Metal Or Metal Oxide Patents (Class 51/309)
  • Patent number: 8858662
    Abstract: Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprise a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material.
    Type: Grant
    Filed: March 4, 2011
    Date of Patent: October 14, 2014
    Assignee: Baker Hughes Incorporated
    Inventors: Anthony A. DiGiovanni, Nicholas J. Lyons, Derek L. Nelms, Danny E. Scott
  • Patent number: 8858665
    Abstract: A method for making a PDC cutting element for use in rock drilling containing sub-micron size diamond particles within the diamond body. Metals that do not readily dissolve carbon are employed to limit the dissolution and re-precipitation of fine diamond during the sintering of the diamond to the substrate.
    Type: Grant
    Filed: September 23, 2011
    Date of Patent: October 14, 2014
    Inventor: Robert Frushour
  • Publication number: 20140298728
    Abstract: A carbide composite for a downhole tool may be formed by depositing a first layer on a substrate, and a second layer at least partially adjacent to the first layer. The first and second layers may each include carbides, metal binders, organic binders, or a combination thereof. The first and second carbide layers may have a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another.
    Type: Application
    Filed: April 3, 2014
    Publication date: October 9, 2014
    Applicant: Smith International, Inc.
    Inventor: Madapusi K. Keshavan
  • Publication number: 20140298729
    Abstract: An abrasive article configured to grind a workpiece having a fracture toughness of at least about 5.5 MPa·m0.5 may include a body comprising abrasive particles contained within a bond material comprising a metal, wherein the body comprises a ratio of VAG/VBM of at least about 1.3, wherein VAG is a volume percent of abrasive particles within a total volume of the body and VBM is a volume percent of bond material within the total volume of the body, and wherein the abrasive particles have an average particle size of at least about 1 micron and not greater than about 20 microns.
    Type: Application
    Filed: March 31, 2014
    Publication date: October 9, 2014
    Applicants: SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.
    Inventors: Srinivasan RAMANATH, William H. LANE, Rachana UPADHYAY, Michael P. HITCHINER
  • Publication number: 20140298730
    Abstract: A method for making a cutter element, the method including combining a plurality of super-hard grains, a powder source of bond material for bonding the super-hard grains in the cutter element, and a fluid medium to form a paste, in which the content of the super-hard grains is sufficient for the content of the super-hard grains in the cutter element to be at least about 3 volume percent. The paste is introduced into an extrusion device and extruded to form a green body, which is sintered to provide the cutter element. In some examples, the cutter element may be for a saw blade or drill bit.
    Type: Application
    Filed: November 8, 2012
    Publication date: October 9, 2014
    Inventor: David Patrick Egan
  • Publication number: 20140299387
    Abstract: A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.
    Type: Application
    Filed: June 18, 2014
    Publication date: October 9, 2014
    Inventors: Anthony A. DiGiovanni, Nicholas J. Lyons, Matthew S. Hale, Konstantin E. Morozov, John H. Liversage, Danny E. Scott, L. Allen Sinor
  • Patent number: 8852546
    Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.
    Type: Grant
    Filed: November 13, 2012
    Date of Patent: October 7, 2014
    Assignee: Smith International, Inc.
    Inventors: Madapusi K. Keshavan, Youhe Zhang, Yuelin Shen, Anthony Griffo, Michael Janssen
  • Publication number: 20140290145
    Abstract: A coating on mono- or poly-crystalline diamond or diamond-containing material includes a first adhesive layer formed directly on the diamond or diamond-containing material, the first layer including tungsten and tungsten carbide alloyed with fluorine in an amount of 0.001 to 0.12 wt % calculated on the total weight of the first layer. The coating further includes a second protective layer formed on the first layer, the second layer including at least tungsten alloyed with fluorine in an amount of 0.001 to 0.12 wt % calculated on the total weight of the second layer. The adhesive layer provides excellent bond strength to diamond, while the protective layer provides good protection against oxidation and molten metals used for attaching the coated diamonds to tools.
    Type: Application
    Filed: April 17, 2013
    Publication date: October 2, 2014
    Applicant: Hardide plc
    Inventors: Yuri ZHUK, Yuri LAKHOTKIN
  • Publication number: 20140290149
    Abstract: A vitrified superabrasive product includes a superabrasive component and a vitrified bond component in which the superabrasive component is dispersed. The vitrified bond includes an oxide of a lanthanoid. Additionally, the vitrified bond component defines pores that can be essentially all less than 800 ?m in diameter. Seventy percent of the pores are in a range of between about 40 ?m and about 500 ?m and have an average aspect ratio less than about 2. The porosity is in a range of between about 50% and about 90% of the total volume of the superabrasive product.
    Type: Application
    Filed: June 12, 2014
    Publication date: October 2, 2014
    Inventors: Ramanujam VEDANTHAM, Rachana UPADHYAY, Gilles QUEREL
  • Publication number: 20140291037
    Abstract: Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material.
    Type: Application
    Filed: June 11, 2014
    Publication date: October 2, 2014
    Inventors: Peter Cariveau, Georgiy Voronin, J. Daniel Belnap
  • Patent number: 8845773
    Abstract: Abrasive particles which are shaped abrasive particles each with an opening are described. The shaped abrasive particles are formed from alpha alumina and have a first face and a second face separated by a thickness t. The opening in each of the shaped abrasive particles can improve grinding performance by reducing the size of a resulting wear flat, can provide a reservoir for grinding aid, and can improve adhesion to a backing in a coated abrasive article.
    Type: Grant
    Filed: February 16, 2012
    Date of Patent: September 30, 2014
    Assignee: 3M Innovative Properties Company
    Inventors: Dwight D. Erickson, Scott R. Culler, Negus B. Adefris, John T. Boden, John D. Haas
  • Patent number: 8846217
    Abstract: Provided is a surface-coated tool, such as a cutting tool, in which a surface of a substrate 2 is coated with a coating layer 6. The coating layer 6 comprises a lower layer 8 and an upper layer 9. The lower layer 8 and the upper layer 9 are both composed of columnar particles 10 extending vertically with respect to the surface of the substrate 2. The mean crystal width of the columnar particles 10b constituting the upper layer 9 is smaller than the mean crystal width of the columnar particles constituting the lower layer. Dispersed particles containing tungsten exist in both the lower layer and the upper layer. The distribution density of the dispersed particles existing in the upper layer is smaller than the distribution density of the dispersed particles existing in the lower layer. The surface-coated tool includes the coating layer to improve wear resistance and fracture resistance.
    Type: Grant
    Filed: October 19, 2009
    Date of Patent: September 30, 2014
    Assignee: Kyocera Corporation
    Inventor: Masahiro Waki
  • Publication number: 20140284116
    Abstract: An abrasive wear-resistant material includes a matrix and sintered and cast tungsten carbide pellets. A device for use in drilling subterranean formations includes a first structure secured to a second structure with bonding material. An abrasive wear-resistant material covers the bonding material. The first structure may include a drill bit body and the second structure may include a cutting element. A method for applying an abrasive wear-resistant material to a drill bit includes providing a bit, mixing sintered and cast tungsten carbide pellets in a matrix material to provide a pre-application material, heating the pre-application material to melt the matrix material, applying the pre-application material to the bit, and solidifying the material. A method for securing a cutting element to a bit body includes providing an abrasive wear-resistant material to a surface of a drill bit that covers a brazing alloy disposed between the cutting element and the bit body.
    Type: Application
    Filed: June 4, 2014
    Publication date: September 25, 2014
    Inventor: James L. Overstreet
  • Publication number: 20140283457
    Abstract: A method for forming a diamond body includes placing a thermally stable polycrystalline diamond body and a first substrate into an enclosure, the thermally stable polycrystalline diamond body comprising a plurality of bonded diamond crystals and a plurality of interstitial regions between the bonded diamond crystals, the interstitial regions being substantially free of a catalyst material, heating the thermally stable polycrystalline diamond body and the first substrate to remove residual materials from the thermally stable polycrystalline diamond body, subjecting the thermally stable polycrystalline diamond body and the first substrate to a vacuum for evacuating such residual material, and pressing under high temperature the enclosure, the thermally stable polycrystalline diamond body and the first substrate while maintaining a vacuum in the enclosure to bond the thermally stable polycrystalline diamond body to the substrate.
    Type: Application
    Filed: June 5, 2014
    Publication date: September 25, 2014
    Inventors: Peter T. Cariveau, Ronald K. Eyre, Yi Fang
  • Publication number: 20140287658
    Abstract: The present invention relates to a bonded abrasive article comprising specific shaped abrasive particles and a bonding medium comprising a vitreous bond. The present invention also relates to the use of an article according to the present invention in grinding applications, in particular in high performance grinding applications and to the use of an article according to the present invention for abrading a workpiece material particularly a workpiece material selected from steels, non-ferrous metals, and alloys. In addition, the present invention relates to a method for abrading a workpiece, the method comprising frictionally contacting at least a portion of an abrasive article according to the invention with a surface of a workpiece; and moving at least one of the workpiece or the abrasive article to abrade at least a portion of the surface of the workpiece.
    Type: Application
    Filed: September 6, 2012
    Publication date: September 25, 2014
    Inventors: Walter Flaschberger, Andrea Veronika Kirschner
  • Patent number: 8840696
    Abstract: A method of forming an abrasive article includes depositing a mixture into an opening of a substrate, contacting an exposed surface of the mixture in the opening to a texturing form to form a textured preform, and removing the mixture from the opening and forming an abrasive particle having a textured surface.
    Type: Grant
    Filed: January 10, 2013
    Date of Patent: September 23, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Michael D. Kavanaugh, Doruk O. Yener, Jennifer H. Czerepinski
  • Patent number: 8840695
    Abstract: A method of forming a mixture including a ceramic material into a sheet, sectioning at least a portion of the sheet using a mechanical object and forming at least one shaped abrasive particle from the sheet, such that the at least one shaped abrasive particle can have a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
    Type: Grant
    Filed: December 31, 2012
    Date of Patent: September 23, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Paul P. Braun, Doruk O. Yener, Jennifer H. Czerepinski, Ralph Bauer, Krishnamoorthy Subramanian, Robin Bright, Anuj Seth, Gregory G. Lafond
  • Publication number: 20140259962
    Abstract: A method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond with a first quantity of magnesium carbonate to form a first layer for forming a working surface, and combining a second quantity of magnesium carbonate to form a second layer adjacent to the first layer, forming an assembly. The method includes placing a quantity of silicon or aluminum in or adjacent to at least a portion of the assembly and sintering the assembly including the silicon or aluminum at high pressure and high temperature, causing the silicon or aluminum to infiltrate at least one layer of the assembly.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Applicant: SMITH INTERNATIONAL, INC.
    Inventor: YAHUA BAO
  • Publication number: 20140262542
    Abstract: Downhole tools include a component, at least a portion of which includes ternary boride cermet. A method of making a downhole tool including a ternary boride cermet includes obtaining a ternary boride cermet material and heating the ternary boride cermet material and a binder to form the downhole tool.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Applicant: SMITH INTERNATIONAL, INC.
    Inventors: MINGDONG CAI, GREGORY T. LOCKWOOD, XIN DENG, SIKE XIA, ANTHONY GRIFFO
  • Publication number: 20140265530
    Abstract: A tip for a pick tool, comprising a polycrystalline diamond (PCD) structure joined to a substrate body. The PCD structure has a strike surface including an apex opposite a boundary with the substrate body. At least an outer volume of the PCD as structure contains filler material between diamond grains, the content of the filler material being more than 5 weight percent of the PCD material in the outer volume. The outer volume is proximate at least an area of the strike surface including the apex, and the thickness of the PCD structure between the apex and the boundary with the substrate body is at least 2.5 mm.
    Type: Application
    Filed: October 26, 2012
    Publication date: September 18, 2014
    Inventors: Robert Fries, Cornelis Roelof Jonker
  • Publication number: 20140273772
    Abstract: The present invention relates to a chemical mechanical polishing conditioner and manufacturing methods thereof. The chemical mechanical polishing conditioner comprises: a planar substrate having a leveling surface; a bonding layer disposed on the surface of the planar substrate; and a plurality of abrasive particles embedded in the surface of the bonding layer and fixed to the surface of the planar substrate by the binding layer; wherein the planar substrate is formed by a deformation compensation for the non-planar substrate during curing the binding layer, and thus the tips of the abrasive particles have a leveled height. Therefore, the present invention can effectively improve the problem of thermal deformation of the substrate of the chemical mechanical polishing conditioner during heating and curing process, and thereby enhancing the surface flatness of chemical mechanical polishing conditioner.
    Type: Application
    Filed: March 5, 2014
    Publication date: September 18, 2014
    Applicant: Kinik Company
    Inventors: Jui-Lin CHOU, Chia Chun WANG, Chia-Feng CHIU, Chung-Yi CHENG
  • Publication number: 20140259959
    Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion of a diffusion species (e.g., a metalloid) introduced from the back side of a cemented carbide further away from the diamond grit or from the flank side of the cemented carbide, as opposed to the side of the cemented carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a diamond grit, a cemented carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the binder of cemented carbide diffuses across the diamond grit, and (2) the diffusion species diffuses through the cemented carbide, and then through the diamond grit, thus providing a protective coating to the diamond grains of the PDC.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Applicant: DIAMOND INNOVATIONS, INC.
    Inventors: Gary Martin Flood, Joel Vaughn
  • Publication number: 20140262535
    Abstract: A boring bit has a shank, a head and teeth distributed around the head. The teeth have a root embedded within the head's core body, a tip extending out of the head, and a narrowing region between the root and the tip. More than approximately two-thirds of the tooth length is embedded in the core body, including a portion of the narrowing region. Stabilizing rods are welded to the tips of the teeth to form a temporary connection, and the core body is formed from a molten metal poured into a cavity of a cast mold. The rods are inserted into indentations in the cast to hold the teeth in place, and the molten metal heats the teeth and weld to substantially loosen the temporary connection. As the molten metal cools, it solidifies around the teeth and secures the root and narrowing region of the teeth within the core body.
    Type: Application
    Filed: March 16, 2014
    Publication date: September 18, 2014
    Applicant: Rockhound Boring Products, LLC
    Inventor: Douglas R. Ford
  • Publication number: 20140259963
    Abstract: A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.
    Type: Application
    Filed: March 13, 2014
    Publication date: September 18, 2014
    Applicant: SMITH INTERNATIONAL, INC.
    Inventor: YAHUA BAO
  • Publication number: 20140262533
    Abstract: A polycrystalline diamond (PCD) composite compact element comprising a PCD structure bonded to a cemented carbide substrate, in which at least a peripheral region of the substrate comprises cemented carbide material having a mean free path (MFP) characteristic of at least about 0.1 microns and at most about 0.7 microns; and an elastic limit of at least about 1.9 GPa.
    Type: Application
    Filed: January 13, 2014
    Publication date: September 18, 2014
    Inventors: Danny Eugene Scott, Jimmy Wayne Eason, David Alexander Curry, Igor Yuri Konyashin
  • Publication number: 20140259960
    Abstract: A nonwoven, fibrous, article including a plurality of entangled fibers is provided. The fibers can have at least one of an anti-microbial agent or a plurality of abrasive particles. A binder material may bond the fibers to each other at points of crossing and contact between the fibers. The fibers may be made from post-consumer materials, post-industrial materials, heavy denier fibers, biodegradable materials, or heat resistant.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Inventor: Martin J. Rotter
  • Publication number: 20140273773
    Abstract: The present invention relates to a segment-type chemical mechanical polishing conditioner and a method for manufacturing thereof. The segment-type chemical mechanical polishing conditioner comprises: a bottom substrate having a center protrusion; an abrasive unit binding layer disposed on the outside of the surface of the bottom substrate; and a plurality of abrasive units placed on the abrasive unit binding layer; wherein the abrasive units have a fan-shaped contour and are arrange along the center protrusion of the bottom substrate to form a discontinuous circular contour. Therefore, the present invention can utilize the center protrusion of the bottom substrate to adjust the arrangements of the abrasive units, and effectively improve the problem of thermal deformation of the surface of the chemical mechanical polishing conditioner during heat-hardening process, thereby enhancing the surface flatness of chemical mechanical polishing conditioner.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Applicant: Kinik Company
    Inventors: Jui-Lin CHOU, Chia Chun WANG, Chia-Feng CHIU, Chung-Yi CHENG
  • Patent number: 8834589
    Abstract: A polishing composition for a magnetic disk substrate of the present invention includes water, silica particles, and at least one or more selected from an acid, a salt of the acid, and an oxidizing agent. The silica particles are observed with a transmission electron microscope to measure a maximum diameter and a projected area of each particle, and a value obtained by dividing the area of a circle whose diameter is the maximum diameter of a silica particle by the projected area of the silica particle and multiplying the result by 100, is in the range of 100 to 130.
    Type: Grant
    Filed: April 26, 2007
    Date of Patent: September 16, 2014
    Assignee: Kao Corporation
    Inventors: Yoshiaki Oshima, Norihito Yamaguchi, Haruhiko Doi
  • Publication number: 20140250797
    Abstract: A method of forming a shaped abrasive particle includes forming a first mixture and a second mixture in a single forming process into an integral precursor shaped abrasive particle, wherein the first mixture has a different composition than a composition of the second mixture.
    Type: Application
    Filed: May 16, 2014
    Publication date: September 11, 2014
    Applicant: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Doruk O. Yener, Paul Braun
  • Publication number: 20140250798
    Abstract: Thermally stable polycrystalline constructions include a body having a polycrystalline ultra-hard phase and a plurality of empty voids. The construction includes a backside support member over at least a portion of the backside surface of the body and a sidewall support member over at least a portion of the sidewall surface of the body extending an axial distance along at least a portion of the body and at least partially covering a circumferential surface of the body. The construction has a compressive stress exerted on the body.
    Type: Application
    Filed: May 22, 2014
    Publication date: September 11, 2014
    Applicant: Smith International, Inc.
    Inventors: Georgiy Voronin, J. Daniel Belnap
  • Publication number: 20140251696
    Abstract: In an embodiment, a cutter assembly for use on a tunnel boring machine may include a cutter ring extending circumferentially about a central axis. The cutter ring may include a radially inner surface and a radially outer surface. The cutter assembly may also include superabrasive cutting elements distributed circumferentially about the axis. Each of the superabrasive cutting elements may be attached to the cutter ring and may include a polycrystalline diamond (“PCD”) body having a working surface. At least a number of the cutting elements may extend beyond the outer surface of the cutter ring.
    Type: Application
    Filed: March 8, 2013
    Publication date: September 11, 2014
    Applicant: US Synthetic Corporation
    Inventor: US Synthetic Corporation
  • Publication number: 20140251698
    Abstract: Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts.
    Type: Application
    Filed: May 20, 2014
    Publication date: September 11, 2014
    Applicant: Baker Hughes Incorporated
    Inventors: Danny E. Scott, Anthony A. DiGiovanni
  • Patent number: 8828527
    Abstract: A surface-coated cutting tool includes a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet; and a hard coating layer formed by vapor-depositing in order, a lower layer (a), an intermediate layer (b), and an upper layer (c) on the tool substrate. The lower layer (a) is a Ti layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, and having a thickness of 3 to 20 ?m. The intermediate layer (b) is an aluminum oxide layer having a thickness of 1 to 5 ?m, and having an ?-type crystal structure in a chemically vapor-deposited state. The upper layer (c) is an aluminum oxide layer having a thickness of 2 to 15 ?m, and containing one or more elements of Ti, Y, Zr, Cr, and B.
    Type: Grant
    Filed: March 18, 2010
    Date of Patent: September 9, 2014
    Assignee: Mitsubishi Materials Corporation
    Inventors: Kohei Tomita, Makoto Igarashi, Akira Osada, Eiji Nakamura
  • Patent number: 8828563
    Abstract: A cutting tool for metal material processing has a hard metal body and a multi-layer coating applied to the hard metal body in at least one surface area. The multi-layer coating includes the following, sequentially in direction from the hard metal body to the surface of the cutting tool: at least one layer TiCx1Ny1, where x1+y1=1, x1?0, y1>0; at least one layer TiCx2Ny2Oz2, where x2+y2+z2=1, 0?z2?0.03 and 0.5?x2?0.85; at least one layer TiN, or TiCx31Ny31, where 0.2?x31?0.8 and x31+y31=1, or TiNy32Bv32, where 0.0001?v32?0.05 and y32+v32=1; at least one layer: TiNy41Bv41Oz41, where y41+v41+z41=1 and 0.0001?v41?0.05 and 0.01?z41?0.6, or TiCx42Ny42Oz42, where x42+y42+z42=1 and 0?y42?0.5 and 0.01?z42?0.6; and at least one outer layer ?-Al2O3. The at least one layer TiCx2Ny2Oz2 has a texture in the direction having a texture coefficient TC(311)=1.3.
    Type: Grant
    Filed: September 2, 2010
    Date of Patent: September 9, 2014
    Assignee: Ceratizit Austria Gesellschaft mbH
    Inventors: Martin Kathrein, Werner Bürgin, Christoph Czettl, Peter Lechleitner, Josef Thurner
  • Publication number: 20140246248
    Abstract: Hardfacing compositions include grains of hard material embedded within a cobalt-based metal alloy that includes ruthenium. Earth-boring tools include such hardfacing compositions on one or more surfaces thereof. Methods of applying hardfacing to an earth-boring tool include embedding grains of hard material in a molten cobalt-based metal alloy including ruthenium on a surface of an earth-boring tool, and cooling and solidifying the molten cobalt-based metal alloy with the grains of hard material embedded therein.
    Type: Application
    Filed: March 1, 2013
    Publication date: September 4, 2014
    Applicant: BAKER HUGHES INCORPORATED
    Inventor: Jimmy W. Eason
  • Publication number: 20140246251
    Abstract: Earth-boring tools may comprise a body comprising a first region and a second region. The first region may be located closer to a rotational axis of the body than the second region. A first cutting element may be located in the first region and a second cutting element may be located in the second region. A first polycrystalline table of the first cutting element may be substantially free of catalyst material to a first depth and a second polycrystalline table of the second cutting element may be substantially free of catalyst material to a second, greater depth.
    Type: Application
    Filed: March 1, 2013
    Publication date: September 4, 2014
    Inventors: Danny E. Scott, Anthony A. DiGiovanni, Nicholas J. Lyons, Derek L. Nelms
  • Publication number: 20140246005
    Abstract: The present invention relates to an electrodeposited diamond wire saw using patterned non-conductive materials in which non-conductive materials are pre-patterned along the outer circumference of a wire on which diamond grit should not be rubbed, before the diamond grit is upset, in order to efficiently improve the manufacturing process, and to a method for manufacturing same. According to one preferred embodiment of the invention, the method for manufacturing an electrodeposited diamond wire saw includes: printing a masking solution on the outer circumference of a wire in a plurality of directions when the wire is inserted for patterning; and upsetting diamond grit on the remaining regions of the outer circumference of the wire, with the exception of the patterned region.
    Type: Application
    Filed: March 19, 2012
    Publication date: September 4, 2014
    Applicant: EHWA DIAMOND INDUSTRIAL CO., LTD.
    Inventors: Seh-Kwang Lee, Rak-Joo Sung, Sang-Wook Park
  • Publication number: 20140245667
    Abstract: A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material.
    Type: Application
    Filed: May 12, 2014
    Publication date: September 4, 2014
    Applicant: Baker Hughes Incorporated
    Inventors: Nicholas J. Lyons, Danny E. Scott
  • Patent number: 8821603
    Abstract: A hard composite member produced by a rapid omni-directional compaction process that includes the steps of: providing a pre-compaction composite comprising a substrate, a superhard member and a layer of braze between the substrate and the superhard member; placing the pre-compaction composite in a pressure transmitting material contained within a shell to form an isostatic die assembly; heating the isostatic die assembly to a temperature at which the pressure-transmitting material is capable of fluidic flow and wherein the temperature ranges between greater than the melting point of the braze layer and less than or equal to about 1200° C.; and in a forging press, compressing the isostatic die assembly to consolidate the pre-compaction composite under omnidirectional pressure at a pressure equal to or greater than about 60,000 psi into a dense, consolidated body.
    Type: Grant
    Filed: March 8, 2007
    Date of Patent: September 2, 2014
    Assignee: Kennametal Inc.
    Inventors: Jonathan W. Bitler, Sara Kiani
  • Patent number: 8821606
    Abstract: A metal bonded grinding stone is manufactured by heating and pressurizing a material including abrasive grains, a cobalt, a tungsten disulfide and a copper tin alloy to obtain a sintered product, and rapid-cooling the sintered product.
    Type: Grant
    Filed: July 21, 2010
    Date of Patent: September 2, 2014
    Assignee: Honda Motor Co., Ltd.
    Inventors: Masato Ujihashi, Toshiya Hirata, Kazuhiko Kitanaka, Naohide Unno, Hiroshi Sugiyama, Noriyuki Namba
  • Patent number: 8821605
    Abstract: The present invention relates to sintered abrasive grit agglomerates based on aluminum oxide, having homogeneously distributed nanoscale pores in the range of 100-300 nm, with a pore volume of at least 15%. The average diameter of primary particles of the aluminum oxide primary particles is less than 5 ?m, wherein said primary particles are connected to each other without additional adhesive agent.
    Type: Grant
    Filed: July 21, 2009
    Date of Patent: September 2, 2014
    Assignee: Center for Abrasives and Refractories Research & Development C.A.R.R.D. GmbH
    Inventors: Maria Christina DiDavide, Reiner Kunz
  • Publication number: 20140237907
    Abstract: Abrasive particles comprising shaped abrasive particles each having a sidewall, each of the shaped abrasive particles comprising alpha alumina and having a first face and a second face separated by a sidewall and having a maximum thickness, T; and the shaped abrasive particles further comprising a plurality of grooves on the second face.
    Type: Application
    Filed: May 6, 2014
    Publication date: August 28, 2014
    Applicant: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Boden T. Boden, Dwight D. Erickson, Scott R. Culler, Negus B. Adefris, John D. Haas
  • Publication number: 20140237904
    Abstract: A cutting tool and a method of making a cutting tool are provided. The cutting tool may comprise a sintered superabrasive tip, a tool body and a non-brazing material. The sintered superabrasive tip may have a plurality of superhard particles. The tool body may retain the superabrasive tip. The non-brazing material fills a gap between the superabrasive tip and the tool body. The method of making a cutting tool may comprise steps of providing a superabrasive tip; providing a tool body; filling a gap between the superabrasive tip and the tool body with a non-brazing material; and depositing a first coating to the non-brazing material.
    Type: Application
    Filed: February 27, 2014
    Publication date: August 28, 2014
    Applicant: DIAMOND INNOVATIONS, INC.
    Inventor: William RUSSELL
  • Publication number: 20140238752
    Abstract: Processes for pre-sharpening cutting structures comprising particles of superabrasive material such as diamond grit, dispersed in a metal matrix material such as cemented tungsten carbide. Matrix material may be removed from a surface of a cutting structure to a desired depth to expose superabrasive particles within the matrix material adjacent the surface, and to increase exposure of partially exposed superabrasive particles at the surface. Electrodischarge machining (EDM), laser machining, electrolytic etching and chemical etching may also be employed. Pre-sharpened cutting structures are also disclosed.
    Type: Application
    Filed: February 27, 2013
    Publication date: August 28, 2014
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: J. Miguel Bilen, Victor L. Reddick, JR., Wesley Dean Fuller
  • Patent number: 8814965
    Abstract: A cubic boron nitride sintered body is excellent in wear resistance. The cubic boron nitride sintered body has about 30 to about 70% by volume of cubic boron nitride; and as the reminder, a binder phase having at least one selected from an oxide, carbide, nitride and boride of Ti, Al, Zr, Y, Ce, Mg or Ca and mutual solid solutions thereof; and inevitable impurities, wherein the cubic boron nitride sintered body contains ?-type Al2O3, ZrB2, ZrO2 and ZrO, and when an X-ray diffraction intensity of a (110) plane of ?-type Al2O3 is represented by Ia, an X-ray diffraction intensity of a (101) plane of ZrB2 is represented by Izb, and an X-ray diffraction intensity of a (111) plane of ZrO is represented by Izo, (Izb/Ia) which shows a ratio of Izb based on Ia satisfies 0.13?(Izb/Ia)?0.30, and (Izo/Ia) which shows a ratio of Izo based on Ia satisfies 0.05?(Izo/Ia)?0.20.
    Type: Grant
    Filed: November 11, 2010
    Date of Patent: August 26, 2014
    Assignee: Tungaloy Corporation
    Inventor: Sho Yokoshi
  • Patent number: 8814968
    Abstract: A thermally conductive sand shell molding system allows for controlling heat flow in a molten metal infiltrate powdered metal drill bit molding system to differentially cool the mold system to control differential shrinking and accompanying stress concentrations.
    Type: Grant
    Filed: January 13, 2011
    Date of Patent: August 26, 2014
    Assignee: National Oilwell Varco, L.P.
    Inventors: Alan Honggen Jiang, Harold Sreshta
  • Publication number: 20140231150
    Abstract: Polycrystalline compacts include smaller and larger hard grains that are interbonded to fox in a polycrystalline hard material. The larger grains may be at least about 150 times larger than the smaller grains. An interstitial material comprising one or more of a boride, a carbide, a nitride, a metal carbonate, a metal bicarbonate, and a non-catalytic metal may be disposed between the grains. The compacts may be used as cutting elements for earth-boring tools such as drill bits, and may be disposed on a substrate. A particulate mixture includes a first plurality of grains of hard material having a first average grain size of about five hundred nanometers (500 nm) or less and having a coating formed over the grains of hard material. The coating comprises at least one of a boride, a carbide, a nitride, a metal carbonate, a metal bicarbonate, and a non-catalytic metal.
    Type: Application
    Filed: April 21, 2014
    Publication date: August 21, 2014
    Applicant: Baker Hughes Incorporated
    Inventor: Anthony A. DiGiovanni
  • Publication number: 20140230339
    Abstract: A method of processing a composite body comprising a super-hard structure and refractory metal material exposed proximate a boundary of the composite body, the refractory metal material comprising refractory metal. The method includes providing a basic corrosive agent, heating the corrosive agent to at least its melting point, contacting the composite body with the corrosive agent in the molten state and treating the composite body with the corrosive agent for a period of time to remove refractory metal material from the composite body.
    Type: Application
    Filed: October 5, 2012
    Publication date: August 21, 2014
    Inventor: Jacobus Stephanus Davel
  • Patent number: 8808859
    Abstract: In an embodiment, a polycrystalline diamond compact (“PDC”) comprises a substrate and a pre-sintered polycrystalline diamond (“PCD”) table including a plurality of bonded diamond grains defining a plurality of interstitial regions, an upper surface, and a back surface that is bonded to the substrate. The pre-sintered PCD table includes a first thermally-stable region extending inwardly from the upper surface, and a second region located between the first thermally-stable region and the substrate. The second region exhibits a thermal stability that is less than that of the first thermally-stable region, and includes at least one interstitial constituent disposed interstitially between the bonded diamond grains thereof. The at least one interstitial constituent may include at least one silicon-containing phase.
    Type: Grant
    Filed: October 31, 2011
    Date of Patent: August 19, 2014
    Assignee: US Synthetic Corporation
    Inventor: Mohammad N. Sani
  • Patent number: RE45154
    Abstract: A tool for machining is made from a hard-metal, cermet or ceramic base material and a single-layer or multi-layer hard material coating on the base material. An additional coating of one or more metals from the group of aluminum, copper, zinc, titanium, nickel, tin or base alloys of these metals is applied to the hard material coating.
    Type: Grant
    Filed: February 28, 2012
    Date of Patent: September 23, 2014
    Assignee: Ceratizit Austria Gesellschaft mbH
    Inventors: Wolfgang Wallgram, Uwe Schleinkofer, Karl Gigl, Josef Thurner, Wilfried Schintlmeister