POLYCRYSTALLINE DIAMOND COMPACT INCLUDING AT LEAST ONE MECHANICALLY-STRESSED POLYCRYSTALLINE DIAMOND TABLE AND METHODS OF MAKING THE SAME

• US 20200131855A1
• Filed: 11/12/2015
• Published: 04/30/2020
• Est. Priority Date: 11/13/2014
• Status: Abandoned Application

• Current Assignee: US Synthetic Corporation (ChampionX Corporation)
• Original Assignee: US Synthetic Corporation (ChampionX Corporation)
• Inventors: Cooley, Craig H., Jones, Paul Douglas, Patten, Landry, Wood, Carl
• Application Number:
  US14/939,544
• Publication Number:
  US 20200131855A1
• Time in Patent Office: Days
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/04 and being essentially inorganic
• CPC Class Codes: E21B 10/55 with preformed cutting elements
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
• CPC Class Codes: E21B 10/58 Chisel-type inserts E21B10/485, E21B10/52 take precedence
• CPC Class Codes: E21B 4/003 Bearing, sealing, lubricating details for roller bits E21B10/22

Abstract

Embodiments disclosed herein relate to polycrystalline diamond compacts (“PDCs”) including at least one mechanically-stressed polycrystalline diamond (“PCD”) table having an upper surface that exhibits a compressive stress state. Providing a selected support structure to the mechanically-stressed PCD table and/or generating a favorable stress state in the upper surface of the mechanically-stressed PCD table may improve a toughness and/or a strength of the mechanically-stressed PCD table and the PDC. In an embodiment, a PDC includes a substrate including an interfacial surface and a preformed PCD table attached to the substrate. The preformed PCD table includes an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate. In such an embodiment, the upper surface of the preformed PCD table exhibits a mechanical deflection and a concave curvature induced by deflecting the preformed PCD table toward the substrate. Methods of forming such PDCs including at least one mechanically-stressed PCD table are also disclosed.

Claims

1. A polycrystalline diamond compact, comprising:

a substrate including an interfacial surface; and

a mechanically-stressed polycrystalline diamond table coupled to the substrate, the mechanically-stressed polycrystalline diamond table including an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting a mechanical deflection and a concave curvature induced by forced contact between the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate, the forced contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface of the substrate;

wherein, prior to the forced contact, the mechanically-stressed polycrystalline diamond table is not coupled to the substrate.

2. The polycrystalline diamond compact of claim 1, wherein, prior to the forced contact, the bottom surface of the mechanically-stressed polycrystalline diamond table and a portion of the substrate at least partially define a region into which the bottom surface of the mechanically-stressed polycrystalline diamond table is deflected.

3. The polycrystalline diamond compact of claim 1, wherein the bottom surface of the mechanically-stressed polycrystalline diamond table contacts the interfacial surface of the substrate such that the bottom surface of the mechanically-stressed polycrystalline diamond table contacts substantially the entire interfacial surface of the substrate.

4. The polycrystalline diamond compact of claim 1, wherein the interfacial surface of the substrate exhibits a concave curvature.

5. The polycrystalline diamond compact of claim 1, wherein the forcing element comprises a mechanical fastener that couples the mechanically-stressed polycrystalline diamond table to the substrate.

6. The polycrystalline diamond compact of claim 5, further comprising a washer positioned between a top portion of the mechanical fastener and the upper surface of the mechanically-stressed polycrystalline diamond table.

7. The polycrystalline diamond compact of claim 5, wherein each of the mechanically-stressed polycrystalline diamond table and the substrate includes an aperture extending therethrough that receives the mechanical fastener.

8. The polycrystalline diamond compact of claim 1, further comprising a washer including an upper washer surface that contacts the bottom surface of the mechanically-stressed polycrystalline diamond table and a bottom washer surface that contacts at least one of the interfacial surface of the substrate or an upper surface of a second polycrystalline diamond table.

9. The polycrystalline diamond compact of claim 1, wherein each of the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate has a pattern thereon.

10. The polycrystalline diamond compact of claim 1, wherein the mechanically-stressed polycrystalline diamond table includes a leached region extending inwardly from the upper surface thereof from which at least a portion of a catalyst is removed.

11. The polycrystalline diamond compact of claim 1, wherein the substrate includes an outer region exhibiting a first modulus of elasticity and an inner region exhibiting a second modulus of elasticity less than the first modulus of elasticity.

12. The polycrystalline diamond compact of claim 1, further comprising at least one second polycrystalline diamond table, wherein the mechanically-stressed polycrystalline diamond table and the at least one second polycrystalline diamond table form a plurality of stacked polycrystalline diamond tables that are coupled to the substrate.

13. The polycrystalline diamond compact of claim 12, wherein the plurality of stacked polycrystalline diamond tables are bonded together.

14. The polycrystalline diamond compact of claim 1, wherein the mechanically-stressed polycrystalline diamond table is brazed to the substrate.

15. The polycrystalline diamond compact of claim 1, wherein the mechanically-stressed polycrystalline diamond table exhibits a thickness of from 0.120 inches to 0.400 inches.

16. The polycrystalline diamond compact of claim 1, wherein the mechanically-stressed polycrystalline diamond table includes a first region that extends inwardly from every surface of the polycrystalline diamond table, and a second region that is remote from every surface of the polycrystalline diamond table, wherein the first region has been leached to remove at least some of a catalyst therein and the second region is substantially unleached.

17. A method of forming a polycrystalline diamond compact, the method comprising:

providing an at least partially leached polycrystalline diamond table including an upper surface and a bottom surface; and

deflecting the at least partially leached polycrystalline diamond table to form a mechanically-stressed polycrystalline diamond table, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting a mechanical deflection and a concave curvature induced by forcing contact between the bottom surface of the at least partially leached polycrystalline diamond table and an interfacial surface of a substrate, the forcing contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface fo the substrate;

wherein, prior to forcing contact, the at least partially leached polycrystalline diamond table is not coupled to the substrate.

18. The method of claim 17, further comprising subjecting the at least partially leached polycrystalline diamond table positioned adjacent to the substrate to a high-pressure/high-temperature process effective to infiltrate the at least partially leached polycrystalline diamond table with an infiltrant from the substrate and bond the mechanically-stressed polycrystalline diamond table to the substrate.

19. The method of claim 17, wherein deflecting the at least partially leached polycrystalline diamond table to form the mechanically-stressed polycrystalline diamond table includes deflecting the at least partially leached polycrystalline diamond table toward the substrate during a high-pressure/high-temperature process.

20. The method of claim 17, wherein forcing element comprises a mechanical fastener.

21. The method of claim 17, further comprising brazing the at least partially leached polycrystalline diamond table to the substrate.

22. The method of claim 17, further comprising brazing the at least partially leached polycrystalline diamond table to a second polycrystalline diamond table.

23. A rotary drill bit, comprising:

a bit body configured to engage a subterranean formation; and

a plurality of polycrystalline diamond cutting elements attached to the bit body, at least one of the plurality of polycrystalline diamond cutting elements including;

a substrate including an interfacial surface; and

a mechanically-stressed polycrystalline diamond table coupled to the substrate, the mechanically-stressed polycrystalline diamond table including an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting mechanical deflection induced by forced contact between the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate, the forced contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface of the substrate;

wherein, prior to the forced contact, the mechanically-stressed polycrystalline diamond table is not coupled to the substrate.

24. The rotary drill bit of claim 23, further comprising at least one fastener that couples the at least one of the plurality of polycrystalline diamond cutting elements to the bit body and the mechanically-stressed polycrystalline diamond table to the substrate.

25. The rotary drill bit of claim 23, wherein the at least one of the plurality of polycrystalline diamond cutting elements is brazed to the bit body.