Nondestructive Device and Method for Evaluating Ultra-Hard Polycrystalline Constructions

• US 20100089663A1
• Filed: 09/25/2009
• Published: 04/15/2010
• Est. Priority Date: 10/18/2005
• Status: Active Grant

• Current Assignee: Smith International Incorporated (SLB)
• Original Assignee: Smith International Incorporated (SLB)
• Inventors: Eyre, Ronald K., Corbett, Loel
• Granted Patent: US 8,130,903 B2
• Time in Patent Office: Days
• US Class Current: 175/428
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
• CPC Class Codes: G01N 2223/076 X-ray fluorescence
• CPC Class Codes: G01N 2223/652 impurities, foreign matter, trace amounts
• CPC Class Codes: G01N 23/223 by irradiating the sample with X-rays or gamma-rays and by measuring X-ray fluorescence
• CPC Class Codes: G01T 1/00 Measuring X-radiation, gamma radiation, corpuscular radiation, or cosmic radiation G01T3/00, G01T5/00 take precedence

Abstract

A device, system and method for nondestructively obtaining qualitative and/or quantitative information relating to the material properties of a region in a diamond body comprises directing x-rays onto the body. The body can comprise sintered or unsintered diamond. The body can ultimately be in the form of a cutting element used with a subterranean drill bit. The x-rays penetrate the body and cause a target element within the desired region including the same to emit x-ray fluorescence. The emitted x-ray fluorescence is received and information relating to content, location, and/or distribution of the target element in the region within the body is determined therefrom. The measured region can extend axially or radially from a surface of the body, and the target elements are nondiamond materials that can be constituents of a substrate attached to the body, or of a container used during HPHT sintering of the body.

Claims

1. A system for determining a measurement characteristic within a region of an ultra-hard construction comprising:

an ultra-hard body;

an X-Ray fluorescence device positioned adjacent the body and comprising;

an emitter positioned adjacent the body to directing X-Ray energy onto a discrete region of the body, wherein the discrete region comprises target elements that emit X-Ray fluorescence when contacted with the X-Ray energy; and

a receiver positioned adjacent the body to receive the X-Ray fluorescence from the body; and

means for determining the measurement characteristic within the discrete region of the body from the X-Ray fluorescence.

2. The system as recited in claim 1 wherein the ultra-hard body comprises an ultra-hard material having a hardness of greater than about 4,000 kg.mm².

3. The system as recited in claim 2 wherein the ultra-hard body comprises sintered polycrystalline diamond.

4. The system as recited in claim 1 wherein the body is unsintered.

5. The system as recited in claim 1 wherein the discrete region of the body is an annular region that extends radially inwardly a depth from a cylindrical outside surface of the body.

6. The system as recited in claim 1 wherein the target elements include one or more elements used to form a can used to house and sinter an ultra-hard material used to form the ultra-hard body during high temperature-high pressure conditions.

7. The system as recited in claim 6 wherein the target elements as selected from the group of materials consisting of niobium, tantalum, molybdenum, zirconium, hafnium and combinations thereof.

8. The system as recited in claim 1 wherein the discrete region of the body extends axially downwardly a depth from a top surface of the body.

9. The system as recited in claim 1 wherein the target elements include one or more elements selected from the group consisting of nondiamond materials mixed with an ultra-hard material before sintering, nondiamond materials combined with the ultra-hard material during sintering, and combinations thereof.

10. The system as recited in claim 1 wherein the target elements are selected from the group of binder materials consisting of Group VIII materials, Si, Ti, Cu, Ag, Au and combinations thereof.

11. The system as recited in claim 1 wherein ultra-hard construction comprises a metallic substrate joined to the body, and wherein the target elements are selected from the group of substrate constituent materials consisting of W, Group VIII materials, C, Si, V, Cr, Mo and combinations thereof.

12. The system as recited in claim 1 wherein the ultra-hard construction comprises a metallic substrate joined to the body, and wherein the discrete region comprises a thickness that extends axially a depth into the body from a top surface of the body

13. The system as recited in claim 1 wherein the measurement characteristic comprises the amount and location of the target elements within the discrete region.

14. The system as recited in claim 1 wherein the means for determining the measurement characteristic provides a map illustrating the measurement characteristic within the discrete region.

15. A bit for drilling subterranean formations comprising a body and a number of cutting elements operatively attached to the body, wherein one or more of the cutting elements comprises the ultra-hard construction with a region evaluated according to the system as recited in claim 1.

26. A bit for drilling subterranean formations comprising a body and a number of cutting elements operatively attached to the body, wherein one or more of the cutting elements comprises the ultra-hard construction with a region evaluated using the device as recited in claim 15.

35. A bit for drilling subterranean formations comprising a body and a number of cutting elements operatively attached to the body, wherein at least one cutting element comprises the ultra-hard body having a region evaluated according to the method as recited in claim 26.

16. A device for nondestructively determining a characteristic of a region within an ultra-hard construction comprising an ultra-hard body, the device comprising:

an emitter positioned adjacent the body for emitting X-ray energy onto the body and into a discrete region of the body, wherein target elements within the region emit fluorescence when contacted with the X-ray energy;

a detector positioned adjacent the body for receiving X-ray fluorescence from the body; and

means for determining the characteristic from the X-ray fluorescence received by the detector.

17. The device as recited in claim 16 wherein the ultra-hard body is formed from sintered polycrystalline diamond.

18. The device as recited in claim 16 wherein the body comprises unsintered diamond grains.

19. The device as recited in claim 16 wherein the discrete region comprises an annular region extending radially inwardly a depth from an outer cylindrical surface of the body.

20. The device as recited in claim 16 wherein the discrete region comprises a thickness that extends axially a depth into the body from a top surface of the body.

21. The device as recited in claim 16 where the ultra-hard construction comprises a metallic substrate attached to the body, and wherein the discrete region comprises a thickness that extends axially a depth in the body from an interface with the substrate.

22. The device as recited in claim 21 wherein the discrete region extends axially from the substrate to a top surface of the body.

23. The device as recited in claim 16 wherein the characteristic comprises the amount of target elements within the discrete region.

24. The device as recited in claim 16 wherein the characteristic comprises the presence and distribution of the target elements within the discrete region.

25. The device as recited in claim 16 further comprising means for generating a map illustrating the characteristic within the discrete region.

27. A method for nondestructively determining a characteristic feature within a region of an ultra-hard construction comprising an ultra-hard body;

the method comprising the steps of;

directing X-ray energy onto a surface of the body into a discrete region of the body;

receiving X-ray fluorescence emitted from target elements within the discrete region; and

determining from the received X-ray fluorescence the characteristic feature within the discrete region.

28. The method as recited in claim 27 wherein the ultra-hard body comprises unsintered diamond grains.

29. The method as recited in claim 27 wherein the ultra-hard body is formed from sintered polycrystalline diamond.

30. The method as recited in claim 27 wherein the discrete region extends radially a distance into the ultra-hard body from an outside surface.

31. The method as recited in claim 27 wherein the discrete region extends axially a depth into the body from a top surface.

32. The method as recited in claim 27 there the ultra-hard construction comprises a metallic substrate attached to the ultra-hard body, and wherein the discrete region extends axially a depth in the body from an interface with the substrate.

33. The method as recited in claim 27 wherein the characteristic feature comprises the amount of the target elements.

34. The method as recited in claim 27 wherein the characteristic feature comprises the distribution of the target elements.

36. A bit for drilling subterranean formations comprising:

a body having a number of blades extending outwardly therefrom;

a number of cutting elements attached to the blades, wherein the cutting elements comprise an ultra-hard construction having an ultra-hard body, wherein the body comprises a region comprising an ultra-hard material and a target element, and wherein a characteristic feature of the region of the body containing the target element is determined by the process of;

directing X-ray energy onto a surface of the body into a discrete region of the body;

receiving X-ray fluorescence emitted from the target elements within the discrete region; and

determining from the received X-ray fluorescence the characteristic feature within the discrete region.