Ultra-Strong and Catalyst-Free Polycrystalline Diamond Cutting Materials for One-Run-To-TD Game-Changing Drilling Technology

2021 ◽  
Author(s):  
Guodong David Zhan ◽  
Chinthaka Gooneratne ◽  
Timothy Eric Moellendick ◽  
Duanwei He ◽  
Jianhui Xu ◽  
...  
Keyword(s):  
Thermal Stability ◽  
Wear Resistance ◽  
Single Crystal ◽  
High Pressures ◽  
Impact Resistance ◽  
Polycrystalline Diamond ◽  
Processing Parameters ◽  
Catalyst Free ◽  
Single Crystal Diamond ◽  
Traditional Manufacturing

Abstract Polycrystalline diamond compact (PDC) bits have been increasing their application drilling many formations in the past 20+ years. However, their performance in drilling very hard, abrasive and interbedded formations still needs improvement. The main weak point comes from their primary cutting elements, PDC cutters, which still need improvements of wear resistance, impact resistance, and thermal stability. During the traditional manufacturing of the PDC cutters, cobalt catalyst has to be used to lower the pressure and temperature. In this study, we developed an ultra high pressure and high temperature (UHPHT) technology to make the PDC cutters without metallic catalyst into reality. Through this development, we can generate pressures of 14 GPa-35 GPa, which is three to seven times of that in the traditional PDC cutter manufacturing technology. In addition, the extreme high temperatures ranging from 1,900 °C to 2,300 °C are achieved, which is 500-900 °C higher than that in traditional process. Using this UHPHT technology, we successfully processed ultra-strong and catalyst-free PDC materials with two high pressures at 14 GPa and 16 GPa, respectively, to study the different responses of the material properties from different processing parameters. The new process applied industry available micro-sized synthetic diamond powders as starting material to eliminate the large volume shrinkage in phase transformation from graphite to diamond which is typically experienced in traditional manufacturing process. The hardness of the 14-GPa CFPCD materials reaches the top limit of the single crystal diamond, more than double that of the traditional PDC cutters. The material also possesses the near-metallic fracture toughness – more than two times of the traditional PDC cutters. Furthermore, the 16-GPa CFPCD material breaks all four single crystal diamond indenters in Vickers hardness tester, an indication of the world's hardest material in the family of diamonds. As a result, the material exhibits industry-recorded wear resistance and thermal stability. The combination of these breakthrough properties of the new CFPCD materials activates the goal in the effort of "One-Run-To-TD" in drilling operation, after the implementation of CFPCD materials as PDC cutters for PDC drill bits.

scholarly journals Ultrastrong catalyst-free polycrystalline diamond

2020 ◽  
Vol 10 (1) ◽  
Author(s):  
Qiang Li ◽  
Guodong Zhan ◽  
Dong Li ◽  
Duanwei He ◽  
Timothy Eric Moellendick ◽  
...  
Keyword(s):  
High Pressure ◽  
Wear Resistance ◽  
High Temperature ◽  
Single Crystal ◽  
Polycrystalline Diamond ◽  
Industrial Applications ◽  
Catalyst Free ◽  
Single Crystal Diamond ◽  
New Material ◽  
Polycrystalline Diamond Compact

AbstractDiamond is the hardest naturally occurring material found on earth but single crystal diamond is brittle due to the nature of catastrophic cleavage fracture. Polycrystalline diamond compact (PDC) materials are made by high pressure and high temperature (HPHT) technology. PDC materials have been widely used in several industries. Wear resistance is a key material property that has long been pursued for its valuable industrial applications. However, the inevitable use of catalysts introduced by the conventional manufacturing process significantly reduces their end-use performance and limits many of their potential applications. In this work, an ultra-strong catalyst-free polycrystalline diamond compact material has been successfully synthesized through innovative ultra-high pressure and ultra-high temperature (UHPHT) technology. These results set up new industry records for wear resistance and thermal stability for PDC cutters utilized for drilling in the oil and gas industry. The new material also broke all single-crystal diamond indenters, suggesting that the new material is too hard to be measured by the current standard single-crystal diamond indentation method. This represents a major breakthrough in hard materials that can expand many potential scientific research and industrial applications.

The Current And Future Status Of Diamond in Electronics

1995 ◽  
Vol 416 ◽  
Author(s):  
Paul R. Chalker ◽  
Ian M. ◽  
Buckley Golder
Keyword(s):  
Single Crystal ◽  
Thermal Management ◽  
Polycrystalline Diamond ◽  
Cvd Diamond ◽  
Cold Cathodes ◽  
Single Crystal Diamond ◽  
Commercial Technology ◽  
Potential Benefits ◽  
Commercial Applications ◽  
Future Status

ABSTRACTBoth passive and active electronic applications of CVD diamond have been proposed since the earliest stages of its development, largely based on an extrapolation of the superlative properties of single crystal diamond. Consequently, CVD diamond research has striven hard to match up to this expectation and significant advances have been made.CVD diamond compares favourably with natural or high pressure synthetic single crystal material for passive electronic applications. The development of CVD diamond deposition technology for thermal management has led producers to address issues such as production cost, yield and quality. CVD polycrystalline diamond is becoming a commodity material and commercial applications in thermal management are emerging. Many of these developments are expected to feed into active electronic applications and will act as a springboard for diamond into commercial technology.The active electronic applications for diamond are more demanding in terms of materials and process technologies. For example, doping, structure delineation and contact schemes have been widely demonstrated and prototype devices are showing potential benefits in sensors, detectors, photonics and cold cathodes. The current and future status of diamond electronics is reviewed.

scholarly journals Nanocrystalline diamond micro-anvil grown on single crystal diamond as a generator of ultra-high pressures

AIP Advances ◽  
2016 ◽  
Vol 6 (9) ◽  
pp. 095027 ◽  
Author(s):  
Gopi K. Samudrala ◽  
Samuel L. Moore ◽  
Nenad Velisavljevic ◽  
Georgiy M. Tsoi ◽  
Paul A. Baker ◽  
...  
Keyword(s):  
Single Crystal ◽  
High Pressures ◽  
Nanocrystalline Diamond ◽  
Single Crystal Diamond

Cutting Performances of Nano-Polycrystalline Diamond

2012 ◽  
Vol 523-524 ◽  
pp. 105-108
Author(s):  
Katsuko Harano ◽  
Hitoshi Sumiya ◽  
Daisuke Murakami
Keyword(s):  
High Temperature ◽  
Single Crystal ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
High Hardness ◽  
Direct Conversion ◽  
High Wear Resistance ◽  
Single Crystal Diamond ◽  
Anisotropic Mechanical Properties ◽  
Hard And Brittle Materials

Single-phase (binder-less) nano-polycrystalline diamond (NPD) has been synthesized by direct conversion sintering from graphite under high pressure and high temperature. NPD is characterized by extremely high hardness compared with single crystal diamond (SCD), even at high temperature. In addition, NPD has high wear resistance, no anisotropic mechanical properties, no cleavages, and high thermal stability. These characteristics suggest that NPD has high potential for use in precision cutting tools for various hard works. In order to evaluate the cutting performance of NPD, cutting tests for various cemented carbides were conducted under various conditions and the results compared with those of single crystal diamond (SCD) and conventional polycrystalline diamond containing metal binder (PCD). The results revealed that NPD has outstanding potential for precision cutting and processing of diverse hard and brittle materials.

Cutting Characteristics of Binderless Diamond Tools in High-Speed Turning of Ti-6Al-4V – Availability of Single-Crystal and Nano-Polycrystalline Diamond –

2016 ◽  
Vol 10 (3) ◽  
pp. 411-419
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
◽  
Akira Hosokawa ◽  
Takashi Ueda ◽  
Tatsuaki Furumoto ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Single Crystal ◽  
Cutting Force ◽  
High Speed ◽  
Diamond Tool ◽  
Cutting Temperature ◽  
Polycrystalline Diamond ◽  
Water Soluble ◽  
Diamond Tools ◽  
Single Crystal Diamond

In this study, the tool performance of two types of binderless diamond tools – single-crystal diamond (SCD) and nano-polycrystalline diamond (NPD) – is investigated in the high-speed cutting of titanium alloy (Ti-6Al-4V) with a water-soluble coolant. The NPD tool allows for a larger cutting force than the SCD tool by dulling of the cutting edge, despite NPD being harder than SCD. This large cutting force and the very low thermal conductivity of NPD yield a high cutting temperature above 500°C, which promotes the adhesion of the workpiece to the tool face, thereby increasing tool wear. Based on the morphology of the tool edge without scratch marks and the elemental analysis by energy-dispersive X-ray spectroscopy (EDX) of both the flank face and the cutting chips, diffusion-dissolution wear is determined to be the dominant mechanism in the diamond tool. A thin TiC layer seems to be formed in the boundary between the diamond tool and the titanium alloy at high temperatures; this is removed by the cutting chips.

Nanopatterning on Nano-Polycrystalline Diamond and Cubic Boron Nitride Using Focused Ion Beam and Heat Treatment to Fabricate Textured Cutting Tools

2016 ◽  
Vol 874 ◽  
pp. 543-548 ◽  
Author(s):  
Noritaka Kawasegi ◽  
Kazuma Ozaki ◽  
Noboru Morita ◽  
Kazuhito Nishimura ◽  
Makoto Yamaguchi ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Boron Nitride ◽  
Single Crystal ◽  
Focused Ion Beam ◽  
High Efficiency ◽  
Ion Beam ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Single Crystal Diamond

Texturing on the surface of cutting tools is an effective method to improve the friction and resultant machining performances of the tool. In this study, to fabricate nanotextures on various tools used for precision cutting, a patterning method on nanopolycrystalline diamond and cubic boron nitride tools was investigated using focused ion beam (FIB) irradiation and heat treatment. Patterning was possible using this method, and the patterning characteristics were different from those of single-crystal diamond. This method was more suitable for cutting tools compared with direct FIB machining because of its high efficiency and significantly low affected layer.

Nanoengineered Polycrystalline Diamond Composites with Advanced Wear Resistance and Thermal Stability

2021 ◽  
Author(s):  
Valery Khabashesku ◽  
Vladimir Filonenko ◽  
Rustem Bagramov ◽  
Igor Zibrov ◽  
Alexander Anokhin
Keyword(s):  
Thermal Stability ◽  
Wear Resistance ◽  
Polycrystalline Diamond

New Catalyst-Free Polycrystalline Diamond with Industry-Record Wear Resistance

2021 ◽  
Author(s):  
Guodong David Zhan ◽  
Bodong Li ◽  
Timothy Eric Moellendick ◽  
Duanwei He ◽  
Jianhui Xu
Keyword(s):  
High Pressure ◽  
Wear Resistance ◽  
Frictional Heat ◽  
Drill Bit ◽  
Ultra High Pressure ◽  
Catalyst Free ◽  
Drill Bits ◽  
Single Crystal Diamond ◽  
New Material ◽  
Metallic Catalyst

Abstract PDC drill bits are the primary drilling tools for oil and gas in most of formations. In a PDC drill bit, PDC cutters are key cutting components to engage with these formations. However, there is often a big challenge for today's PDC drill bits when drilling very hard and abrasive formation. The main weakness in the PDC cutter is due to the unavoidable use of metallic catalyst which is used to bond the diamond grains in the PDC cutters. The thermal expansion of the metallic catalysts resulting from high frictional heat at the cutter/rock interface during drilling operation is higher than that of diamond grains, causing the thermal stress between the metallic catalyst and diamond grain which can break the PDC cutter. Therefore, development of catalyst-free PDC cutters would be a game-changing technology for drill bit by delivering significant increase in performance, durability, and drilling economics. In this study, an innovative ultra-high pressure and ultra-high temperature technology was developed with ultra-high pressures up to 35 GPa, much higher than current PDC cutter technology. We report a new type of catalyst-free PDC cutting material, synthesized under one of conditions using ultra-high pressure of 16 GPa. The new material breaks all single-crystal-diamond indenters in Vickers hardness testing which sets a new world record as the hardest diamond material as of today. Also, the material shows the highest thermal stability in the family of diamonds in air at 1,200°C, which is about 600 °C higher than current PDC cutters. As a consequence of these superior properties, this new material exhibited industry-recorded wear resistance, which is four times of that of current PDC cutters. All of these achievements demonstrated a breakthrough in PDC cutter technology development and presented a feasibility for the goal of "One-Run-To-TD" game-changing drilling technology.

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