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US 7,017,677 B2Granted
Coarse carbide substrate cutting elements and method of forming the same
AssigneeSmith International, Inc.
InventorsMadapusi K. Keshavan, Anthony Griffo, David Truax, Dah-Ben Liang
Life of this patent
Estimating the term…
Abstract
Cutting elements having coarse grain substrates and ultra hard material layers are provided. The substrates are formed from coarse grain size particles of tungsten carbide. A method of forming such cutting elements and a drag bit incorporating such cutting elements are also provided.
Claims31
A shear cutter comprising:
- a substrate having an end surface, wherein the substrate is formed by the consolidation of a composition comprising tungsten carbide and a binder material, the substrate after consolidation not having a double cemented microstructure and having at least one substrate property selected from the group consisting of a median particle size of at least 6 μm, a Rockwell A hardness less than 86, and an impurity content of the tungsten carbide being not greater than about 0.1% by weight;
- and
- an ultra hard material layer over the end surface of the substrate, wherein the ultra hard material comprises ultra hard material particles, wherein the median particle size of the ultra hard particles is approximately the same as the median particle size of the substrate.
A shear cutter comprising:
- a substrate having an end surface, wherein the substrate is formed by the consolidation of a composition comprising tungsten carbide and a binder material, the substrate after consolidation not having a double cemented microstructure and having at least one substrate property selected from the group consisting of a median particle size of at least 6 μm, a Rockwell A hardness less than 86, and an impurity content of the tungsten carbide being not greater than about 0.1% by weight;
- and
- an ultra hard material layer over the end surface of the substrate, wherein the substrate comprises at least a 6% concentration of particles having a grain size of at least 7 μm or more.
A cutting element comprising:
- a substrate having an end surface, wherein the substrate is formed by the consolidation of a composition comprising tungsten carbide and a binder material, the substrate after consolidation having at least one substrate property selected from the group consisting of a median particle size of at least 6 μm, a Rockwell A hardness less than 86, and an impurity content of the tungsten carbide being not greater than about 0.1% by weight;
- and
- an ultra hard material layer over the end surface of the substrate, wherein the ultra hard material comprises ultra hard material particles, and wherein the median particle size of the ultra hard particles is approximately the same as the median particle size of the substrate.
A cutting element comprising:
- a substrate having an end surface, wherein the substrate is formed by the consolidation of a composition comprising tungsten carbide and a binder material, the substrate after consolidation having at least one substrate property selected from the group consisting of a median particle size of at least 6 μm, a Rockwell A hardness less than 86, and an impurity content of the tungsten carbide being not greater than about 0.1% by weight, wherein the substrate comprises at least a 6% concentration of particles having a grain size of at least 7 μm or more;
- and
- an ultra hard material layer over the end surface of the substrate.
Dependencies are inferred from the claim text.