and pointed, wider and narrower, higher and shorter, and/or of different materials. The different types of inserts can both be included within a single row of a cone.

Abstract: The present invention provides a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material.

Abstract: A laminated cutting element for use on a rotary-type earth-boring drill bit for drilling subterranean formations preferably including at least one first segment formed of a hard, continuous-phase material impregnated with a particulate superabrasive material laminated to and including at least one second segment formed of a continuous-phase material having essentially no particulate superabrasive material impregnated therein. Alternatively, the at least one second segment may have superabrasive and/or abrasive material impregnated therein which is less abrasive than the superabrasive material impregnated in the at least one first segment. Preferably, the continuous-phase material in which the at least one first segment and the at least one second segment are made is a metal matrix material. A further alternative of the present invention includes a single segment formed of a continuous-phase material in which a particulate superabrasive material is impregnated.

Abstract: The side tracking system includes a window mill having a full diameter cutting surface and a reduced diameter tapered cutting surface and a whipstock having a ramp engaging the reduced diameter cutting surface. The materials of the whipstock have a first cutablity and the materials of the casing have a second cutability. The reduced diameter cutting surface contacts the whipstock ramp at a first contact area and the full diameter cutting surface contacts the wall of the casing at a second contact area. As weight is applied to the mill, there is a first contact stress at the first contact area and a second contact stress at the second contact area. A cutability ratio is the first cutability divided by the second cutability and a contact stress ratio is the first contact stress divided by the second contact stress. The mill cuts the casing rather than the whipstock by maintaining the product of the cutability ratio and the contact stress ratio less than one.

Abstract: An earth-boring bit comprises a bit body bit body in which are mounted a plurality of cutting structures inserts, wherein at least a portion of the cutting structures comprise diamond-impregnated inserts having a total thermal exposure of less than 25 minutes above 1500° F. The diamonds can be natural or synthetic diamond. The bit body itself may be diamond-impregnated, in which case it is preferred that the diamonds in the inserts make up at least 40% of the total diamond in the bit.

Abstract: A rotatable point-attack bit retained for rotation in a block bore, and used for impacting, fragmenting and removing material from a mine wall. An improved elongated tool body having at the front end a diamond-coated tungsten carbide wear tip that is rotationally symmetric about its longitudinal axis and contiguous with a second section steel shank at the rear end. The two distinct parts are joined by a high impact resistant braze at ratios that prevent tool breakage.

Abstract: A new composition for forming a matrix body which includes spherical sintered tungsten carbide and an infiltration binder including one or more metals or alloys is disclosed. In some embodiments, the composition may include a Group VIIIB metal selected from one of Ni, Co, Fe, and alloys thereof. Moreover, the composition may also include cast tungsten carbide. In addition, the composition may also include carburized tungsten carbide.

Abstract: PCD and PCBN composite constructions have an ordered structure of two or more material phases that are combined together in a packed or interwoven configuration. One of the material phases is formed from materials selected from the group consisting of: polycrystalline diamond, polycrystalline cubic boron nitride; carbides, borides, nitrides, and carbonitrides from groups IVA, VA, and VIA of the Periodic Table; and mixtures thereof. Another material phase is preferably formed from a material having a degree of ductility that is higher than that of the first material phase. Example second material phase materials include those selected from the group consisting of cermets, Co, Ni, Fe, W, Mo, Cu, Al, Nb, Ti, Ta, and mixtures thereof.

Abstract: A polycrystalline diamond cutter and method of manufacturing a polycrystalline diamond cutter is disclosed. The method of manufacture comprising assembling a first substrate component, a second substrate component and diamond crystals into a desired configuration. The assembly is subjected to high temperature and high pressure conditions to cause the diamond crystals to bond to one another and to the first and second substrate components. The method forms a cutter having a single body of polycrystalline diamond bonded to the substrate components.

Abstract: A polycrystalline diamond cutter and method of manufacturing a polycrystalline diamond cutter is disclosed. The method of manufacture comprising assembling a first substrate component, a second notched substrate component and diamond crystals into a desired configuration. The assembly is subjected to high temperature and high pressure conditions to cause the diamond crystals to bond to one another and to the first and second substrate components. The method forms a cutter having a single body of polycrystalline diamond bonded to the substrate components.

Abstract: Disclosed is an abrasive compact layer wherein the compact layer contains >30% by volume large single crystal diamonds, and wherein said diamond crystals are characterized as having a well defined cubo-octahedral diamond shapes (aspect ratios>0.87), and high toughness index crystals (TI>50).

Abstract: An insert for a drill bit is disclosed which includes an exposed surface having a contact portion adapted to periodically contact earthen formation. The contact portion includes a polycrystalline diamond material having a hardness in the range of about 2000 HV to about 3000 HV. In some embodiments, the polycrystalline diamond material includes a composite having a first phase material including polycrystalline diamond and a second phase material selected from the group of oxide particulates metal carbides, and metallic particulates, nitrides, and mixtures of thereof.