US20080099249A1 - Tool with a large volume of a superhard material - Google Patents
Tool with a large volume of a superhard material Download PDFInfo
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- US20080099249A1 US20080099249A1 US11/668,254 US66825407A US2008099249A1 US 20080099249 A1 US20080099249 A1 US 20080099249A1 US 66825407 A US66825407 A US 66825407A US 2008099249 A1 US2008099249 A1 US 2008099249A1
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- Prior art keywords
- tool
- metal carbide
- superhard material
- diamond
- segment
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C35/00—Details of, or accessories for, machines for slitting or completely freeing the mineral from the seam, not provided for in groups E21C25/00 - E21C33/00, E21C37/00 or E21C39/00
- E21C35/18—Mining picks; Holders therefor
- E21C35/183—Mining picks; Holders therefor with inserts or layers of wear-resisting material
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- E21B10/573—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
- E21B10/5735—Interface between the substrate and the cutting element
Definitions
- the invention relates to an improved cutting element or insert that may be used in machinery such as crushers, picks, grinding mills, roller cone bits, rotary fixed cutter bits, earth boring bits, percussion bits or impact bits, and drag bits. More particularly, the invention relates to inserts comprised of a cemented metal carbide segment with a non-planar interface and an abrasion resistant layer of a superhard material affixed thereto using a high pressure high temperature press apparatus. Such inserts typically comprise a superhard material formed under high temperature and pressure conditions, usually in a press apparatus designed to create such conditions, cemented to a carbide segment containing a metal binder or catalyst such as cobalt. The segment is often softer than the superhard material to which it is bound.
- a cutting element or insert is normally fabricated by placing a cemented carbide segment into a container or cartridge with a layer of diamond crystals or grains loaded into the cartridge adjacent one face of the segment. A number of such cartridges are typically loaded into a reaction cell and placed in the high pressure high temperature press apparatus. The segments and adjacent diamond crystal layers are then compressed under HPHT conditions which promotes a sintering of the diamond grains to form the polycrystalline diamond structure. As a result, the diamond grains become mutually bonded to form a diamond layer over the substrate face, which is also bonded to the substrate face.
- Such inserts are often subjected to intense forces, torques, vibration, high temperatures and temperature differentials during operation. As a result, stresses within the structure may begin to form. Drill bits for example may exhibit stresses aggravated by drilling anomalies during well boring operations such as bit whirl or spalling often resulting in delamination or fracture of the abrasive layer or carbide segment thereby reducing or eliminating the cutting element's efficacy and decreasing overall drill bit wear life.
- the ceramic layer of an insert sometimes delaminates from the carbide segment after the sintering process and/or during percussive and abrasive use. Damage typically found in percussive and drag bits is a result of shear failures, although non-shear modes of failure are not uncommon. The interface between the ceramic layer and carbide segment is particularly susceptible to non-shear failure modes.
- U.S. Pat. No. 5,544,713 by Dennis which is herein incorporated by reference for all that it contains, discloses a cutting element which has a metal carbide stud having a conic tip formed with a reduced diameter hemispherical outer tip end portion of said metal carbide stud.
- U.S. Pat. No. 5,848,657 by Flood et al which is herein incorporated by reference for all that it contains, discloses domed polycrystalline diamond cutting element wherein a hemispherical diamond layer is bonded to a tungsten carbide substrate, commonly referred to as a tungsten carbide stud.
- the inventive cutting element includes a metal carbide stud having a proximal end adapted to be placed into a drill bit and a distal end portion. A layer of cutting polycrystalline abrasive material disposed over said distal end portion such that an annulus of metal carbide adjacent and above said drill bit is not covered by said abrasive material layer.
- a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to the base at an interfacial surface.
- the driving mechanism may be attached to a milling drum, a drill pipe, a trenching machine, a mining machine, or combinations thereof.
- the tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface.
- the tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface.
- a volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.
- the tip has a volume of 0.2 to 2.0 ml.
- the tip also has a rounded geometry that may be conical, semispherical, domed, or a combination thereof.
- a maximum thickness of the superhard material may be approximately equal to a maximum thickness of the first metal carbide segment.
- the superhard material may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof.
- the material may also be sintered with a catalytic element such as iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
- a catalytic element such as iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
- the first cemented metal carbide segment may have a diameter of 9 to 13 mm and may have a height of 2 to 6 mm.
- the carbide segment may also comprise a region proximate the non-planar interface that has a higher concentration of a binder than its distal region.
- the base has a second carbide segment that is brazed to the tip with a first braze that has a melting temperature from 800 to 970 degrees Celsius.
- the first braze has a melting temperature from 700 to 1200 degrees Celsius and comprises silver, gold, copper, nickel, palladium, boron, chromium, silicon, germanium, aluminum, iron, cobalt, manganese, titanium, tin, gallium, vanadium, indium, phosphorus, molybdenum, platinum, zinc, or combinations thereof.
- the second cemented metal carbide may have a volume of 0.1 to 0.4 ml and comprises a generally frustoconical geometry.
- the metal carbide segments may comprise tungsten, titanium, molybdenum, niobium, cobalt, and/or combinations thereof.
- the first end of the second segment has a cross sectional thickness of about 6 to 20 mm and the second end of the second segment has a cross sectional thickness of 25 to 40 mm.
- a portion of the superhard material is 0.5 to 3 mm away from the interface between the carbide segments.
- FIG. 1 is a cross-sectional diagram of an embodiment of attack tools on a rotating drum attached to a motor vehicle.
- FIG. 2 is an orthogonal diagram of an embodiment of an attack tool.
- FIG. 3 is an orthogonal diagram of another embodiment of an attack tool.
- FIG. 4 is an orthogonal diagram of another embodiment of an attack tool.
- FIG. 5 is an exploded perspective diagram of another embodiment of an attack tool.
- FIG. 6 is a cross-sectional diagram of an embodiment of a first cemented metal carbide segment and a superhard material.
- FIG. 7 is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material.
- FIG. 8 is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material.
- FIG. 8 a is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material.
- FIG. 9 is a perspective diagram of an embodiment of an insert incorporated in a percussion drill bit.
- FIG. 10 is a perspective diagram of an embodiment of a roller cone drill bit assembly.
- FIG. 11 is a perspective diagram of an embodiment of an excavator including a trenching attachment.
- FIG. 12 is a perspective diagram of an embodiment of an insert incorporated in a mining drill bit.
- FIG. 13 is a perspective diagram of another embodiment of an insert incorporated in a drill bit.
- FIG. 1 is a cross-sectional diagram of an embodiment of attack tools 100 on a rotating drum 101 attached to a motor vehicle 102 .
- the motor vehicle 102 may be a cold planer used to degrade manmade formations such as pavement 103 prior to the placement of a new layer of pavement.
- the motor vehicle may be a mining vehicle used to degrade natural formations or an excavating machine.
- Tools 100 may be attached to a drum 102 as shown or in other embodiments a chain may be used. As the drum or chain rotate so the tools 100 engage the formation and thereby degrade it.
- the formation may be hard and/or abrasive and cause substantial wear on prior art tools.
- the wear-resistant tool 100 of the present invention may be selected from the group consisting of drill bits, asphalt picks, mining picks, hammers, indenters, shear cutters, indexable cutters, and combinations thereof.
- FIG. 2 is an orthogonal diagram of an embodiment of an attack tool 100 comprising a base 200 suitable for attachment to a driving mechanism and a tip 201 attached to an interfacial surface 202 of the base 200 .
- the driving mechanism may be attached to a milling drum, a drill pipe, a trenching machine, a mining machine, or combinations thereof.
- the tip 201 has a first cemented metal carbide segment 203 that is bonded to a superhard material 204 at a non-planar interface 205 , the tip 201 having a curved working surface 206 opposite the interfacial surface 202 .
- the curved working surface 206 may be conical, semispherical, domed or combinations thereof.
- the tip 201 may comprise a height 207 of 4 to 10 mm and a volume of 0.2 to 0.8 ml.
- the first cemented metal carbide segment 203 may comprise a height 208 of 2 to 6 mm.
- the first metal carbide segment 203 comprises a region 209 proximate the non-planar interface 205 that has a higher concentration of a binder than a distal region 210 of the first metal carbide segment 203 to improve bonding or add elasticity to the tool.
- the volume of the superhard material 204 may be about 75% to 150% of the volume of the first cemented metal carbide segment 203 . In the some embodiments, the volume of the superhard material 204 is 95% of the volume of the first cemented metal carbide segment 203 .
- the superhard material 204 may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bounded diamond, or combinations thereof.
- the superhard material 204 may be sintered with a catalytic element comprising iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals, alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
- a catalytic element comprising iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals, alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
- the first cemented metal carbide segment 203 may have a relatively small surface area to bind with the superhard material 204 reducing the amount of superhard material required and reducing the overall cost of the attack tool. In embodiments where high temperature and high pressure processing are required, the smaller the first metal carbide segment 203 is the cheaper it may be to produce large volumes of attack tool since more segments 203 may be placed in a high temperature high pressure apparatus at once.
- FIG. 3 is an orthogonal diagram of another embodiment of an attack tool 100 with a first cemented metal carbide segment 203 .
- the braze material has a melting temperature of 800 to 970 degrees Celsius.
- the second metal carbide segment 300 may have a first end 301 that comprises a cross sectional thickness of about 6 to 20 mm and a second end 302 that comprises a cross sectional thickness of 25 to 40 mm.
- the second carbide segment 300 and the tip 201 are brazed together with a first braze material comprising a melting temperature from 700 to 1200 degrees Celsius.
- This first braze material may comprise silver, gold, copper, nickel, palladium, boron, chromium, silicon, germanium, aluminum, iron, cobalt, manganese, titanium, tin, gallium, vanadium, indium, phosphorus, molybdenum, platinum, zinc, or combinations thereof.
- the first braze material may comprise 30 to 60 weight percent nickel, 30 to 62 weight percent palladium, and 3 to 15 weight percent silicon.
- the first braze material may comprise 44.5 weight percent nickel, 45.5 weight percent palladium, 5.0 weight percent silicon, and 5.0 weight percent cobalt.
- the braze material may comprise 47.2 weight percent nickel, 46.7 weight percent palladium, and 6.1 weight percent silicon.
- Active cooling during brazing may be critical in some embodiments, since the heat from brazing may leave some residual stress in the bond between the first cemented metal carbide segment 203 and the superhard material 204 .
- the second braze material may be layered for easing the stresses that may arise when bonding carbide to carbide.
- Such braze materials may be available from the Trimet® series provided by Lucas-Milhaupt, Inc a Handy & Harman Company located at 5656 S. Pennsylvania Ave. Cudahy, Wis. 53110, USA.
- a portion of the superhard material 204 may be a distance 303 of 0.5 to 3 mm away from an interface 304 between the carbide segments 203 , 300 .
- the greater the distance 303 the less thermal damage is likely to occur during brazing. However, increasing the distance 303 may also increase the moment on the first metal carbide segment and increase stresses at the interface 304 .
- the metal carbide segments 203 , 300 may comprise tungsten, titanium, molybdenum, niobium, cobalt, and/or combinations thereof.
- the second metal carbide segment 300 comprises a generally frustoconical geometry and may have a volume of 1 to 10 ml. The geometry may be optimized to move cuttings away from the tool 100 , distribute impact stresses, reduce wear, improve degradation rates, protect other parts of the tool 100 , and/or combinations thereof.
- FIG. 4 is an orthogonal diagram of another embodiment of an attack tool 100 with cemented metal carbide segments 203 , 300 .
- the second metal carbide segment 300 may have a smaller volume than that shown in FIG. 3 , helping to reduce the weight of the tool 100 which may require less horsepower to move or it may help to reduce the cost of the attack tool 100 .
- FIG. 5 is an exploded perspective diagram of another embodiment of an attack tool 100 .
- the attack tool 100 comprises a wear-resistant base 200 suitable for attachment to a driving mechanism and a hard tip 201 attached to an interfacial surface 202 of the base 200 .
- the attack tool 100 also comprises cemented metal carbide segments 203 , 300 brazed together with a first braze 500 disposed in an interface 304 opposite the wear resistant base 200 , a shank 501 , and a second braze 502 disposed in an interfacial surface 202 between the base 200 and the second cemented carbide segment 300 .
- the second cemented metal carbide segment 300 may comprise an upper end 503 that may be substantially equal to or slightly smaller than the lower end of the first cemented metal carbide segment 203 .
- FIGS. 6-8 are cross-sectional diagrams of several embodiments of a first cemented metal carbide segment 203 and a superhard material 204 wherein the superhard material 204 comprises a thickest portion 600 approximately equal to a thickest portion 601 of the first cemented metal carbide segment 203 .
- the thickest portion 600 of the superhard material 204 may comprise a distance of 0.100 to 0.500 inch. It is believed that the greater the distance is from the tip of the superhard material to the interfacial surface 202 , the less impact a formation will have on the first cemented metal carbide segment 203 . Thus, the superhard material 204 may self buttressed and not rely on the first cemented metal carbide segment 203 for support.
- the cemented metal carbide 203 may also comprise a diameter 602 of 9 to 18 mm.
- the interface 205 between the first cemented metal carbide segment 203 and the superhard material 204 may be non-planar.
- the superhard material 204 may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof.
- the superhard material 204 may comprise layers of varying concentrations of cobalt or of another catalyst such that a lower portion of the superhard material has a higher concentration of catalyst than a curved working surface of the superhard material.
- the superhard material 204 may be at least 4,000 HK and in some embodiments it may be 1 to 20000 microns thick.
- the superhard material 204 may comprise a region 603 (preferably rear the curved working surface 206 ) that is free of binder material.
- the average grain size of the superhard material 204 may be 10 to 100 microns in size.
- the first cemented metal carbide segment 203 and the superhard material 204 may comprise many geometries.
- the superhard material 204 in FIG. 6 comprises a domed geometry 700 .
- FIG. 7 depicts the superhard material 204 comprising a generally conical geometry 701 .
- the generally conical geometry 701 may comprise a generally thicker portion 600 directly over a flat portion 702 of the interfacial surface 202 .
- the superhard material 204 comprises a blunt geometry such that its radius of curvature is relatively large compared to a radius of curvature of superhard material with a sharper geometry. Blunt geometries may help to distribute impact stresses during formation degradation, but cutting efficiency may be reduced.
- FIG. 8 comprises a conical geometry.
- the non-planar interface between the superhard material 204 and the first cemented metal carbide segment 203 may also comprise a flat portion. Sharper geometries, such as shown in FIG. 8 and FIG. 8 a , may increase cutting efficiency.
- FIG. 8 a comprises a 0.094 radius.
- FIGS. 9-13 show the current invention depicting the insert with various embodiments as an insert 900 in a percussion drill bit 901 , an insert 1000 in a roller bit 1001 , an insert 1100 in an excavator 1101 , an insert 1200 in a mining drill bit 1201 , and an insert 1300 in a threaded rock bit 1301 .
Abstract
Description
- This application is a continuation in-part of U.S. patent application Ser. No. 11/553,338 which was filed on Oct. 26, 2006 and was entitled Superhard Insert with an Interface. U.S. patent application Ser. No. 11/553,338, which is herein incorporated by reference for all that it contains, is currently pending.
- The invention relates to an improved cutting element or insert that may be used in machinery such as crushers, picks, grinding mills, roller cone bits, rotary fixed cutter bits, earth boring bits, percussion bits or impact bits, and drag bits. More particularly, the invention relates to inserts comprised of a cemented metal carbide segment with a non-planar interface and an abrasion resistant layer of a superhard material affixed thereto using a high pressure high temperature press apparatus. Such inserts typically comprise a superhard material formed under high temperature and pressure conditions, usually in a press apparatus designed to create such conditions, cemented to a carbide segment containing a metal binder or catalyst such as cobalt. The segment is often softer than the superhard material to which it is bound. Some examples of superhard materials that high temperature high pressure (HPHT) presses may produce and sinter include cemented ceramics, diamond, polycrystalline diamond, and cubic boron nitride. A cutting element or insert is normally fabricated by placing a cemented carbide segment into a container or cartridge with a layer of diamond crystals or grains loaded into the cartridge adjacent one face of the segment. A number of such cartridges are typically loaded into a reaction cell and placed in the high pressure high temperature press apparatus. The segments and adjacent diamond crystal layers are then compressed under HPHT conditions which promotes a sintering of the diamond grains to form the polycrystalline diamond structure. As a result, the diamond grains become mutually bonded to form a diamond layer over the substrate face, which is also bonded to the substrate face.
- Such inserts are often subjected to intense forces, torques, vibration, high temperatures and temperature differentials during operation. As a result, stresses within the structure may begin to form. Drill bits for example may exhibit stresses aggravated by drilling anomalies during well boring operations such as bit whirl or spalling often resulting in delamination or fracture of the abrasive layer or carbide segment thereby reducing or eliminating the cutting element's efficacy and decreasing overall drill bit wear life. The ceramic layer of an insert sometimes delaminates from the carbide segment after the sintering process and/or during percussive and abrasive use. Damage typically found in percussive and drag bits is a result of shear failures, although non-shear modes of failure are not uncommon. The interface between the ceramic layer and carbide segment is particularly susceptible to non-shear failure modes.
- U.S. Pat. No. 5,544,713 by Dennis, which is herein incorporated by reference for all that it contains, discloses a cutting element which has a metal carbide stud having a conic tip formed with a reduced diameter hemispherical outer tip end portion of said metal carbide stud.
- U.S. Pat. No. 6,196,340 by Jensen, which is herein incorporated by reference for all that it contains, discloses a cutting element insert provided for use with drills used in the drilling and boring through of subterranean formations.
- U.S. Pat. No. 6,258,139 by Jensen, which is herein incorporated by reference for all that it contains, discloses a cutting element, insert or compact which is provided for use with drills used in drilling and boring subterranean formation or in machining of metal, composites or wood-working.
- U.S. Pat. No. 6,260,639 by Yong et al., which is herein incorporated by reference for all that it contains, discloses a cutter element for use in a drill bit, having a substrate comprising a grip portion and an extension and at least a cutting layer affixed to said substrate.
- U.S. Pat. No. 6,408,959 by Bertagnolli et al., which is herein incorporated by reference for all that it contains, discloses a cutting element, insert or compact which is provided for use with drills used in the drilling and boring of subterranean formations.
- U.S. Pat. No. 6,484,826 by Anderson et al., which is herein incorporated by reference for all that it contains, discloses enhanced inserts formed having a cylindrical grip and a protrusion extending from the grip.
- U.S. Pat. No. 5,848,657 by Flood et al, which is herein incorporated by reference for all that it contains, discloses domed polycrystalline diamond cutting element wherein a hemispherical diamond layer is bonded to a tungsten carbide substrate, commonly referred to as a tungsten carbide stud. Broadly, the inventive cutting element includes a metal carbide stud having a proximal end adapted to be placed into a drill bit and a distal end portion. A layer of cutting polycrystalline abrasive material disposed over said distal end portion such that an annulus of metal carbide adjacent and above said drill bit is not covered by said abrasive material layer.
- In one aspect of the invention, a tool has a wear-resistant base suitable for attachment to a driving mechanism and also a hard tip attached to the base at an interfacial surface. The driving mechanism may be attached to a milling drum, a drill pipe, a trenching machine, a mining machine, or combinations thereof. The tip has a first cemented metal carbide segment bonded to a superhard material at a non-planar interface. The tip has a height between 4 and 10 mm and also has a curved working surface opposite the interfacial surface. A volume of the superhard material is about 75% to 150% of a volume of the first cemented metal carbide segment.
- In the preferred embodiment, the tip has a volume of 0.2 to 2.0 ml. The tip also has a rounded geometry that may be conical, semispherical, domed, or a combination thereof. A maximum thickness of the superhard material may be approximately equal to a maximum thickness of the first metal carbide segment. The superhard material may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof. The material may also be sintered with a catalytic element such as iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
- The first cemented metal carbide segment may have a diameter of 9 to 13 mm and may have a height of 2 to 6 mm. The carbide segment may also comprise a region proximate the non-planar interface that has a higher concentration of a binder than its distal region.
- In some embodiments, the base has a second carbide segment that is brazed to the tip with a first braze that has a melting temperature from 800 to 970 degrees Celsius. The first braze has a melting temperature from 700 to 1200 degrees Celsius and comprises silver, gold, copper, nickel, palladium, boron, chromium, silicon, germanium, aluminum, iron, cobalt, manganese, titanium, tin, gallium, vanadium, indium, phosphorus, molybdenum, platinum, zinc, or combinations thereof. The second cemented metal carbide may have a volume of 0.1 to 0.4 ml and comprises a generally frustoconical geometry. The metal carbide segments may comprise tungsten, titanium, molybdenum, niobium, cobalt, and/or combinations thereof. The first end of the second segment has a cross sectional thickness of about 6 to 20 mm and the second end of the second segment has a cross sectional thickness of 25 to 40 mm. A portion of the superhard material is 0.5 to 3 mm away from the interface between the carbide segments.
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FIG. 1 is a cross-sectional diagram of an embodiment of attack tools on a rotating drum attached to a motor vehicle. -
FIG. 2 is an orthogonal diagram of an embodiment of an attack tool. -
FIG. 3 is an orthogonal diagram of another embodiment of an attack tool. -
FIG. 4 is an orthogonal diagram of another embodiment of an attack tool. -
FIG. 5 is an exploded perspective diagram of another embodiment of an attack tool. -
FIG. 6 is a cross-sectional diagram of an embodiment of a first cemented metal carbide segment and a superhard material. -
FIG. 7 is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material. -
FIG. 8 is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material. -
FIG. 8 a is a cross-sectional diagram of another embodiment of a first cemented metal carbide segment and a superhard material. -
FIG. 9 is a perspective diagram of an embodiment of an insert incorporated in a percussion drill bit. -
FIG. 10 is a perspective diagram of an embodiment of a roller cone drill bit assembly. -
FIG. 11 is a perspective diagram of an embodiment of an excavator including a trenching attachment. -
FIG. 12 is a perspective diagram of an embodiment of an insert incorporated in a mining drill bit. -
FIG. 13 is a perspective diagram of another embodiment of an insert incorporated in a drill bit. -
FIG. 1 is a cross-sectional diagram of an embodiment ofattack tools 100 on arotating drum 101 attached to amotor vehicle 102. Themotor vehicle 102 may be a cold planer used to degrade manmade formations such as pavement 103 prior to the placement of a new layer of pavement. In other embodiments the motor vehicle may be a mining vehicle used to degrade natural formations or an excavating machine.Tools 100 may be attached to adrum 102 as shown or in other embodiments a chain may be used. As the drum or chain rotate so thetools 100 engage the formation and thereby degrade it. The formation may be hard and/or abrasive and cause substantial wear on prior art tools. The wear-resistant tool 100 of the present invention may be selected from the group consisting of drill bits, asphalt picks, mining picks, hammers, indenters, shear cutters, indexable cutters, and combinations thereof. -
FIG. 2 is an orthogonal diagram of an embodiment of anattack tool 100 comprising a base 200 suitable for attachment to a driving mechanism and atip 201 attached to aninterfacial surface 202 of thebase 200. The driving mechanism may be attached to a milling drum, a drill pipe, a trenching machine, a mining machine, or combinations thereof. Thetip 201 has a first cementedmetal carbide segment 203 that is bonded to asuperhard material 204 at anon-planar interface 205, thetip 201 having acurved working surface 206 opposite theinterfacial surface 202. Thecurved working surface 206 may be conical, semispherical, domed or combinations thereof. Thetip 201 may comprise aheight 207 of 4 to 10 mm and a volume of 0.2 to 0.8 ml. The first cementedmetal carbide segment 203 may comprise aheight 208 of 2 to 6 mm. The firstmetal carbide segment 203 comprises aregion 209 proximate thenon-planar interface 205 that has a higher concentration of a binder than adistal region 210 of the firstmetal carbide segment 203 to improve bonding or add elasticity to the tool. The volume of thesuperhard material 204 may be about 75% to 150% of the volume of the first cementedmetal carbide segment 203. In the some embodiments, the volume of thesuperhard material 204 is 95% of the volume of the first cementedmetal carbide segment 203. Thesuperhard material 204 may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bounded diamond, or combinations thereof. Also, thesuperhard material 204 may be sintered with a catalytic element comprising iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals, alkali earth metals, ruthenium, rhodium, palladium, chromium, manganese, tantalum or combinations thereof. - In some embodiments, the first cemented
metal carbide segment 203 may have a relatively small surface area to bind with thesuperhard material 204 reducing the amount of superhard material required and reducing the overall cost of the attack tool. In embodiments where high temperature and high pressure processing are required, the smaller the firstmetal carbide segment 203 is the cheaper it may be to produce large volumes of attack tool sincemore segments 203 may be placed in a high temperature high pressure apparatus at once. -
FIG. 3 is an orthogonal diagram of another embodiment of anattack tool 100 with a first cementedmetal carbide segment 203. In this embodiment, the braze material has a melting temperature of 800 to 970 degrees Celsius. The secondmetal carbide segment 300 may have afirst end 301 that comprises a cross sectional thickness of about 6 to 20 mm and asecond end 302 that comprises a cross sectional thickness of 25 to 40 mm. Thesecond carbide segment 300 and thetip 201 are brazed together with a first braze material comprising a melting temperature from 700 to 1200 degrees Celsius. This first braze material may comprise silver, gold, copper, nickel, palladium, boron, chromium, silicon, germanium, aluminum, iron, cobalt, manganese, titanium, tin, gallium, vanadium, indium, phosphorus, molybdenum, platinum, zinc, or combinations thereof. The first braze material may comprise 30 to 60 weight percent nickel, 30 to 62 weight percent palladium, and 3 to 15 weight percent silicon. In embodiments, the first braze material may comprise 44.5 weight percent nickel, 45.5 weight percent palladium, 5.0 weight percent silicon, and 5.0 weight percent cobalt. In other embodiments, the braze material may comprise 47.2 weight percent nickel, 46.7 weight percent palladium, and 6.1 weight percent silicon. Active cooling during brazing may be critical in some embodiments, since the heat from brazing may leave some residual stress in the bond between the first cementedmetal carbide segment 203 and thesuperhard material 204. In some embodiments, the second braze material may be layered for easing the stresses that may arise when bonding carbide to carbide. Such braze materials may be available from the Trimet® series provided by Lucas-Milhaupt, Inc a Handy & Harman Company located at 5656 S. Pennsylvania Ave. Cudahy, Wis. 53110, USA. - A portion of the
superhard material 204 may be adistance 303 of 0.5 to 3 mm away from aninterface 304 between thecarbide segments distance 303, the less thermal damage is likely to occur during brazing. However, increasing thedistance 303 may also increase the moment on the first metal carbide segment and increase stresses at theinterface 304. Themetal carbide segments metal carbide segment 300 comprises a generally frustoconical geometry and may have a volume of 1 to 10 ml. The geometry may be optimized to move cuttings away from thetool 100, distribute impact stresses, reduce wear, improve degradation rates, protect other parts of thetool 100, and/or combinations thereof. -
FIG. 4 is an orthogonal diagram of another embodiment of anattack tool 100 with cementedmetal carbide segments metal carbide segment 300 may have a smaller volume than that shown inFIG. 3 , helping to reduce the weight of thetool 100 which may require less horsepower to move or it may help to reduce the cost of theattack tool 100. -
FIG. 5 is an exploded perspective diagram of another embodiment of anattack tool 100. Theattack tool 100 comprises a wear-resistant base 200 suitable for attachment to a driving mechanism and ahard tip 201 attached to aninterfacial surface 202 of thebase 200. Theattack tool 100 also comprises cementedmetal carbide segments first braze 500 disposed in aninterface 304 opposite the wearresistant base 200, ashank 501, and asecond braze 502 disposed in aninterfacial surface 202 between the base 200 and the second cementedcarbide segment 300. - Further, the second cemented
metal carbide segment 300 may comprise anupper end 503 that may be substantially equal to or slightly smaller than the lower end of the first cementedmetal carbide segment 203. -
FIGS. 6-8 are cross-sectional diagrams of several embodiments of a first cementedmetal carbide segment 203 and asuperhard material 204 wherein thesuperhard material 204 comprises athickest portion 600 approximately equal to athickest portion 601 of the first cementedmetal carbide segment 203. Thethickest portion 600 of thesuperhard material 204 may comprise a distance of 0.100 to 0.500 inch. It is believed that the greater the distance is from the tip of the superhard material to theinterfacial surface 202, the less impact a formation will have on the first cementedmetal carbide segment 203. Thus, thesuperhard material 204 may self buttressed and not rely on the first cementedmetal carbide segment 203 for support. The cementedmetal carbide 203 may also comprise adiameter 602 of 9 to 18 mm. Theinterface 205 between the first cementedmetal carbide segment 203 and thesuperhard material 204 may be non-planar. Thesuperhard material 204 may comprise polycrystalline diamond, vapor-deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond, or combinations thereof. Thesuperhard material 204 may comprise layers of varying concentrations of cobalt or of another catalyst such that a lower portion of the superhard material has a higher concentration of catalyst than a curved working surface of the superhard material. Thesuperhard material 204 may be at least 4,000 HK and in some embodiments it may be 1 to 20000 microns thick. Thesuperhard material 204 may comprise a region 603 (preferably rear the curved working surface 206) that is free of binder material. The average grain size of thesuperhard material 204 may be 10 to 100 microns in size. - The first cemented
metal carbide segment 203 and thesuperhard material 204 may comprise many geometries. Thesuperhard material 204 inFIG. 6 comprises adomed geometry 700.FIG. 7 depicts thesuperhard material 204 comprising a generallyconical geometry 701. The generallyconical geometry 701 may comprise a generallythicker portion 600 directly over aflat portion 702 of theinterfacial surface 202. InFIGS. 6 and 7 thesuperhard material 204 comprises a blunt geometry such that its radius of curvature is relatively large compared to a radius of curvature of superhard material with a sharper geometry. Blunt geometries may help to distribute impact stresses during formation degradation, but cutting efficiency may be reduced. Thesuperhard material 204 inFIG. 8 comprises a conical geometry. The non-planar interface between thesuperhard material 204 and the first cementedmetal carbide segment 203 may also comprise a flat portion. Sharper geometries, such as shown inFIG. 8 andFIG. 8 a, may increase cutting efficiency.FIG. 8 a comprises a 0.094 radius. -
FIGS. 9-13 show the current invention depicting the insert with various embodiments as aninsert 900 in a percussion drill bit 901, aninsert 1000 in a roller bit 1001, aninsert 1100 in anexcavator 1101, aninsert 1200 in amining drill bit 1201, and aninsert 1300 in a threadedrock bit 1301. - Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
Claims (20)
Priority Applications (17)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/668,307 US7347292B1 (en) | 2006-10-26 | 2007-01-29 | Braze material for an attack tool |
US11/668,254 US7353893B1 (en) | 2006-10-26 | 2007-01-29 | Tool with a large volume of a superhard material |
US11/673,634 US8109349B2 (en) | 2006-10-26 | 2007-02-12 | Thick pointed superhard material |
US11/686,831 US7568770B2 (en) | 2006-06-16 | 2007-03-15 | Superhard composite material bonded to a steel body |
US11/691,978 US7588102B2 (en) | 2006-10-26 | 2007-03-27 | High impact resistant tool |
PCT/US2007/075670 WO2008105915A2 (en) | 2006-08-11 | 2007-08-16 | Thick pointed superhard material |
EP07873780.6A EP2049769B1 (en) | 2006-08-11 | 2007-08-16 | Thick pointed superhard material |
CN2007800377928A CN101523014B (en) | 2006-08-11 | 2007-08-16 | Thick pointed superhard material |
US11/934,245 US7740414B2 (en) | 2005-03-01 | 2007-11-02 | Milling apparatus for a paved surface |
US11/948,158 US7469756B2 (en) | 2006-10-26 | 2007-11-30 | Tool with a large volume of a superhard material |
US12/493,013 US9068410B2 (en) | 2006-10-26 | 2009-06-26 | Dense diamond body |
US12/625,908 US20100065339A1 (en) | 2006-10-26 | 2009-11-25 | Thick Pointed Superhard Material |
US12/625,728 US8028774B2 (en) | 2006-10-26 | 2009-11-25 | Thick pointed superhard material |
US12/627,009 US20100071964A1 (en) | 2006-10-26 | 2009-11-30 | Thick Pointed Superhard Material |
US12/828,287 US8960337B2 (en) | 2006-10-26 | 2010-06-30 | High impact resistant tool with an apex width between a first and second transitions |
US13/342,523 US9540886B2 (en) | 2006-10-26 | 2012-01-03 | Thick pointed superhard material |
US14/592,235 US10029391B2 (en) | 2006-10-26 | 2015-01-08 | High impact resistant tool with an apex width between a first and second transitions |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US11/553,338 US7665552B2 (en) | 2006-10-26 | 2006-10-26 | Superhard insert with an interface |
US11/668,254 US7353893B1 (en) | 2006-10-26 | 2007-01-29 | Tool with a large volume of a superhard material |
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US11/553,338 Continuation-In-Part US7665552B2 (en) | 2005-03-01 | 2006-10-26 | Superhard insert with an interface |
US11/686,831 Continuation-In-Part US7568770B2 (en) | 2006-06-16 | 2007-03-15 | Superhard composite material bonded to a steel body |
US11/934,245 Continuation-In-Part US7740414B2 (en) | 2005-03-01 | 2007-11-02 | Milling apparatus for a paved surface |
Related Child Applications (3)
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US11/668,307 Continuation US7347292B1 (en) | 2006-10-26 | 2007-01-29 | Braze material for an attack tool |
US11/673,634 Continuation-In-Part US8109349B2 (en) | 2005-03-01 | 2007-02-12 | Thick pointed superhard material |
US11/948,158 Continuation US7469756B2 (en) | 2006-10-26 | 2007-11-30 | Tool with a large volume of a superhard material |
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US7353893B1 US7353893B1 (en) | 2008-04-08 |
US20080099249A1 true US20080099249A1 (en) | 2008-05-01 |
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US11/668,307 Active US7347292B1 (en) | 2006-10-26 | 2007-01-29 | Braze material for an attack tool |
US11/668,254 Active US7353893B1 (en) | 2005-03-01 | 2007-01-29 | Tool with a large volume of a superhard material |
US11/948,158 Active US7469756B2 (en) | 2006-10-26 | 2007-11-30 | Tool with a large volume of a superhard material |
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US11/668,307 Active US7347292B1 (en) | 2006-10-26 | 2007-01-29 | Braze material for an attack tool |
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US11/948,158 Active US7469756B2 (en) | 2006-10-26 | 2007-11-30 | Tool with a large volume of a superhard material |
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CN115822594A (en) * | 2023-02-10 | 2023-03-21 | 太原向明智控科技有限公司 | Device and method for judging coal mining process of end part feed of coal mining machine |
Also Published As
Publication number | Publication date |
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US20080100124A1 (en) | 2008-05-01 |
US7469756B2 (en) | 2008-12-30 |
US7347292B1 (en) | 2008-03-25 |
US7353893B1 (en) | 2008-04-08 |
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