# US 10,119,340 B2 · Cutting elements, methods for manufacturing such cutting elements, and tools incorporating such cutting elements > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,119,340 B2 - Document ID: US10119340B2 - Status: Granted - Kind: B2 - Application number: 14/152,065 - Filed: 2014-01-10 - Published: 2014-05-08 - Granted: 2018-11-06 - Earliest claimed: 2009-05-20 - Assignees: Smith International, Inc. - Applicants: Smith International, Inc. - Inventors: J. Daniel Belnap; Georgiy Voronin; Feng Yu; Peter T. Cariveau; Youhe Zhang; Yuelin Shen; Guodong Zhan - Web page: https://patentgrep.com/patent/US10119340B2 ## CPC - E21B 10/55: with preformed cutting elements - E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - B01J 3/062: {characterised by the composition of the materials to be processed} - B01J 2203/062: Diamond - B01J 2203/0655: Diamond - B01J 2203/0685: Crystal sintering - B22F 2003/244: {Leaching} - B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware} - B22F 2998/10: Processes characterised by the sequence of their steps - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives - C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} - C22C 2026/006: {with additional metal compounds being carbides} - E21B 10/5735: {Interface between the substrate and the cutting element} - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - C22C: ALLOYS (treatment of alloys C21D, C22F) ## Abstract The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance. ## Claims ### Claim 1 A cutting element comprising: a substrate comprising a substrate interface surface, the substrate interface surface comprising a protrusion; and a polycrystalline diamond body comprising, a diamond interface surface interfacing with the substrate interface surface, a top surface opposite the diamond interface surface, a cutting edge meeting the top surface, and a material microstructure comprising a plurality of bonded-together diamond grains having an average grain size and interstitial regions between the diamond grains; wherein at least a region of the polycrystalline diamond body has the following properties: a diamond volume fraction, as measured by electron backscatter diffraction, greater than (0.9077)·(the diamond average grain size ^0.0221), with the diamond average grain size provided in microns, and the diamond average grain size is not greater than 8 microns. ### Claim 2 (depends on 1) The cutting element as recited in claim 1 wherein the substrate interface surface comprises an annular surface portion and wherein the protrusion is a step protrusion and comprises a diameter and a height as measured from the annular surface portion. ### Claim 3 (depends on 2) The cutting element as recited in claim 2 wherein the substrate comprises a diameter and wherein the diameter of the protrusion is less than about 0.7 times the diameter of the substrate. ### Claim 4 (depends on 2) The cutting element as recited in claim 2 wherein the substrate comprises a diameter and wherein the diameter of the protrusion is less than the diameter of the substrate but greater than half the diameter of the substrate. ### Claim 5 (depends on 2) The cutting element as recited in claim 2 wherein the ratio of the height to the diameter of the protrusion is less than about 0.1. ### Claim 6 (depends on 1) The cutting element as recited in claim 1 wherein the at least a region comprises a plurality of the interstitial regions that are substantially free of a catalyst material, and the at least a region extends from the cutting edge to a depth of at least 300 microns. ### Claim 7 (depends on 1) The cutting element as recited in claim 1 wherein the at least a region comprises a plurality of the interstitial regions that are substantially free of a catalyst material, and wherein the at least a region extends from the cutting edge to a depth of at least 500 microns. ### Claim 8 (depends on 1) The cutting element as recited in claim 1 wherein the at least a region has the following property: the diamond volume fraction is greater than (0.9187)·(the average grain size ^ 0.0183). ### Claim 9 (depends on 1) The cutting element as recited in claim 1 wherein the at least a region has the following property: the diamond volume fraction is greater than (0.9291)·(the average grain size ^ 0.0148). ### Claim 10 (depends on 1) The cutting element as recited in claim 1, wherein the diamond average grain size is not greater than 6 microns. ### Claim 11 (depends on 1) A drill bit comprising a bit body and at least one cutting element as recited in claim 1 disposed on the bit body. ### Claim 12 A cutting element comprising: a substrate comprising a substrate interface surface, the substrate interface surface comprising a protrusion; and a polycrystalline diamond body formed by sintering at a cold cell pressure greater than 5.4 GPa, the polycrystalline diamond body comprising, a diamond interface surface interfacing with the substrate interface surface, a top surface opposite the diamond interface surface; a cutting edge meeting the top surface; and a material microstructure comprising a plurality of bonded-together diamond grains having an average grain size and interstitial regions between the diamond grains; wherein at least a region of the polycrystalline diamond body satisfies one of the following conditions: an average grain size within the range of 2-4 microns, and a diamond volume fraction greater than 93%, or an average grain size within the range of 4-6 microns, and a diamond volume fraction greater than 94%, or an average grain size within the range of 6-8 microns, and a diamond volume fraction greater than 95%, and wherein the diamond volume fraction is that which is determined by electron backscatter diffraction. ### Claim 13 (depends on 12) The cutting element as recited in claim 12 wherein the substrate interface surface comprises an annular surface portion and wherein the protrusion is a step protrusion and comprises a diameter and a height as measured from the annular surface portion. ### Claim 14 (depends on 13) The cutting element as recited in claim 13 wherein the substrate comprises a diameter and wherein the diameter of the protrusion is less than about 0.7 times the diameter of the substrate. ### Claim 15 (depends on 13) The cutting element as recited in claim 13 wherein the substrate comprises a diameter and wherein the diameter of the protrusion is less than the diameter of the substrate but greater than half the diameter of the substrate. ### Claim 16 (depends on 13) The cutting element as recited in claim 13 wherein the ratio of the height to the diameter of the protrusion is less than about 0.1. ### Claim 17 (depends on 12) The cutting element as recited in claim 12 wherein the at least a region comprises a plurality of the interstitial regions that are substantially free of a catalyst material, and wherein the at least a region extends from the cutting edge to a depth of at least 300 microns. ### Claim 18 (depends on 12) The cutting element as recited in claim 12 wherein the at least a region comprises a plurality of the interstitial regions that are substantially free of a catalyst material, and wherein the at least a region extends from the cutting edge to a depth of at least 500 microns. ### Claim 19 (depends on 12) A drill comprising a bit body and at least one cutting element as recited in claim 12 disposed on the bit body.