# US 2010/0075122 A1 · High Energy Treatment Of Cutter Substrates Having A Wear Resistant Layer

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- Number: US 2010/0075122 A1
- Document ID: US20100075122A1
- Status: Published application
- Kind: A1
- Application number: 12/555,947
- Filed: 2009-09-09
- Published: 2010-03-25
- Earliest claimed: 2008-09-19
- Assignees: Varel International lnd., L.P.
- Inventors: Michael R. Reese; Kelly O. Malone
- Web page: https://patentgrep.com/patent/US20100075122A1

## CPC

- C21D 7/06: by shot-peening or the like
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 2003/247: {Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface}
- C21D 2221/00: Treating localised areas of an article
- Y10T 428/24942: including components having same physical characteristic in differing degree
- Y10T 428/24983: Hardness
- Y10T 428/30: Self-sustaining carbon mass or layer with impregnant or other layer
- Y10T 428/31678: Of metal
- C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B)
- 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
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.

## Claims

### Claim 1

A high energy treated cutter, comprising:
a substrate having a top surface, an outer region, and an inner core, wherein the substrate comprises a mixture of a metallic material and a binder material; and
a wear resistant layer coupled to the top surface of the substrate,
wherein the high energy treated cutter undergoes a high energy treatment, wherein the substrate is exposed to the high energy treatment, and wherein the wear resistant layer is protected from the high energy treatment.

### Claim 2 (depends on 1)

The high energy treated cutter of claim 1, wherein the metallic material comprises tungsten carbide.

### Claim 3 (depends on 1)

The high energy treated cutter of claim 1, wherein the binder material comprises cobalt.

### Claim 4 (depends on 1)

The high energy treated cutter of claim 1, wherein the wear resistant layer is fabricated from at least one material selected from the group consisting of polycrystalline diamond, cubic boron nitride, and thermally stable polycrystalline diamond.

### Claim 5 (depends on 1)

The high energy treated cutter of claim 1, wherein the outer region has a lesser concentration of the binder material than the inner core.

### Claim 6 (depends on 1)

The high energy treated cutter of claim 1, wherein the outer region has a greater hardness than the inner core.

### Claim 7 (depends on 1)

The high energy treated cutter of claim 1, wherein the inner core has a greater toughness than the outer region.

### Claim 8 (depends on 1)

The high energy treated cutter of claim 1, wherein the high energy treatment comprises generating impact forces on the surface of the outer region of the substrate.

### Claim 9

A method for performing high energy treatment on a cutter to form a high energy treated cutter, comprising:
obtaining at least one cutter comprising
a substrate comprising a mixture of a metallic material and a binder material, the substrate having a top surface, an outer region, and an inner core and
a wear resistant layer coupled to the top surface;
providing protection around the wear resistant layer; and
applying a high energy treatment to the at least one cutter to form at least one high energy treated cutter,
wherein the substrate is exposed to the high energy treatment and the wear resistant layer is protected from exposure to the high energy treatment.

### Claim 10 (depends on 9)

The method of claim 9, wherein the metallic material comprises tungsten carbide.

### Claim 11 (depends on 9)

The method of claim 9, wherein the binder material comprises cobalt.

### Claim 12 (depends on 9)

The method of claim 9, wherein the wear resistant layer is fabricated from at least one material selected from the group consisting of polycrystalline diamond, cubic boron nitride, and thermally stable polycrystalline diamond.

### Claim 13 (depends on 9)

The method of claim 9, wherein the high energy treatment causes the outer region to have a lesser concentration of the binder material than the inner core.

### Claim 14 (depends on 9)

The method of claim 9, wherein the high energy treatment causes the outer region to have a greater hardness than the inner core.

### Claim 15 (depends on 9)

The method of claim 9, wherein the high energy treatment causes the inner core to have a greater toughness than the outer region.

### Claim 16 (depends on 9)

The method of claim 9, wherein the high energy treatment comprises generating impact forces on the surface of the outer region of the substrate.

### Claim 17 (depends on 9)

The method of claim 9, wherein applying a high energy treatment comprises:
placing the at least one cutter in a cascading machine having at least one rotatable drum;
adding a medium into the at least one rotatable drum; and
rotating the at least one rotatable drum,
wherein the substrate of the at least one cutter is subjected to high energy impact, the at least one cutter being transformed into the at least one high energy treated cutter.

### Claim 18 (depends on 17)

The method of claim 17, wherein the medium comprises water.

### Claim 19 (depends on 17)

The method of claim 17, wherein the medium comprises an abrasive medium.

### Claim 20 (depends on 17)

The method of claim 17, wherein providing protection comprises a first protective cover securely coupled around the wear resistance layer, the first protective cover covering the wear resistance layer during the high energy treatment.

### Claim 21 (depends on 20)

The method of claim 20, wherein the first protective cover is fabricated from at least one material selected from the group consisting of rubber, elastomer, polyurethane, copper, and epoxy.

### Claim 22 (depends on 20)

The method of claim 20, wherein the first protective cover extends along a portion of the outer perimeter of the substrate, the portion of the outer perimeter located adjacent to the wear resistance layer.

### Claim 23 (depends on 20)

The method of claim 20, wherein the first protective cover is secured to the wear resistance layer via a clamp coupled around the circumference of the first cover or a glue coupled between the first cover and the wear resistance layer.

### Claim 24 (depends on 23)

The method of claim 23, wherein the clamp is fabricated from at least one material selected from the group consisting of metal, plastic, and synthetic material.

### Claim 25 (depends on 23)

The method of claim 23, wherein the clamp is further secured to the first protective cover via a second protective cover surrounding the clamp.

### Claim 26 (depends on 9)

The method of claim 9, wherein applying a high energy treatment comprises:
spraying a high energy media stream onto the substrate of the at least one cutter via at least one spray nozzle,
wherein the substrate is subjected to high energy impact, the at least one cutter being transformed into the at least one high energy treated cutter.

### Claim 27 (depends on 26)

The method of claim 26, wherein the high energy media stream comprises at least one material selected from the group consisting of steel, tungsten carbide, and ceramic.

### Claim 28 (depends on 27)

The method of claim 27, wherein the at least one material is angular.

### Claim 29 (depends on 27)

The method of claim 27, wherein the at least one material is spherical.

### Claim 30 (depends on 27)

The method of claim 27, wherein the high energy media stream further comprises a liquid slurry.

### Claim 31 (depends on 26)

The method of claim 26, wherein the at least one spray nozzle is movable.

### Claim 32 (depends on 26)

The method of claim 26, wherein a portion of the at least one spray nozzle is movable.

### Claim 33 (depends on 26)

The method of claim 26, wherein providing protection comprises:
obtaining a tray table having an upper surface and a bottom surface, the tray table comprising at least one recess formed in the upper surface, the recess having a depth of at least the thickness of the wear resistance layer, the shape and the size of the recess being substantially similar to the shape and the size of the wear resistance layer;
placing the wear resistance layer of the at least one cutter into the at least one recess thereby protecting the wear resistance layer from exposure to the high energy treatment.

### Claim 34 (depends on 33)

The method of claim 33, wherein the tray table is convex shaped.

### Claim 35 (depends on 33)

The method of claim 33, wherein the tray table is rotatable.

### Claim 36 (depends on 33)

The method of claim 33, further comprising applying a glue between the at least one recess and the wear resistant layer to secure the wear resistant layer in the at least one recess.

### Claim 37 (depends on 33)

The method of claim 33, further comprising applying a weight to the at least one cutter positioned within the at least one recess, the weight securing the wear resistant layer to the at least one recess during the high energy treatment.

### Claim 38 (depends on 33)

The method of claim 33, wherein the at least one recess extends through the tray table, wherein the upper surface has a first opening and the bottom surface has a second opening, the first opening being larger than the second opening.

### Claim 39 (depends on 38)

The method of claim 38, wherein the wear resistant layer is secured within the recess via a vacuum pulling on the wear resistance layer through the second opening.

### Claim 40

A method for performing high energy treatment on a cutter to form a high energy treated cutter, comprising:
obtaining at least one cutter comprising
a substrate comprising a mixture of a metallic material and a binder material, the substrate having a top surface, an outer region, and an inner core; and
a wear resistant layer coupled to the top surface;
providing protection around the wear resistant layer;
placing the at least one cutter in a cascading machine having at least one rotatable drum;
adding a medium into the at least one rotatable drum; and
rotating the at least one rotatable drum to create high energy impact between the at least one cutter,
wherein the substrate of the at least one cutter is subjected to high energy treatment, wherein the wear resistant layer is protected from exposure to the high energy treatment, and wherein the at least one cutter is transformed into the at least one high energy treated cutter.

### Claim 41

A method for performing high energy treatment on a cutter to form a high energy treated cutter, comprising:
obtaining at least one cutter comprising
a substrate comprising a mixture of a metallic material and a binder material, the substrate having a top surface, an outer region, and an inner core; and
a wear resistant layer coupled to the top surface;
obtaining a tray table having an upper surface and a bottom surface, the tray table comprising at least one recess formed in the upper surface, the recess having a depth of at least the thickness of the wear resistance layer;
placing the wear resistance layer of the at least one cutter into the at least one recess thereby protecting the wear resistance layer from exposure to the high energy treatment;
spraying a high energy media stream onto the substrate of the at least one cutter via at least one spray nozzle; and
collecting the high energy media stream and recycling the high energy media stream to the at least one spray nozzle,
wherein the substrate of the at least one cutter is subjected to high energy treatment, wherein the wear resistant layer is protected from exposure to the high energy treatment, and wherein the at least one cutter is transformed into the at least one high energy treated cutter.