Embodiments are directed to nozzles for three-dimensional printing and related assemblies and methods. An example method includes, on a first side of a material, forming a hole into the material to define an at least partially conical inner conduit extending at least partially through the material, and, on a second side of the material, forming a through-hole into the material to define an exit orifice of the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid pathway through the nozzle.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B23K 26/55 - Working by transmitting the laser beam through or within the workpiece for creating voids inside the workpiece, e.g. for forming flow passages or flow patterns
B05B 1/00 - Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
B23B 1/00 - Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
B23H 1/00 - Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
2.
RADIAL AND THRUST BEARING ASSEMBLIES, RELATED SYSTEMS AND METHODS
A bearing assembly, comprising: an inner assembly including an inner support ring (706) positioned about an inner ring axis; an outer assembly including an outer support ring (708) positioned about an outer ring axis; superhard contact elements (704) coupled to the inner support ring and the outer support ring having superhard contact surfaces, the inner assembly configured to move relative to the outer assembly when a rotational force is applied to the bearing assembly; and one or more thrust bearing elements (750) comprising a hardened surface configured to at least partially contain the inner assembly relative to the outer assembly, the one or more thrust bearing elements positioned and configured to support the bearing assembly when an axial loading is applied between the inner assembly and the outer assembly in a direction at least partially along at least one of the inner ring axis or the outer ring axis.
Embodiments include superhard cutting elements and cutting tools including the cutting elements. In an embodiment, a cutting element includes a superhard table defining at least one cutting edge, a top surface at least partially defined by the superhard table, a bottom surface opposite the top surface, at least one lateral surface extending from or nearly from the top surface to or nearly to the bottom surface, and an opening extending from the top surface to the bottom surface that is spaced from the lateral surface. The opening is at least partially defined by at least one shaft surface extending from or nearly from the bottom surface and at least one tapered countersink surface extending from or nearly from the shaft surface. The tapered countersink surface exhibits a countersink angle measured between opposing portions of the at least one tapered countersink surface that is greater than about 45°.
At least one embodiment of a polycrystalline diamond element that may be used in machining various material includes a polycrystalline diamond body having a plurality of bonded diamond grain defining a plurality of interstitial regions, at least some of the plurality of interstitial regions at least partially occupied and/or previously occupied by at least one interstitial constituent. The polycrystalline diamond element also includes at least one leaching feature within the polycrystalline diamond body positioned and configured to reduce leaching cycle time of the at least one interstitial constituent.
A cutting tool which may be used in machining various material may include a body and one or more cutting elements associated therewith. In one example, the cutting element(s) may comprise a superhard table, such as a polycrystalline diamond table. In some embodiments, the polycrystalline diamond table may have a diamond density of approximately 95 percent volume or greater. In some embodiments, the thickness of the superhard table may be approximately 0.15 inch. In some embodiments, the superhard table may include a chip-breaking feature or structure. Methods of shaping, finishing, or otherwise machining materials are also provided, including the machining of materials comprising titanium.
Force coupling or torque coupling assemblies, apparatuses, systems, and methods include assemblies that each include superhard contact elements. At least some of the superhard contact elements may be configured to remain in contact with each other when a rotational force and/or a thrust force is applied between the assemblies.
F16D 1/08 - Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end with hub and longitudinal key
Embodiments of the invention relate to automatically dull grading drill bits and portions thereof based on three-dimensional digital models made from one or more images of the drill bits taken at a drilling site by an electronic device with a time-of-flight camera, wherein a method for evaluating drill bits at a site of a drilling rig is disclosed. The method includes receiving, from a requestor, a plurality of images of a drill bit that has been used, at least some of the plurality of images including time-of-flight images that have been captured by an electronic device (e.g„ a computing device, an electronic device, etc.) on-site at or near a drill rig. The method includes generating a digital model of the drill bit based on the plurality of images.
Bearing assemblies, apparatuses, systems, and methods include bearing assemblies where one of the bearing assemblies may include angled bearing surfaces having a planar shape.
Bearing assemblies, apparatuses, systems, and methods include bearing assemblies where one of the bearing assemblies may include bearing surfaces defining an at least partially conical inner surface.
e.g.e.g., defines a non-cylindrical or non-rectangular shape). The non-vertical conduit surface may be positioned such that it is not parallel to a central axis of the nozzle extending from the top surface to the bottom surface.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
11.
NOZZLES INCLUDING POLYCRYSTALLINE DIAMOND OR POLYCRYSTALLINE CUBIC BORON NITRIDE AND RELATED ASSEMBLIES AND METHODS
Embodiments are directed to nozzles for three-dimensional printing and related nozzle assemblies and methods. An example nozzle includes at least one top surface, at least one bottom surface, and at least one nozzle lateral surface extending from or near the top surface to or near the bottom surface. The nozzle also includes at least one conduit surface defining a conduit. At least a portion of the conduit surface comprise at least one of polycrystalline diamond ("PCD"), polycrystalline cubic boron nitride ("PcBN"), or another suitable superhard material. The nozzle may be attached to a base to form a nozzle assembly. The nozzle may be attached to the base by at least one of deforming the base relative to the nozzle, threadedly attaching (either directly or indirectly) the nozzle to the base, or press-fitting a hollow hollowed-sleeve into a passageway defined by the base.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
12.
ATTACHMENT OF PDC BEARING MEMBERS, BEARING ASSEMBLIES INCORPORATING SAME AND RELATED METHODS
Bearing assemblies and methods of manufacturing bearing assemblies are provided in the present disclosure. In one embodiment, a bearing assembly includes a base member and at least one bearing element coupled to the base member. The bearing element may be coupled with the base member by at least two different coupling techniques, including two of: a mechanical fastener, a clamped structure, a geometrical fit, welding, and brazing. In one embodiment, a first technique may include use of a mechanical fastener and a second technique may include welding or brazing. In another embodiment, a first technique may include use of a clamping mechanism or structure and a second technique may include welding or brazing. In another embodiment, a first technique may include use of a geometrical fit and a second technique may include welding or brazing.
Bearing assemblies and methods of using bearings are provided in the present disclosure. In one embodiment, a bearing ring is provided having a plurality of carrier components removably coupled therewith. Each carrier component may carry one or more bearing elements. Upon wearing of the bearing elements beyond a desired amount, the carrier components may be removed from the bearing ring and installed in a different bearing ring to place the mearing elements at their original bearing surface radius. In another embodiment, individual bearing elements may be radially adjustable relative to the bearing ring to define and redefine the radius of a radial bearing surface.
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.
C22C 1/05 - Mixtures of metal powder with non-metallic powder
C22C 29/08 - Alloys based on carbides, oxides, borides, nitrides or silicides, e.g. cermets, or other metal compounds, e. g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
E21B 10/46 - Drill bits characterised by wear resisting parts, e.g. diamond inserts
E21B 10/567 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
15.
CUTTING TOOL WITH PCD INSERTS, SYSTEMS INCORPORATING SAME AND RELATED METHODS
A cutting tool which may be used in machining various material may include a body and one or more cutting elements associated therewith. In one example, the cutting element(s) may comprise a superhard table, such as a polycrystalline diamond table. In some embodiments, the polycrystalline diamond table may have a diamond density of approximately 95 percent volume or greater. In some embodiments, the thickness of the superhard table may be approximately 0.15 inch. In some embodiments, the superhard table may include a chip breaking feature or structure. Methods of shaping, finishing or otherwise machining materials are also provided, including the machining of materials comprising titanium.
E21B 10/42 - Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits
E21B 10/43 - Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits characterised by the arrangement of teeth or other cutting elements
16.
BEARING ASSEMBLIES, RELATED BEARING APPARATUSES AND RELATED METHODS
Embodiments disclosed herein are directed to bearing assemblies, related bearing apparatuses, and related methods. An example of a bearing assembly disclosed herein may include a support structure having a first end and a second end. The bearing assembly also includes a superhard bearing element secured to the first end of the support structure. The superhard bearing element includes a superhard sealing surface that may be configured to contact a sealing surface of an opposing bearing element, a base surface contacting the support structure and opposing the superhard sealing surface, and at least one lateral surface extending between the superhard sealing surface and the base surface. The support structure and the superhard bearing element may both include at least one conduit extending therethrough through which a fluid may flow.
e.g., e.g., during use). Other embodiments employ one or more sacrificial anodes as an alternative to or in combination with the corrosion resistant region.
Polycrystalline diamond includes a working surface and a peripheral surface extending around an outer periphery of the working surface. The polycrystalline diamond includes a first volume including an interstitial material and a second volume having a leached region that includes boron and titanium. A method of fabricating a polycrystalline diamond element includes positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material that includes a group 13 element, and positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of material including the group 13 element than the first volume of diamond particles. Various other articles, assemblies, and methods are also disclosed.
C04B 35/528 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
Bearing assemblies that include a plurality of polycrystalline diamond ("PCD") bearing elements, bearing apparatuses including such bearing assemblies, and methods of operating and fabricating such bearing assemblies and apparatuses are disclosed. In an embodiment, the plurality of PCD bearing elements of one or more of the bearing assemblies disclosed herein include at least one first PCD bearing element. At least a portion of the first PCD bearing element exhibits a coercivity of about 125 Oersteds or more and a specific magnetic saturation of about 14 Gauss·cm3/gram or less. The first PCD bearing element includes a bearing surface with at least one groove formed therein. In an embodiment, the plurality of PCD bearing elements also include at least one second PCD bearing element. The second PCD bearing element exhibits a coercivity that is less than and a specific magnetic saturation that is greater than the first PCD bearing element.
Embodiments disclosed herein are directed to energy beam ablation machining methods that are used to machine polycrystalline diamond tables (e.g., polycrystalline diamond compacts that each includes polycrystalline diamond tables). Embodiments disclosed herein also are directed to polycrystalline diamond tables machined according to at least one of the energy beam ablation machining methods disclosed herein.
B24D 18/00 - Manufacture of grinding tools, e.g. wheels, not otherwise provided for
B24D 3/00 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
B23P 17/04 - Metal-working operations, not covered by a single other subclass or another group in this subclass characterised by the nature of the material involved or the kind of product independently of its shape
Embodiments disclosed herein are directed to tilting pad bearing assemblies and bearing apparatuses using the same. As will be discussed in more detail below, the tilting pad bearing assemblies include a plurality of tilting pads. The tilting pads include at least one or more first tilting pads and one or more second tilting pads. Each of the first tilting pads includes a first superhard bearing surface having a first material. Each of the second tilting pads includes a second bearing surface having a second material. The first material includes a superhard material and the second material includes a material that is different than the first material
Embodiments disclosed herein are directed to tilting pad bearing assemblies, bearing apparatuses including the tilting pad bearing assemblies, and methods of using the bearing apparatuses. The tilting pad bearing assemblies disclosed herein include a plurality of tilting pads. At least some of the superhard tables exhibit a thickness that is at least about 0.120 inch and/or at least two layers having different wear and/or thermal characteristics.
A superabrasive element includes a substrate and a superabrasive table bonded to the substrate, the superabrasive table including a polished surface having a polished finish, the polished surface extending over at least a central, apical region of the superabrasive table, and an unpolished surface including an unpolished finish, the unpolished surface surrounding a majority of the polished surface. A method of manufacturing a superabrasive element includes providing a superabrasive element having a substrate and a superabrasive table bonded to the substrate and polishing at least a central, apical region of the superabrasive table to form a polished surface, without polishing an unpolished surface of the superabrasive table, the unpolished surface surrounding a majority of the polished surface.
B23D 61/18 - Sawing tools of special type, e.g. wire saw strands, saw blades or saw wire equipped with diamonds or other abrasive particles in selected individual positions
B24D 99/00 - Subject matter not provided for in other groups of this subclass
24.
POLYCRYSTALLINE DIAMOND COMPACTS, AND RELATED METHODS AND APPLICATIONS
Embodiments relate to polycrystalline diamond compacts ("PDCs") including a polycrystalline diamond ("PCD") table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.
Embodiments disclosed herein relate to bearing apparatuses including a bearing assembly having a continuous superhard bearing element including a continuous superhard bearing surface and a tilting pad bearing assembly. The disclosed bearing apparatuses may be employed in pumps, turbines or other mechanical systems. In an embodiment, the bearing apparatus includes a first and second bearing assembly. The first bearing assembly includes a first support ring and a plurality of tilting pads. Each tilting pad is tilted and/or tiltably secured relative to the first support ring. The second bearing assembly includes a continuous superhard bearing element. The continuous superhard bearing element includes a continuous superhard bearing surface facing the plurality of tilting pads and exhibits a maximum lateral width greater than about 2 inches.
A probe for use with measuring equipment, such as a coordinate measuring machine (CMM) or a profilometer includes a shaft and a probe tip coupled with the shaft. At least a portion of the probe tip comprises a superabrasive material such as polycrystalline diamond. The probe tip may exhibit a variety of different geometries including, for example, substantially spherical, substantially cylindrical with a high aspect (length to diameter) ratio, or substantially disc-shaped. In other embodiments, the tip may include a converging portion leading to a fine-radiussed end point. The tip may be manufactured by forming a body using a high-pressure, high-temperature (HPHT) process and the shaping the body using a process such as electrical discharge machining (EDM), grinding or laser cutting.
Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.
In an embodiment, a porous composite particulate material includes a plurality of composite particles. Each composite particle includes an acid-base-resistant core particle at least partially surrounded by one or more layers of acid-base-resistant shell particles. The shell particles are adhered to the core particle by a polymeric layer. The shell particles and/or core particles may be made from an acid-base-resistant material that is stable in harsh chemical conditions. For example, the shell particles and/or core particles may be made from diamond, graphitic carbon, silicon carbide, boron nitride, tungsten carbide, ultra-clean diamond, combinations of the foregoing, or other acid-base-resistant materials. The porous composite particulate materials disclosed herein and related methods and devices may be used in separation technologies, including, but not limited to, chromatography, and solid phase extraction.
Embodiments of the invention generally relate to tunnel boring machine cutter assemblies, such as ripping and scraping cutter or tool assemblies, (collectively "cutter assemblies"), and related methods of use and manufacturing. The various embodiments of the cutter assemblies described herein may be used in tunnel boring machines ("TBMs"), earth pressure balance machines ("EPBs"), raise drilling systems, large diameter blind drilling systems, and other types of mechanical drilling and excavation systems.
E21B 10/46 - Drill bits characterised by wear resisting parts, e.g. diamond inserts
E21D 9/087 - Making by using a driving shield with additional boring or cutting means with a rotary drilling-head cutting simultaneously the whole cross-section, i.e. full-face machines
E21D 9/10 - Making by using boring or cutting machines
E21D 9/11 - Making by using boring or cutting machines with a rotary drilling-head cutting simultaneously the whole cross-section, i.e. full-face machines
30.
POLYCRYSTALLINE DIAMOND COMPACT AND METHOD OF MAKING A POLYCRYSTALLINE DIAMOND COMPACT
The invention relates to polycrystalline diamond compacts ("PDCs") including a polycrystalline diamond ("PCD") table (114) in which cobalt, iron or nickel is alloyed with phosphorous to improve the thermal stability of the PCD table. The PDC includes a substrate (107) and a PCD table(114) including an upper surface (112) spaced from an interfacial surface (103/106) that is bonded to the substrate (107). The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. TThe alloy is disposed in at least a portion of the plurality of interstitial regions. The alloy contains at least 80 weight% of an intermetallic compound of Co/Ni/Fe and P.
C04B 35/528 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
B01J 3/06 - Processes using ultra-high pressure, e.g. for the formation of diamonds; Apparatus therefor, e.g. moulds or dies
B24D 3/06 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic
B22F 5/00 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
31.
MIRROR INCLUDING POLYCRYSTALLINE DIAMOND BODY FOR USE WITH A MOTOR, SCANNING SYSTEMS INCLUDING THE SAME, AND RELATED METHODS
Mirrors for a deflection unit in a scanning system, scanning systems using such mirrors, and methods of manufacturing such mirrors are disclosed. In an embodiment, a mirror for a deflection unit in a laser system includes a sintered polycrystalline diamond body including a plurality of randomly oriented diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a material disposed interstitially therein. The mirror includes a reflective surface formed at least partially from the sintered polycrystalline diamond body or provided thereon. The reflective surface exhibits a surface roughness of less than about 50 nm Rrms.
A bearing assembly includes a support ring circumferentially surrounding a central bearing axis and a plurality of superhard bearing elements coupled to the support ring. Each of the plurality of superhard bearing elements has a base, a superhard bearing surface, and a lateral periphery extending between the base and the superhard bearing surface. The superhard bearing surface has a partial-ellipsoidal surface shape. A bearing apparatus includes an inner bearing assembly and an outer bearing assembly. A subterranean drilling system includes an output shaft operably coupled to a bearing apparatus.
Embodiments of the invention are directed to cutting tool assemblies (100) that include one or more superhard working surfaces (121) and one or more shields (130) and to a rotary drum assembly (300) that comprises such cutting tool assemblies (100).
B28D 1/18 - Working stone or stone-like materials, e.g. brick, concrete, not provided for elsewhere; Machines, devices, tools therefor by milling, e.g. channelling by means of milling tools
E21C 35/183 - Mining picks; Holders therefor with inserts or layers of wear-resisting material
34.
BEARING ASSEMBLIES INCLUDING SUPERHARD BEARING ELEMENTS CONFIGURED TO PROMOTE LUBRICATION AND/OR COOLING THEREOF, BEARING APPARATUS INCLUDING THE SAME, AND RELATED METHODS
Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements (108) distributed circumferentially about an axis. Each of the superhard bearing elements includes a bearing surface and a side. At least one of the plurality of superhard bearing elements includes a hollow (130) at least partially defined by a side of the superhard bearing element that is configured to force fluid toward the bearing surface during operation. The bearing assembly may also include a support ring that carries the superhard bearing elements.
A bearing assembly (710a, 710b) includes a support ring (720b), a plurality of bearing-element carrier members (724) coupled to the support ring, and a plurality of superhard bearing elements (730b) having a lateral periphery extending between a base and a superhard bearing surface. At least one superhard bearing element (730b) of the plurality of superhard bearing elements is attached to each of the plurality of bearing-element carrier members (724). A bearing apparatus includes a rotor (710a), a stator (710b), and a bearing assembly (710a, 710b). A method for assembling a bearing assembly includes attaching at least one superhard bearing element (730b) to each of a plurality of bearing-element carrier members (724) and coupling the plurality of bearing-element carrier members (724) to a support ring (720b).
Embodiments of the invention are directed to bearing assemblies configured to effectively carry nonuniform loads, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, under some operational conditions, one or more portions (220a) of the bearing assemblies and bearing apparatus may be preferentially loaded, such as to carry preferentially higher loads (e.g., radial and/or axial loads) than other portion(s) of the bearing assemblies and bearing apparatus.
Embodiments of the invention are directed to compact bearing assemblies configured to operate in small spaces and/or in harsh environments, bearing apparatuses including such bearing assemblies, and method of operating such bearing assemblies and apparatuses. For instance, one or more compact bearing assemblies may at least partially rotatably secure a shaft of a power generation unit to a housing thereof. Also, a first compact bearing assembly (100) may connect or couple to the shaft and may rotatably engage a second compact bearing assembly (200), which may be connected or otherwise secured to the housing.
Embodiments relate to polycrystalline diamond compacts ("PDCs") including a polycrystalline diamond ("PCD") table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.
Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, the bearing assembly includes a support ring (102) extending circumferentially about a central axis and a plurality of superhard bearing elements (110) distributed circumferentially about the central axis. Each of the superhard bearing elements is mounted to the support ring and includes a bearing surface (118). The bearing assembly further includes one or more thermal management elements including at least one thermally conductive structures or at least one of the superhard tables exhibiting a non-uniform thickness structured to promote cooling thereof during use. The thermal management elements are in thermal communication with the bearing surfaces and are configured to promote heat transfer away from the bearing surfaces.
F16C 17/08 - Sliding-contact bearings for exclusively rotary movement for axial load only for supporting the end face of a shaft or other member, e.g. footstep bearings
F16C 17/04 - Sliding-contact bearings for exclusively rotary movement for axial load only
Embodiments of the invention are directed to bearing assemblies configured to effectively provide heat dissipation for bearing elements, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed about an axis. Each superhard bearing element of the plurality of superhard bearing elements has a superhard table including a superhard surface. The bearing assembly includes a support ring structure coupled to the plurality of superhard bearing elements. One or more of the superhard bearing elements includes a superhard table, which may improve heat transfer from such superhard bearing elements.
Embodiments disclosed herein are directed to a system for removing road material. In an embodiment, the system may include a milling drum and at least one pick mounted on the milling drum. The pick may include polycrystalline diamond at least partially forming one or more working surfaces of the pick.
This disclosure relates to a system for removing road material. In an embodiment, the system may include a milling drum and at least one pick mounted on the milling drum. Furthermore, the pick may include polycrystalline diamond at least partially forming one or more working surfaces of the pick.
Embodiments of the invention are directed to roll assemblies configured to exhibit improved wear resistance of stud elements. Accordingly, the roll assemblies of may improve and/or increase the useful life of high pressure grinding roll apparatuses. In an embodiment, one or more stud elements (120) may include superhard material, which may provide superior wear resistance characteristics and may increase the useful life of the rolls assemblies (100) and high pressure grinding roll apparatuses.
Bearing assemblies (110, 120) are configured to effectively provide heat distribution from and/or heat dissipation for bearing element, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. The bearing assembly includes a plurality of superhard bearing elements (130a, 130b) distributed about an axis. Each superhard bearing element of the plurality of superhard bearing elements has a superhard material including a superhard surface. A support ring structure (150) includes a support ring (151) that supports the plurality of superhard bearing elements and a thermally-conductive structure (160) in thermal communication with the superhard table of each of the plurality of superhard bearing elements. The thermally-conductive structure has a higher thermal conductivity than the support ring of the support ring structure.
F16C 17/24 - Sliding-contact bearings for exclusively rotary movement characterised by features not related to the direction of the load with devices affected by abnormal or undesired conditions, e.g. for preventing overheating, for safety
Bearing apparatuses are disclosed in which one bearing surface of the bearing apparatus includes diamond, while another bearing surface includes a non-diamond superhard material (e.g., silicon carbide). For example, a bearing apparatus may include a bearing stator assembly and a bearing rotor assembly. The bearing stator assembly and bearing rotor assembly each include a support ring and one or more superhard bearing elements generally opposed to one another. The bearing surface(s) of the rotor or stator may include diamond, while the bearing surface(s) of the other of the rotor or stator do not include diamond. Another bearing apparatus may include both thrust- and radial bearing components. The generally opposed thrust- bearing elements may include diamond, while the generally opposed radial bearing elements may not include diamond, but include a non- diamond superhard material, such as silicon carbide.
A cutter assembly (200) for use on a tunnel boring machine (10) may include a cutter ring (202) extending circumferentially about a central axis (222). The cutter ring (202) may include a radially inner surface (202B) and a radially outer surface (202A). The cutter assembly (200) may also include superabrasive cutting elements (214) distributed circumferentially about the axis. Each of the superabrasive cutting elements may be attached to the cutter ring (202) and may include a polycrystalline diamond ("PCD") body (216) having a working surface. At least a number of the cutting elements may extend beyond the outer surface (202A) of the cutter ring.
A disc cutter for use on a tunnel boring machine (10) may include a shaft and a cutter assembly (213) rotatably mounted on the shaft (202). The cutter assembly may include a cutter ring (206) extending circumferentially about a central axis (230) and one or more bearing apparatuses (212A, 212B) rotatably mounting the cutter assembly to the shaft. Each bearing apparatuses may include a rotor (226) extending circumferentially about the central axis and a first plurality of superhard bearing elements (248) distributed circumferentially about the central axis. Each first superhard bearing element may be attached to the rotor and may include a bearing surface (254). The bearing apparatuses may further include a stator (224) extending circumferentially about the central axis and a second plurality of superhard bearing elements (234) attached to the stator that are generally opposed to the first plurality of superhard bearing elements of the rotor.
A roller bearing apparatus (100) includes a rotor (102; 104) having first superhard raceway elements (110; 122) distributed circumferentially about an axis (114). Each first superhard raceway element includes a raceway surface (118; 124) configured to form a first portion of a raceway. The apparatus includes a stator (104; 102) including second superhard raceway elements (122; 110) generally opposed to the first superhard raceway elements (110; 122). Each second superhard raceway element includes a raceway surface configured to form a second portion of the raceway. The apparatus includes rolling elements (128) interposed between the rotor and stator and positioned and configured to roll on the raceway. One or more of the rolling elements may be configured to elastically deform on the raceway during use. At least a portion of the raceway exhibits a first modulus of elasticity at least 3 to 50 times greater than a second modulus of elasticity of at least a portion of the one or more of the rolling elements.
Various embodiments of the invention relate to bearing assemblies, apparatuses and motor assemblies that include geometric features configured to impart a selected amount of heat transfer and/or hydrodynamic film formation. In an embodiment, a bearing assembly may include a plurality of superhard bearing pads distributed circumferentially about an axis. At least some of the plurality of superhard bearing pads may include a plurality of sub-superhard bearing elements defining a bearing surface. At least some of the plurality of sub-superhard bearing elements may be spaced from one another by one or more voids to impart a selected amount of heat transfer and hydrodynamic film formation thereon during operation. The bearing assembly may also include a support ring that carries the plurality of superhard bearing pads. In addition, at least a portion of the sub-superhard bearing elements may extend beyond the support ring.
Bearing components, bearing assemblies and related methods are provided. In one embodiment, a bearing element includes a base layer (120) and a polycrystalline diamond (PCD) layer (118) comprising a plurality of PCD elements coupled with the base layer wherein each PCD element comprising a substrate (112) and a diamond table (124). The plurality of PCD elements may be fit together to form a substantially continuous bearing surface. For example, the diamond tables may exhibit substantially square or rectangular geometries that are fit together to define the bearing surface. In other embodiments, the bearing elements may be spaced apart from one another. In other embodiments, the bearing clement may include a single PCD element formed from a prefabricated PCD compact or cutting tool blank. Various bearing assemblies may incorporate such a bearing element including, for example, thrust bearings, journal bearings, and tilting pad bearing assemblies.
F16C 17/14 - Sliding-contact bearings for exclusively rotary movement characterised by features not related to the direction of the load specially adapted for operating in water
F16C 17/18 - Sliding-contact bearings for exclusively rotary movement characterised by features not related to the direction of the load with floating brasses or bushes, rotatable at a reduced speed
F16C 17/06 - Sliding-contact bearings for exclusively rotary movement for axial load only with tiltably-supported segments, e.g. Michell bearings
F16C 33/12 - Structural composition; Use of special materials or surface treatments, e.g. for rust-proofing
Embodiments relate to tilting superhard bearing element bearing assemblies and apparatuses. The disclosed assemblies/apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly includes a support ring (902) and a plurality of superhard bearing elements (904) each of which is tilted and/or tiltably secured relative to the support ring (902) and distributed circumferentially about an axis. Each of the superhard bearing elements (904) includes a bearing surface (916) and a base portion (920). The base portion (920) of the at least one of the superhard bearing elements (904) includes a curved tilting feature (924) configured to allow the at least one of the superhard bearing elements (904) to be tiltable about a tilt axis. The bearing assembly includes retaining features (924) that secure the superhard bearing elements (904) to the support ring (902).
An injection mold component for use in an injection mold 120, comprising: a cemented carbide substrate; a superhard material 270 bonded to the cemented carbide substrate and forming a wear-resistant surface; and wherein at least one of: the wear-resistant surface at least partially defines an internal diameter of an ejector sleeve; or the wear-resistant surface is disposed on one or more side surfaces of a slide body 240. Such injection mold components, assemblies, and systems may decrease wear of certain injection mold components, which may result in improved productivity of the injection mold and molding systems that utilize such components.
B29C 45/40 - Removing or ejecting moulded articles
B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
53.
BEARING ASSEMBLIES, APPARATUSES, AND MOTOR ASSEMBLIES USING THE SAME
Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, a bearing assembly (100) may include a plurality of superhard bearing elements (108) distributed circumferentially about an axis (116). Each of the superhard bearing elements (108) may include a bearing surface (114). At least one of the plurality of superhard bearing elements (108) may include at least one texture feature that may be formed in a lateral surface thereof. The bearing assembly (100) may also include a support ring (102) that carries the superhard bearing elements.
In an embodiment, a roller bearing assembly (100) may include superhard bearing elements (106) distributed circumferentially about an axis (108), with gaps (107) located between adjacent ones of the superhard bearing elements (106). Each of the superhard bearing elements (106) may include a bearing surface (112) and a pair of side surfaces (106B) intersecting the bearing surface (112). Each of the side surfaces (106B) may form a respective oblique angle relative to the axis. The roller bearing assembly (10) may include a support ring (102) having the superhard bearing elements (106) affixed thereto. The bearing surfaces (112) of the superhard bearing elements (106) may be positioned and configured to form at least a portion of a superhard raceway for rolling elements to roll over. The oblique angle may be selected to at least partially inhibit the gaps (107) from impeding the rolling elements during operation.
F16C 19/26 - Bearings with rolling contact, for exclusively rotary movement with bearing rollers essentially of the same size in one or more circular rows, e.g. needle bearings for radial load mainly with a single row of rollers
For drill bit cutter indexing, a housing (310) is disposed in a drill bit (100). An indexing cog (305) is in physical communication with a cutter (115) and interlocks with the housing (310) in a first index position (325) of a plurality of index positions (325) in response to a first compressive load applied to the cutter (115). A motivator (315) disengages the indexing cog (305) from the housing (310) and positions the indexing cog (305) to interlock with the housing (310) at an initial second index position (325) in response to a removal of the compressive load from the cutter (115).
Embodiments relate to polycrystalline diamond compacts ("PDCs") and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond ("PCD") table is infiltrated with a low viscosity cobalt-based alloy infiltrant. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature ("HPHT") process. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom to form an at least partially leached PCD table. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process effective to at least partially infiltrate the at least partially leached PCD table with an alloy infiltrant comprising at least one of a cobalt- based or nickel based alloy infiltrant having a composition at or near a eutectic composition of the alloy infiltrant.
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
The bearing assembly includes a support ring (102) to which one or more superhard bearing elements (106) are mounted. The support ring (102) includes one or more relief features (118) configured to reduce residual stresses in the superhard bearing elements (106) that are induced by brazing the superhard bearing elements (106) to the support ring (10), operational loads, other processes, or combinations of the foregoing. Reducing the residual stresses in the superhard bearing elements (106) may help prevent damage to the superhard bearing elements (106). The bearing assembly may be used in subterranean drilling systems and/or other types of systems.
Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, a bearing assembly 100 includes a plurality of superhard bearing elements 108 distributed circumferentially about an axis 124. At least some of the superhard bearing elements 108 may include a first end surface 118, a second end surface 120 generally opposite the first end surface 118, a first side surface 114 extending between the first end surface 118 and the second end surface 120, a second side surface 116 generally opposite the first side surface 114, and a bearing surface 122 extending between the first end surface 118, the second end surface 120, the first side surface 114 and the second side surface 116. Such superhard bearing elements 108 may also include a ramped feature 130 negatively sloping away from the bearing surface 122. The bearing assembly may further include a support ring 102 that carries the plurality of superhard bearing elements 108.
In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
In an embodiment, a bearing assembly includes superhard bearing elements distributed circumferentially about an axis. At least one of the superhard bearing elements may include a first arcuate end portion, a second arcuate end portion, a first substantially planar face, a second substantially planar face, and a bearing surface. The first and second arcuate end portions may be generally opposite each other. The first substantially planar face may extend between the first and second arcuate end portions. The second substantially planar face may be generally opposite the first substantially planar face. The first substantially planar face may have a length greater than a length of the second substantially planar face. The bearing surface may extend between the first arcuate end portion, the second arcuate end portion, the first substantially planar face, and the second substantially planar face. The bearing assembly includes a support ring that carries the superhard bearing elements.
Embodiments of the invention relate to tilting pad bearing assemblies (100) and apparatuses. The disclosed tilting pad bearing assemblies and apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly or apparatus includes a support ring (102) and a plurality of tilting pads (104). Each tilting pad (104) is tilted and/or tiltably secured relative to the support ring (102). In some embodiments, one or more of the tilting pads (104) include a plurality of superhard bearing segments (126) assembled to form a superhard bearing surface (116). One or more seams (136) are positioned between adjacent superhard bearing segments (126) of the superhard bearing segments (126). In other embodiments, one or more of the tilting pads (104) may include at least one or only one superhard bearing segment (126), such as a polycrystalline diamond bearing segment.
In an embodiment, a polycrystalline diamond compact ("PDC") includes a substrate and a pre-sintered polycrystalline diamond ("PCD") table bonded to the substrate. The pre-sintered PCD table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending between the upper surface and the back surface. The pre-sintered PCD table includes a region including at least a residual amount of at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, and a bonding region. The at least one interstitial constituent includes at least one metal carbonate and/or at least one metal oxide. The region extends inwardly from the upper surface and the at least one lateral surface.
E21B 10/46 - Drill bits characterised by wear resisting parts, e.g. diamond inserts
63.
INJECTION MOLD INSERTS INCLUDING A MOLD CAVITY AT LEAST PARTIALLY DEFINED BY A SUPERHARD MATERIAL, AND RELATED INJECTION MOLD ASSEMBLIES, PRESSES, AND METHODS
Embodiments relate to injection mold assemblies that include superhard materials, such as polycrystalline diamond compacts, and related injection mold presses, components, and methods. The superhard materials are positioned to define at least a portion of a mold cavity for injection molding. Superhard materials may be fully or partially encapsulated by a substrate and the superhard materials and substrate may be secured to the injection mold. Superhard materials may be formed or otherwise separated from a substrate and secured to the injection mold without support of a substrate. Superhard materials may also be attachable to an injection mold to define only a portion of a mold cavity. In an embodiment, an injection mold insert includes a superhard material for insertion into a generic cavity within an injection mold assembly.
In an embodiment, a method of fabricating a polycrystalline diamond compact ("PDC") includes forming a polycrystalline diamond ("PCD") table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature ("HPHT") process. The PCD table includes bonded diamond grains defining interstitial regions, with the metal- solvent catalyst disposed therein. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process under diamond-stable temperature-pressure conditions to partially infiltrate the at least partially leached PCD table with an infiltrant. A maximum temperature (T), a total process time (t), and a maximum pressure (P) of the second HPHT process are chosen so that β is about 2 °Celsius-hours/gigapascals ("°C.h/GPa") to about 325 °C.h/GPa, with β represented as β = tT./P.
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
E21B 10/567 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
65.
BEARING ASSEMBLY INCLUDING BEARING SUPPORT RING CONFIGURED TO REDUCE THERMAL WARPING DURING USE. BEARING APPARATUSES USING THE SAME, AND RELATED METHODS
Various embodiments relate to a bearing assembly (100) including a support ring (102) configured to reduce thermal warping under operational temperature conditions, a bearing apparatus that may utilize such a thrust-bearing assembly, and applications that incorporate the disclosed bearing apparatuses such as downhole motors in subterranean drilling systems, directional drilling systems, and many other apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements (106) distributed circumferentially about an axis. The thrust-bearing assembly further includes a support ring having the plurality of superhard bearing elements mounted thereto. The support ring includes at least one thermal-warping-reducing feature configured to reduce a radial moment, compared to if the at least one thermal-warping-reducing feature were absent from the support ring, which is thermally induced in the support ring when the support ring and the plurality of superhard bearing elements are exposed to operational temperature conditions.
In an embodiment, a porous composite particulate material includes a plurality of composite particles. Each composite particle includes an acid-base-resistant core particle at least partially surrounded by one or more layers of acid-base-resistant shell particles. The shell particles are adhered to the core particle by a polymeric layer. The shell particles and/or core particles may be made from an acid-base-resistant material that is stable in harsh chemical conditions. For example, the shell particles and/or core particles may be made from diamond, graphitic carbon, silicon carbide, boron nitride, tungsten carbide, niobium carbide, zirconia, noble metals, acid-base stable highly cross- linked polymers, acid-base stable at least partially cross-linked polymers, titania, alumina, thoria combinations of the foregoing, or other acid-base-resistant materials. The porous composite particulate materials disclosed herein and related methods and devices may be used in separation technologies, including, but not limited to, chromatography and solid phase extraction.
B01J 20/286 - Phases chemically bonded to a substrate, e.g. to silica or to polymers
B01J 20/28 - Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
B01J 2/00 - Processes or devices for granulating materials, in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
67.
POLYCRYSTALLINE DIAMOND COMPACTS, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS
Embodiments of the invention relate to polycrystalline diamond ("PCD") exhibiting enhanced diamond- to-diamond bonding. In an embodiment, polycrystalline diamond compact ("PDC") includes a PCD table having a maximum thickness. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds ("Oe") or more and a specific magnetic saturation of about 15 Gauss -cm3/grams ("G-cm3/g") or less. The PDC includes a substrate having an interfacial surface that is bonded to the PCD table. The interfacial surface exhibits a substantially planar topography. Other embodiments are directed to methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
In an embodiment, a polycrystalline diamond compact ("PDC") comprises a cemented carbide substrate including a first cemented carbide portion exhibiting a first concentration of chromium carbide and a second cemented carbide portion bonded to the first cemented carbide portion and exhibiting a second concentration of chromium carbide that is greater than the first concentration. The PDC further comprises a polycrystalline diamond ("PCD") table bonded to the first cemented carbide portion. The PCD table includes a plurality of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween, with the plurality of bonded diamond grains defining a plurality of interstitial regions. The PCD table includes chromium present in a concentration less than about 0.25 weight %.
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
E21B 10/567 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
E21B 10/573 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
69.
POLYCRYSTALLINE DIAMOND COMPACTS, AND RELATED METHODS AND APPLICATIONS
Embodiments of the invention relate to polycrystalline diamond compacts ("PDCs") and methods of fabricating polycrystalline diamond tables and PDCs in a manner that facilitates removal of metal-solvent catalyst used in the manufacture of polycrystalline diamond tables of such PDCs. In an embodiment, sacrificial particles may be mixed with diamond particles that facilitate removal of the metal- solvent catalyst from the sintered polycrystalline diamond table during leaching.
B22F 3/24 - After-treatment of workpieces or articles
B22F 5/00 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
BEARING ASSEMBLY INCLUDING AT LEAST ONE SUPERHARD BEARING ELEMENT HAVING AT LEAST ONE REGISTRATION FEATURE, BEARING APPARATUS INCLUDING SAME, AND METHODS FOR MAKING SAME
Embodiments of the invention relate to a bearing assembly including at least one superhard bearing element having at least one bearing registration feature configured to facilitate orientating of a curved, pre-machined bearing surface thereof with respect to a bearing body, methods of fabricating such bearing assemblies, and bearing apparatuses incorporating such bearing assemblies. Subterranean drilling systems incorporating such bearing assemblies are also disclosed.
A heating apparatus (20) for induction heating is disclosed. The heating apparatus may comprise a bearing ring (32), at least one bearing element (74) disposed in the bearing ring (32), and a braze material (80) adjacent to the at least one bearing element (74) and the bearing ring (32). The heating apparatus may additionally comprise an inductor (24) positioned radially adjacent to at least a portion of the bearing ring. A current source (22) may be electrically coupled to the inductor. A bearing orienting member (34) may also abut a surface of the at least one bearing element. The bearing orienting member (34) may orient a surface of the at least one bearing element. A heating method is also disclosed.
In an embodiment, a bearing apparatus comprises a first bearing assembly (202) including a plurality of circumf erentially-spaced first bearing elements (212) each of which includes a first bearing surface (214). The bearing apparatus further includes a second bearing assembly (204) including a plurality of circumf erentially-spaced second bearing elements (224) each of which includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation. At least one of the second bearing elements may be circumf erentially spaced from an adjacent one of the second bearing elements by a lateral spacing greater than a lateral dimension of the at least one of the second bearing elements.
E21B 4/00 - Drives for drilling, used in the borehole
73.
POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A CEMENTED TUNGSTEN CARBIDE SUBSTRATE THAT IS SUBSTANTIALLY FREE OF TUNGSTEN CARBIDE GRAINS EXHIBITING ABNORMAL GRAIN GROWTH AND APPLICATIONS THEREFOR
Embodiments relate to polycrystalline diamond compacts ("PDCs") including a polycrystalline diamond ("PCD") table that is substantially free of defects formed due to abnormal grain growth of tungsten carbide grains, and methods of fabricating such PDCs. In an embodiment, a PDC comprises a cemented tungsten carbide substrate including an interfacial surface that is substantially free of tungsten carbide grains exhibiting abnormal grain growth, and a PCD table bonded to the interfacial surface of the cemented tungsten carbide substrate. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a metal-solvent catalyst disposed therein. The PCD table may be substantially free of chromium or the PCD table and the cemented tungsten carbide substrate may each include chromium.
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
E21B 10/573 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
74.
POLYCRYSTALLINE DIAMOND, POLYCRYSTALLINE DIAMOND COMPACT, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS
Embodiments of the invention relate to polycrystalline diamond ("PCD") exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds ("Oe") or more and a specific magnetic saturation of about 15 Gauss cm3/grams ("G cm3/g") or less. Other embodiments are directed to polycrystalline diamond compacts ("PDCs") employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to a HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a method includes subjecting a mixture to heat and pressure sufficient to form a PCD material. The mixture comprises a plurality of diamond particles exhibiting a diamond particle size distribution characterized, in part, by a parameter θ that is less than about 1.0, where Φ=x/6σ, x is the average particle size of the diamond particle size distribution, and σ is the standard deviation of the diamond particle size distribution. In an embodiment, the diamond particle size distribution can be generally modeled by the following equation: CPFT/100= Dn-Dns/Dnl-Dns, wherein CPFT is the cumulative percent finer than, D is diamond grain size, DL is the largest- sized diamond grain, Ds is the smallest-sized diamond grain, and n is a distribution modulus.
Hydrodynamic bearing assemblies and apparatuses are disclosed. Such hydrodynamic bearing assemblies may be employed in bearing apparatuses for use in downhole motors of a subterranean drilling system or other mechanical systems. In one embodiment of the present invention, a hydrodynamic bearing assembly includes a plurality of bearing segments distributed circumferentially about an axis. Each bearing segment includes a superhard bearing surface. The plurality of bearing segments define a plurality of seams. Each seam is formed between circumferentially-adjacent bearing segments of the plurality of bearing segments. Further embodiments of the present invention include hydrodynamic bearing apparatuses and downhole motors that may utilize any of the disclosed hydrodynamic bearing assemblies.
E21B 4/00 - Drives for drilling, used in the borehole
F16C 17/04 - Sliding-contact bearings for exclusively rotary movement for axial load only
F16C 17/02 - Sliding-contact bearings for exclusively rotary movement for radial load only
77.
SEPARATION DEVICE AND CHEMICAL REACTION APPARATUS MADE FROM POLYCRYSTALLINE DIAMOND, APPARATUSES INCLUDING SAME SUCH AS SEPARATION APPARATUSES, AND METHODS OF USE
A separation device includes a body (50) of sintered diamond particles. The body (50) includes a proximal inlet end (54), a distal outlet end (52), and a plurality of interconnected pores (62) extending therebetween.
Methods of manufacturing a superabrasive element and/or compact are disclosed. In one embodiment, a superabrasive volume including a tungsten carbide layer may be formed. Polycrystalline diamond elements and/or compacts are disclosed. Rotary drill bits for drilling a subterranean formation and including at least one superabrasive element and/or compact are also disclosed.
B24D 3/10 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic for porous or cellular structure, e.g. for use with diamonds as abrasives
B24D 18/00 - Manufacture of grinding tools, e.g. wheels, not otherwise provided for
79.
SUPERABRASIVE ELEMENT COMPRISING ULTRA-DISPERSED DIAMOND GRAIN STRUCTURES, STRUCTURES UTILIZING SAME, AND METHODS OF MANUFACTURE
Superabrasive elements, methods of fabricating such elements, and applications utilizing such elements. In one embodiment, a superabrasive element includes a mass of polycrystalline diamond including ultra-dispersed diamond grain structures present in an amount greater than zero weight percent and less than about 75 weight percent of the mass of polycrystalline diamond. Various structures and apparatuses that utilize the superabrasive elements, such as polycrystalline diamond compacts (PDCs) and drill bits are disclosed. Methods of manufacture are also disclosed.
C04B 35/52 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite
Embodiments of the present invention relate to diamond-silicon carbide composites, superabrasive compacts including such diamond-silicon carbide composites, and methods of fabricating such diamond-silicon carbide composites and superabrasive compacts. In one embodiment, a superabrasive compact includes a substrate and a superabrasive table bonded to the substrate. Thee superabrasive table comprises diamond-silicon carbide composite including a matrix comprising nanometer-sized silicon carbide grains and micrometer-sized diamond grains dispersed through the matrix. In another embodiment, a method of fabricating a superabrasive compact is disclosed. An assembly comprising a mixture including diamond particles and silicon is formed. The silicon comprises amorphous silicon, crystalline silicon crystallized from amorphous silicon formed by a milling process, or combinations thereof. A substrate is positioned in proximity to the mixture. The assembly is subjected to heat and pressure to form a superabrasive compact comprising a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including diamond grains dispersed through a matrix of silicon carbide grains.
B24D 3/10 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic for porous or cellular structure, e.g. for use with diamonds as abrasives
B24D 18/00 - Manufacture of grinding tools, e.g. wheels, not otherwise provided for
In one embodiment of the present invention, a method of fabricating a superabrasive article is disclosed. A mass of unsintered diamond particles may be infiltrated with metal-solvent catalyst from a metal-solvent- catalyst-containing material to promote formation of a sintered body of diamond grains including interstitial regions. At least a portion of the interstitial regions may also be infiltrated with silicon from a silicon- containing material. The silicon reacts with the sintered body to form silicon carbide within a portion of the interstitial regions.
B24D 3/10 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic for porous or cellular structure, e.g. for use with diamonds as abrasives
B24D 18/00 - Manufacture of grinding tools, e.g. wheels, not otherwise provided for
82.
SUPERABRASIVE MATERIALS AND METHODS OF MANUFACTURE
Methods of manufacturing sintered superabrasive structures are disclosed. For example, a plurality of agglomerated granules comprising at least one superabrasive material may be provided and exposed to a pressure and a temperature sufficient to sinter the at least one superabrasive material. In another example, a plurality of agglomerated granules comprising diamond may be provided and exposed to a pressure and a temperature sufficient to form polycrystalline diamond. Articles of manufacture including at least one superabrasive material are disclosed. For example, a polycrystalline diamond compact may comprise a volume of polycrystalline diamond bonded to a substrate, wherein the volume of polycrystalline diamond includes a plurality of agglomerated granules which have been sintered. A drill bit comprising at least one cutting element including a volume of polycrystalline diamond bonded to a substrate wherein the volume of polycrystalline diamond includes a plurality of agglomerated granules which have been sintered is disclosed.
B01J 3/06 - Processes using ultra-high pressure, e.g. for the formation of diamonds; Apparatus therefor, e.g. moulds or dies
B24D 3/08 - Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic for close-grained structure, e.g. using metal with low melting point
E21B 10/567 - Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
83.
CUTTING ELEMENT APPARATUSES, DRILL BITS INCLUDING SAME, METHODS OF CUTTING, AND METHODS OF ROTATING A CUTTING ELEMENT
A rotary drill bit for drilling a subterranean formation may comprise a bit body, a cutting element coupled to the bit body, and a torque-generating assembly configured to apply torque, either continuously or periodically, to the cutting element. The torque- generating assembly may be powered by the rotary motion of the rotary drill bit or may be hydraulically or electrically powered. The cutting element may comprise a substrate, a table of superabrasive material disposed on an end of the substrate, and at least one impelling feature formed along the exterior surface of the substrate. In addition, a method of rotating a cutting element coupled to a drill bit for drilling a subterranean formation may comprise providing a cutting element comprising a table bonded to a substrate, coupling the substrate of the cutting element to a drill bit body, and applying torque to the substrate of the cutting element.
Bearing apparatuses including contacting bearing surfaces having superhard materials are disclosed. In one embodiment, the present invention relates to bearings including polycrystalline diamond inserts or compacts defining a plurality of surfaces that move relative to one another and contact one another. For example, apparatuses may include radial bearings, or other bearings including arcuate bearing surfaces that move in relation to one another, without limitation. In one embodiment, a superhard bearing element may include a superhard table (e.g., polycrystalline diamond) forming an arcuate bearing surface. Further, such a superhard bearing element may include a chamfer formed about at least a portion of a periphery of the arcuate bearing surface. Bearing apparatuses including such bearing elements and various mechanical systems are also disclosed.
patents
