GRADED DRILLING CUTTER

• US 20080178535A1
• Filed: 01/25/2008
• Published: 07/31/2008
• Est. Priority Date: 01/26/2007
• Status: Abandoned Application

• Current Assignee: Diamond Innovations Incorporated (Sandvik AB)
• Original Assignee: Diamond Innovations Incorporated (Sandvik AB)
• Inventors: Wan, Shan
• Application Number:
  US12/020,247
• Publication Number:
  US 20080178535A1
• Time in Patent Office: Days
• US Class Current: 51/297
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements

Abstract

In an embodiment, an abrasive compact includes ultra-hard particles which are sintered, bonded, or otherwise consolidated into a solid body. The compact also includes various physical characteristics having a continuous gradient, a multiaxial gradient, or multiple independent gradients.

Claims

1. An abrasive compact comprising:

a plurality of superabrasive particles consolidated into a solid mass, the particles having a characteristic gradient that is continuous, monotonic and uniaxial.

2. The abrasive compact of claim 1 wherein the characteristic gradient comprises a particle size gradient.

3. The compact of claim 2 in which a maximum rate of change of particle size is less than 1 micron of particle size per 1 micron of translation.

4. The abrasive compact of claim 1, wherein the characteristic gradient comprises a pore size gradient.

5. The compact of claim 4 in which a maximum rate of change of pore size is less than 1 micron of diameter per 1 micron of translation.

6. The abrasive compact of claim 1, wherein the characteristic gradient comprises a particle shape gradient.

7. The compact of claim 6 in which a maximum rate of change of particle aspect ratio is less than 0.1 per 1 micron of translation.

8. The abrasive compact of claim 1, wherein the characteristic gradient comprises a concentration of the superabrasive particles.

9. An abrasive compact comprising:

a plurality of superabrasive particles consolidated into a solid mass, the mass having a first continuous gradient along a first axis of the mass and a second continuous gradient along a second axis of the mass.

10. The compact of claim 9, wherein each of the gradients comprises a particle size gradient.

11. The compact of claim 9, wherein the first continuous gradient comprises a particle size gradient and the second continuous gradient comprises one of a pore size gradient, a particle shape gradient, or a superabrasive particle concentration gradient.

12. The compact of claim 11, wherein the first continuous gradient is monotonic and uniaxial.

13. The compact of claim 11, wherein the first continuous gradient is oscillating.

14. A method of creating an abrasive compact, comprising:

combining ultra-hard particles with a fluid to create a mixed slurry;

allowing the mixed slurry to separate and form a graded layer;

removing remaining liquid from the graded layer;

selecting a portion of the graded layer;

placing a substrate against the selected portion of the graded layer to create an initial assembly;

processing the initial assembly to produce a sintered abrasive compact supported on the substrate to form a recovered assembly; and

finishing the supported sintered compact into an abrasive tool.

15. The method of claim 14:

wherein the allowing comprises allowing the mixed slurry to settle in a non-planar fixture; and

wherein the placing comprises placing an interface surface of the substrate so that the interface surface matches a surface of the graded layer.

16. The method of claim 14, wherein the placing comprises orienting the graded layer and the substrate so that a surface of the substrate having more coarse particles is near the substrate.