Abstract:
Cutting elements for use with earth-boring tools include a cutting table having at least two sections where a boundary between the at least two sections is at least partially defined by a discontinuity formed in the cutting table. Earth-boring tools including a tool body and a plurality of cutting elements carried by the tool body. The cutting elements include a cutting table secured to a substrate. The cutting table includes a plurality of adjacent sections, each having a discrete cutting edge where at least one section is configured to be selectively detached from the substrate in order to substantially expose a cutting edge of an adjacent section. Methods for fabricating cutting elements for use with an earth-boring tool including forming a cutting table comprising a plurality of adjacent sections.
Abstract:
Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles.
Abstract:
Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprise a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material.
Abstract:
An earth-boring drilling tool comprises a cutting element. The cutting element comprises a substrate, a diamond table, and at least one sensing element formed from a doped diamond material disposed at least partially within the diamond table. A method for determining an at-bit measurement for an earth-boring drill bit comprises receiving an electrical signal generated within a doped diamond material disposed within a diamond table of a cutting element of the earth-boring drill bit, and correlating the electrical signal with at least one parameter during a drilling operation.
Abstract:
Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprising a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material.
Abstract:
Coated diamond particles have solid diamond cores and at least one graphene layer. Methods include coating diamond particles with a charged species and coating the diamond particles with a graphene layer. A composition includes a substance and a plurality of coated diamond particles dispersed within the substance. Each coated diamond particle has a diamond core and at least one graphene layer formed over at least a portion of the diamond core.
Abstract:
Downhole tool bearings are provided with diamond-enhanced materials. The diamond-enhanced materials comprise diamond grains in a matrix of tungsten or silicon carbide or a silicon-bonded diamond material. A brazed diamond grit or diamond particles coated with a reactive braze may be utilized for bearing applications. Bearing rings for use in downhole tools may be formed at least in part with the diamond-enhanced material. In one embodiment, the bearing rings may be used in a positive displacement motor. In additional embodiments, the bearing rings may be used in a submersible pump.
Abstract:
An earth boring drill bit (10) including replaceable gage pads (28). The gage pads and the corresponding surface of the earth boring drill bit may include complementary securing elements (40,46) which mutually engage one another. The gage pad may be removably affixed to the earth boring drill bit an affixation elements, such as a bolt, a mechanical locking element, brazing, welding, mechanical affixation, or another known technique. The invention also includes a method of testing differently configured gage pads employing a single earth boring drill bit, a method of replacing the gage pads of an earth boring drill bit at the drilling site, a method of customizing an earth boring drill bit to include one or more gage pads of desired configuration, and a method of altering the balance or net imbalance of an earth boring drill bit by replacing at least one gage pad thereof.
Abstract:
A cutting element comprises a supporting substrate, and a polycrystalline compact attached to an end of the supporting substrate. The polycrystalline compact comprises a region adjacent the end of the supporting substrate, and another region at least substantially laterally circumscribing the region and having lesser permeability than the region. A method of forming a cutting element, and an earth-boring tool are also described.