Polyscrystalline diamond compact including erosion and corrosion resistant substrate
AssigneeUS Synthetic Corporation
InventorDebkumar Mukhopadhyay
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Abstract
Embodiments disclosed herein relate to polycrystalline diamond compacts that have a substrate including a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having and at least one alloying element, wherein the at least one alloying element constitutes less than 12 wt % of the substrate and wherein the cobalt constitutes less than 12 wt % of the substrate; and methods of making the same.
Claims28
A polycrystalline diamond compact, comprising:
- a substrate including:
- a first plurality of carbide grains;
- a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having cobalt and at least one alloying element;
- wherein the at least one alloying element constitutes less than 12 wt % of the substrate;
- wherein the cobalt constitutes less than 12 wt % of the substrate;
- and
- a polycrystalline diamond table bonded to the substrate;
- wherein the substrate includes one or more of a density of about 14.0 g/cc to about 15.0 g/cc, a hardness of about 88.0 HRa to about 89.0 HRa, a fracture toughness of about 12.0 MPa·m1/2 to about 14.0 MPa·m1/2, a transverse rupture strength of about 400 ksi to about 550 ksi, or a corrosion rate of about 0.1 mil/year to about 4.0 mil/year.
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-18. (canceled)
A method of forming a polycrystalline diamond compact, the method comprising:
- providing a substrate, the substrate including:
- a first plurality of carbide grains;
- a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having cobalt and at least one alloying element;
- wherein the at least one alloying element constitutes less than 12 wt % of the substrate;
- wherein the cobalt constitutes less than 12 wt % of the substrate;
- disposing a volume of diamond particles adjacent to the substrate to form an assembly;
- and
- subjecting the assembly to a high-pressure high-temperature process to sinter the diamond particles to form a polycrystalline diamond table and to bond the substrate to the polycrystalline diamond table;
- wherein the substrate includes one or more of a density of about 14.0 g/cc to about 15.0 g/cc, a hardness of about 88.0 HRa to about 89.0 HRa, a fracture toughness of about 12.0 MPa·m1/2 to about 14.0 MPa·m1/2, a transverse rupture strength of about 400 ksi to about 550 ksi, or a corrosion rate of about 0.1 mil/year to about 4.0 mil/year.
A rotary drill bit, comprising:
- a bit body configured to engage a subterranean formation;
- and
- a plurality of polycrystalline diamond cutting elements affixed to the bit body, at least one of the polycrystalline diamond cutting elements including:
- a substrate including:
- a first plurality of carbide grains;
- a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having cobalt and at least one alloying element;
- wherein the at least one alloying element constitutes less than 12 wt % of the substrate;
- wherein the cobalt constitutes less than 12 wt % of the substrate;
- and a polycrystalline diamond body bonded to the substrate;
- wherein the substrate includes one or more of a density of about 14.0 g/cc to about 15.0 g/cc, a hardness of about 88.0 HRa to about 89.0 HRa, a fracture toughness of about 12.0 MPa·m1/2 to about 14.0 MPa·m1/2, a transverse rupture strength of about 400 ksi to about 550 ksi, or a corrosion rate of about 0.1 mil/year to about 4.0 mil/year.
-42. (canceled)
Dependencies are inferred from the claim text.