CUTTING ELEMENT AND A METHOD OF MANUFACTURING A CUTTING ELEMENT
First Claim
1. A cutting element comprising:
- a substrate comprising tungsten carbide and a metal binder which substrate has a magnetic saturation value in the range of from 80% to less than 85%; and
cutting layer disposed on a surface of the substrate which cutting layer comprises an ultra hard material.
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Accused Products
Abstract
The present disclosure relates in one aspect to a cutting element comprising a substrate and a cutting layer disposed on a surface of the substrate. The cutting layer comprises an ultra hard material. The substrate comprises tungsten carbide and a metal binder. The substrate has a magnetic saturation value in the range of from 80% to less than 85%. In another aspect, the magnetic saturation value may increase within the substrate along a gradient, wherein proximal to the interface with the cutting layer, the substrate has a magnetic saturation value in the range of from 80% to less than 85%. Also included are drill bits incorporating such cutting elements. Additionally, the present disclosure relates to methods of manufacturing cutting elements.
72 Citations
34 Claims
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1. A cutting element comprising:
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a substrate comprising tungsten carbide and a metal binder which substrate has a magnetic saturation value in the range of from 80% to less than 85%; and cutting layer disposed on a surface of the substrate which cutting layer comprises an ultra hard material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A cutting element comprising:
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a substrate comprising a tungsten carbide and a metal binder; and a cutting layer disposed on a surface of the substrate which cutting layer comprises an ultra hard material; wherein the magnetic saturation value increases within the substrate along a gradient in the direction away from the interface of the substrate and the cutting layer, and wherein within the substrate proximal to the interface, the magnetic saturation value is in the range of from 80% to less than 85%. - View Dependent Claims (10, 11)
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12. A method of manufacturing a cutting element comprising:
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selecting a substrate comprising tungsten carbide and a metal binder which substrate has a magnetic saturation value in the range of from 80% to less than 85%; and forming a cutting layer over a surface of the substrate which cutting layer comprises an ultra hard material. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
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20. A drill bit comprising:
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a bit body; and a plurality of cutting elements affixed to said bit body, wherein at least one of said plurality of cutting elements comprises a substrate containing tungsten carbide and a metal binder which substrate has a magnetic saturation value in the range of from 80% to less than 85%, and a cutting layer disposed on a surface of the substrate which cutting layer comprises an ultra hard material. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27)
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28. A method of manufacturing cutting elements comprising:
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selecting a first batch of substrates containing tungsten carbide and a metal binder, wherein the substrates have magnetic saturation values that vary by at most 5%; selecting a second batch of substrates containing tungsten carbide and a metal binder, wherein the substrates have magnetic saturation values which vary by at most 5%, and wherein the magnetic saturation values of both the first batch of substrates and the second batch of substrates vary by at most 5%; and forming a cutting layer comprising an ultra hard material on the surfaces of the first and second batches of substrates. - View Dependent Claims (29, 30, 31, 32, 33, 34)
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Specification