POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS WITH TRANSITION ZONES AND DOWNHOLE CUTTING TOOLS INCORPORATING THE SAME

• Main Authors: NORRIS, DWAIN, HALL, DAVID R, CROCKETT, RONALD B, KESHAVAN, MADAPUSI K, CANNON, NEIL
• Format: Patent
• Language: English; French; German
• Published: 14.09.2016
• Subjects: ALLOYS; CASTING; CHEMISTRY; EARTH DRILLING; EARTH DRILLING, e.g. DEEP DRILLING; FERROUS OR NON-FERROUS ALLOYS; FIXED CONSTRUCTIONS; GRINDING; MAKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; METALLURGY; MINING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR ASLURRY OF MINERALS FROM WELLS; PERFORMING OPERATIONS; POLISHING; POWDER METALLURGY; TOOLS FOR GRINDING, BUFFING, OR SHARPENING; TRANSPORTING; TREATMENT OF ALLOYS OR NON-FERROUS METALS; WORKING METALLIC POWDER

A cutting element may include a substrate including a plurality of metal carbide particles and a first metal binder having a first metal binder content; an outer layer of polycrystalline diamond material at an end of the cutting element, the polycrystalline diamond material including a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the interconnected diamond particles, the plurality of interstitial regions containing a second metal binder having a second metal binder content. The cutting element also includes at least one transition zone between the substrate and the outer layer, the at least one transition zone including a plurality of refractory metal carbide particles and a third metal binder having a third metal binder content, the third metal binder content being less than the first metal binder content and the second metal binder content.