U.S. patent application number 12/264172 was filed with the patent office on 2009-03-05 for high energy cutting elements and bits incorporating the same.
Invention is credited to Madapusi K. Keshavan.
Application Number | 20090057033 12/264172 |
Document ID | / |
Family ID | 36803767 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090057033 |
Kind Code |
A1 |
Keshavan; Madapusi K. |
March 5, 2009 |
HIGH ENERGY CUTTING ELEMENTS AND BITS INCORPORATING THE SAME
Abstract
High energy cutting elements and bits incorporating the same are
provided. The cutting elements have at least a portion of their
cutting layers which will be exposed to high temperatures during
drilling formed from a PCBN material capable of operating at
temperatures of at least 1000.degree. C.
Inventors: |
Keshavan; Madapusi K.; (The
Woodlands, TX) |
Correspondence
Address: |
CHRISTIE, PARKER & HALE, LLP
PO BOX 7068
PASADENA
CA
91109-7068
US
|
Family ID: |
36803767 |
Appl. No.: |
12/264172 |
Filed: |
November 3, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11449523 |
Jun 7, 2006 |
7451838 |
|
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12264172 |
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60705518 |
Aug 3, 2005 |
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Current U.S.
Class: |
175/432 ;
175/433 |
Current CPC
Class: |
C04B 35/5831 20130101;
C04B 2235/3843 20130101; C04B 2235/3813 20130101; C04B 2235/3804
20130101; C04B 2235/3865 20130101; C04B 2235/786 20130101; E21B
10/567 20130101; C04B 2235/3856 20130101; C04B 2235/3886
20130101 |
Class at
Publication: |
175/432 ;
175/433 |
International
Class: |
E21B 10/573 20060101
E21B010/573 |
Claims
1. A shear cutting element comprising: a substrate; a cutting layer
over the substrate comprising at least a portion comprising PCBN
for contacting a formation during drilling, wherein said at least a
portion comprising PCBN has a thermal gradient in the range from
about 200 to 2000.degree. C./mm.
2. The cutting element as recited in claim 1 wherein said entire
cutting layer is a PCBN cutting layer.
3. The cutting element as recited in claim 2 wherein the cutting
element further comprises a PCD layer interposed between the PCBN
layer and the substrate.
4. The cutting element as recited in claim 3 wherein the PCD layer
is completely encapsulated by the PCBN layer and the substrate.
5. The cutting element as recited in claim 1 wherein the cutting
layer further comprises another portion comprising an ultra hard
material adjacent to the at least a portion comprising PCBN.
6. The cutting element as recited in claim 5 wherein the ultra hard
material is PCD.
7. The cutting element as recited in claim 1 wherein said cutting
layer comprises a plurality of portions comprising PCBN.
8. The cutting element as recited in claim 1 wherein said cutting
layer is formed from a plurality of PCBN layers bonded
together.
9. A bit as recited in claim 8 wherein said at least a portion
comprising PCBN is part of one of said plurality of layers.
10. The cutting element as recited in claim 1 wherein said at least
a portion comprising PCBN has a strength of at least 100 ksi.
11. The cutting element as recited in claim 1 wherein said at least
a portion comprising PCBN has a strength in the range of 100 ksi to
200 ksi.
12. The cutting element as recited in claim 1 wherein the cutting
layer comprises an ultra hard material portion, wherein said at
least a portion comprising PCBN forms a cutting edge of the cutting
layer.
13. The cutting element as recited in claim 12 wherein the cutting
layer comprises a periphery, wherein said at least a portion
comprising PCBN extends only along a portion of said periphery.
14. The cutting element as recited in claim 12 wherein said at
least a portion comprising PCBN forms a peripheral portion of the
cutting layer surrounding said ultra hard material portion.
15. The cutting element as recited in claim 14 wherein said at
least a portion comprising PCBN extends to the substrate.
16. The cutting element as recited in claim 12 wherein said at
least a portion comprising PCBN is spaced apart from the
substrate.
17. The cutting element as recited in claim 16 wherein said ultra
hard material portion is sandwiched between the substrate and said
at least a portion comprising PCBN.
18. The cutting element as recited in claim 12 wherein said at
least a portion comprising PCBN extends to the substrate.
19. The cutting element as recited in claim 1 wherein said at least
a portion comprising PCBN comprises greater than 90% by PCBN.
20. A shear cutting element comprising: a substrate; a cutting
layer over the substrate comprising at least a portion comprising a
thermally stable ultra hard material for contacting a formation
during drilling, wherein said at least a portion has a thermal
gradient in the range from about 200 to 2000.degree. C./mm.
21. The cutting element as recited in claim 20 wherein said
thermally stable ultra hard material comprises PCBN.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation application of U.S.
application Ser. No. 11/449,523 filed on Jun. 7, 2006 which claims
priority and is based upon U.S. Provisional Application No.
60/705,518 filed on Aug. 3, 2005, the contents of which are fully
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to cutting elements and more
specifically to high energy shear cutting elements having a cutting
layer comprising polycrystalline cubic boron nitride (PCBN) and to
bits incorporating the same and more specifically to turbine driven
bits incorporating the same.
[0003] Shear cutting elements used in earth-boring bits have a
tungsten carbide substrate body over which is bonded a
polycrystalline diamond ("PCD") material cutting layer which is
used to do the cutting. PCD materials, however, have many
limitations. For example, the thermal stability of PCD deteriorates
due to graphitization at temperatures above 650.degree. C. This is
typically caused by the air and the presence of cobalt around the
diamond crystals. Similarly, cracking tends to develop at
temperatures above 650.degree. C. due to thermal mismatch between
the diamond crystals and cobalt forming the PCD material layer.
[0004] In an effort to get PCD to operate at higher temperatures,
the catalyst found in PCD material is sometimes fully leached so as
to enhance the thermal stability of the PCD material. In such case,
the PCD can withstand temperatures up to 1000.degree. C. in air.
However, graphitization of the PCD does increase with temperatures
above 1000.degree. C. Consequently, shear cutting elements having a
PCD cutting layer cannot be used to cut earth formation when the
cutting layer temperature will exceed 650.degree. C. or
1000.degree. C., depending on whether the PCD layer is leached.
[0005] Cutting layer temperatures of cutting elements on bits
driven by high speed turbines or motors (hereinafter "turbine
bits") exceed 1000.degree. C. These bits are operated at greater
than 300 RPM, to cut formations having a strength greater than
10,000 psi. Turbines driving turbine bits typically operate at RPM
levels of 1,000 RPM or greater and the turbine bits rotate at
levels of about 300 RPM or greater.
[0006] PCBN has been disclosed for use in cutting elements for
drilling of formations. However, to date no PCBN materials is used
as a cutting layer in earth-boring conditions due to its relatively
poor strength and toughness when compared to PCD.
SUMMARY OF THE INVENTION
[0007] Cutting elements for drilling earth formations at high
temperature and high speeds as well as bits incorporating such
cutting elements are provided. In one exemplary embodiment, a bit
for drilling earth formations is provided having a shear cutting
element mounted thereon. The shear cutting element includes a
substrate and a cutting layer over the substrate. The cutting layer
includes a PCBN portion for contacting a formation during drilling.
The bit is operable at rotational speeds exposing the PCBN portion
to temperatures of at least 1000.degree. C. In one exemplary
embodiment, the entire cutting layer is made of PCBN. The PCBN in
an exemplary embodiment has a strength of 100 ksi and in another
exemplary embodiment has a strength in the range of 100 to 200 ksi.
In a further exemplary embodiment, another ultra hard material is
provided adjacent to the PCBN portion. The ultra hard material in
one exemplary embodiment is PCD. The ultra hard material may form a
layer interposed between the PCBN portion and the substrate. The
PCD layer may be partly of wholly leached. In another exemplary
embodiment, the PCBN material may be a single layer of material or
may be formed from multiple layers of PCBN material having the same
or different characteristics.
[0008] In yet a further exemplary embodiment where PCD is used
along with PCBN to form the cutting element cutting layer, the PCBN
protects the PCD from high temperatures. For example in cases where
the PCD is not leached, the PCBN material ensures that the
operating temperature of the PCD is maintained at or below
650.degree. C. In cases where the PCD is fully leached, the
operating temperature of the PCD is maintained at or below
1000.degree. C. In another exemplary embodiment, the PCBN has a
thermal gradient ranging from about 200 to 2000.degree. C./mm.
[0009] In one exemplary embodiment, the bit is driven by a turbine
operating at least at 1000 RPM. In another exemplary embodiment,
the bit rotates at a rotational speed of at least 300 RPM and in a
further exemplary embodiment the bit rotates in the range of 400 to
1400 RPM. In yet a further exemplary embodiment, during drilling
the weight on the bit is in the range of 10,000 lbs. to 45,000 lbs.
In another exemplary embodiment, during drilling the weight on the
bit is in the range of 15,000 lbs. to 45,000 lbs. In yet another
exemplary embodiment, during drilling the weight on the bit is in
the range of 10,000 lbs. to 15,000 lbs. The bit may be any type of
bit incorporating shear cutting elements, as for example a drag bit
or a roller cone bit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a drag bit incorporating
exemplary cutting elements of the present invention.
[0011] FIG. 2 is a partial cut out view of a rotary cone bit
incorporating exemplary cutting elements of the present
invention.
[0012] FIGS. 3-9 are cross-sectional views of exemplary embodiment
cutting elements of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0013] In an exemplary embodiment, shear cutting elements are
provided which include a cutting layer including polycrystalline
cubic boron nitride ("PCBN") for use with turbine bits for drilling
earth formations with a shearing action where the temperature at
the cutting layer of the cutting element exceeds 1000.degree. C.
during drilling. In other exemplary embodiments, turbine driven
bits incorporating such cutting elements are provided.
[0014] Although PCBN materials have not been suitable for use with
cutting elements mounted on earth boring bits, applicant believes
that PCBN is a suitable material for a cutting layer in a shear
cutting element used in a turbine bit. PCBN provides for thermal
stability at high temperature and is able to withstand the loads
provided during drilling with turbine bits. Applicant has
discovered that turbine bits, although operating at higher RPMs,
tend to have lower vibrations and impact loads. Consequently,
applicant believes that the PCBN material will withstand the
operating environment during drilling. Thus, applicant believes
that PCBN is a suitable material for use in a cutting layer of
shear cutting element on a turbine bit.
[0015] The exemplary shear cutting elements for use with turbine
bits include PCBN in their cutting layer for making contact with
the earth formations during drilling. The PCBN material is capable
of operating at temperatures is excess of about 1000.degree. C.
These cutting elements are high-energy cutting elements in that
they may be used with turbine bits for high speed high temperature
drilling. Turbines drive the turbine bits at RPMs at greater than
300 RPM. Some turbine bits operate in the range of 400 to 1400 RPM.
Turbine bits may be used to cut formations having strength of
greater than 10,000 psi.
[0016] The exemplary high-energy cutting elements may be used on
many types of bits where the cutting elements cut via a shearing
action. For example, these cutting elements may be used as cutting
elements 2 in a drag bit 4 or may be used as gage cutters 6 in a
rotary cone bit 8, as for example shown in FIGS. 1 and 2,
respectively.
[0017] The exemplary cutting elements are formed using known
sintering methods whereby CBN powder is sintered onto a substrate
such as a tungsten carbide substrate forming a PCBN layer bonded to
the substrate. The substrate may form the body of the cutting
element. In other exemplary embodiments, the substrate with bonded
PCBN form a compact which may then be bonded to a body of the
cutting element. In other exemplary embodiments, the PCBN cutting
layer may be formed separately and then bonded to the body of the
cutting element.
[0018] Exemplary PCBN materials that may be used to form the
cutting layers of these high-energy cutting elements may be PCBN
materials having a strength greater than 100 ksi and in an
exemplary embodiment in the range of about 100 to 200 ksi. Such
PCBN materials are known in the art. An exemplary PCBN material may
formed by coarse grain cubic boron nitride ("CBN") crystals mixed
with about 10% to about 20% fine CBN crystals in the range of 0-2
microns, which are synthesized with a catalyst material such as Al,
Al--Si, TiCN, cobalt aluminide or mixtures thereof during the
sintering process. Exemplary coarse grain CBN crystals have a size
in the range of 2-10 microns. In another exemplary embodiment, the
PCBN material has CBN having an average grain size in the range of
10-20 microns and has a density greater than 93%. In another
exemplary embodiment, the PCBN material has an average grain size
less than 5 microns.
[0019] Other PCBN materials that are suitable, include PCBN
materials which have been developed for turning applications of
ferrous and non-ferrous materials where the working material
temperatures exceed 1000.degree. C. and in many instances exceed
1100.degree. C. Exemplary materials include materials used in the
finish turning of steel and other high temperature metals such
Stellite, Inconel etc. Other PCBN materials may also be used which
have been developed for use in high-speed applications where heat
is an issue. In one exemplary embodiment, such materials include in
the range of 45% to 80% CBN by volume. Further exemplary embodiment
PCBN materials that may be used are described in U.S. Pat. No.
6,331,497, the contents of which are fully incorporated herein by
reference. Other exemplary PCBN materials may include CBN having a
crystal size in the range of from about 10 to 17 microns and
including in the range of from 2 to 15% by weight of a material
selected from the group of refractory compounds consisting of
titanium diboride, aluminum diboride, titanium carbide, titanium
nitride, titanium carbonitride, and titanium aluminum carbonitride.
The carbonitride system encompasses a range of compositions from
titanium nitride to titanium carbide. Preferably, the carbonitride
has a carbon to nitrogen proportion in the range of from 20 atomic
percent carbon and 70 atomic percent nitrogen to 70 atomic percent
carbon and 30 atomic percent nitrogen. The mixture of CBN and
refractory compound is infiltrated with aluminum and/or silicon,
preferably a eutectic composition of silicon and aluminum.
[0020] In one exemplary embodiment, a PCBN layer 10 is bonded to a
substrate 12 forming a cutting element 14, as for example shown in
FIG. 3. In this exemplary embodiment, the PCBN layer 10 makes up
the entire cutting layer.
[0021] In another exemplary embodiment, the PCBN cutting layer is
engineered to have a thermal gradient in the range of 2000 to
2000.degree. C./mm. In other words, the cutting layer is designed
such that the temperature drops from about 200.degree. C. to
2000.degree. C. per millimeter away from the working surface 24 as
for example shown in FIG. 4. Exemplary cutting layers may contain
greater than 90% by weight PCBN or may be formed from mixtures of
PCBN and other ceramic materials. In alternate exemplary
embodiments, any of the aforementioned PCBN cutting layers may be
formed from two or more PCBN layers 26 each having the same or
different thermal gradients, and/or the same or different
thicknesses as for example, shown in FIG. 5.
[0022] In another exemplary embodiment, the cutting layer may be a
composite of PCD and PCBN. In this regard, the cutting layer may be
engineered to have better strength and toughness when compared to a
PCBN material by itself. For example a PCBN layer 16 may be bonded
to a PCD 18 layer as for example shown in FIG. 6. In an alternate
exemplary embodiment, a PCBN layer 20 may cover the entire PCD
layer 22, as for example shown in FIG. 7 where the PCBN layer
encapsulates the PCD layer. The composite cutting layer
incorporating a PCD material as well as a PCBN material may be
formed in accordance with the principles described in U.S. Pat.
Nos. 4,403,015; 5,510,193; and 5,603,070, the contents of which are
fully incorporated herein by reference.
[0023] With these exemplary embodiment cutting elements, the PCBN
outer layer serves to protect the PCD material from the operating
temperatures in excess of 1000.degree. C. In an exemplary
embodiment, by using a PCBN material over the PCD material which
has a thermal gradient in the range of about 2000 to about
2000.degree. C., the temperature to which the PCD material is
exposed to can be controlled by controlling the thickness and/or
the thermal gradient of the PCBN layer. In an exemplary embodiment,
the PCBN layer serves to keep the temperature of the PCD material
below 650.degree. C., or below 1000.degree. C. if the PCD material
is leached. In this regard, the PCD material is not subject to
graphitization due to high temperature exposure.
[0024] In another embodiment, any of the aforementioned PCBN
materials may be used to form a cutting layer having a layer 28
surrounding another ultra hard material layer 30, such as a PCD
ultra hard material layer 30, as for example shown in FIG. 8. In
this regard the cutting edge 32 that will be exposed to the highest
temperatures during drilling is made of PCBN. The PCBN material may
extend around the entire periphery of the cutting element, as for
example shown in FIG. 8. In other exemplary embodiments, the PCBN
material may form only the portion of the cutting layer defining an
edge 34 that will make contact with the earth formation during
drilling, as for example shown in FIG. 9. The remaining portion 36
of the cutting layer may be made from another material such as
another PCBN material or another PCD material, as for example shown
in FIG. 9. The PCBN portion to make contact with the earth
formations may extend along the entire thickness of the cutting
layer 38 as shown in FIG. 8 or may extend along a portion of the
thickness of the cutting layer 38 as shown in FIG. 9. Again, the
PCBN material serves to protect the other ultra hard material in
the cutting layer from the high operational temperatures.
[0025] Thus, as can be seen, with the present invention, the
cutting elements may be engineered for the task at hand by
providing the appropriate PCBN materials proximate the cutting edge
of the cutting element which is subjected to high temperatures, as
for example, temperatures in excess of 1000.degree. C. during
drilling. For example by using a combination of PCBN with PCD to
form the cutting layer of the exemplary cutting elements an
engineered cutting layer material is formed that is capable of
withstanding the high operating temperatures and have sufficient
strength and toughness for the drilling at task.
[0026] Applicant believes that the exemplary embodiment cutting
elements mounted on turbine-driven bits would be able to operate in
cutting environments where the weight on the bit will be at least
10,000 lbs. and in one exemplary embodiment, will be in the range
of 10,000 lbs. to 45,000 lbs. In another exemplary embodiment, the
weight on the bit will be in the range of 10,000 lbs. to 15,000
lbs. In a further exemplary embodiment, the weight on the bit will
be in the range of 15,000 lbs. to 45,000 lbs.
[0027] It should be noted that the term "substrate" as used herein
means any body onto which an exemplary cutting layer is bonded to.
For example a substrate may be the body of a cutting element or a
transition layer bonded to the body of a cutting element.
[0028] Although the present invention has been described and
illustrated to respect to exemplary embodiments, it is to be
understood that it is not to be so limited, since changes and
modifications may be made therein which are within the full
intended scope of this invention as hereinafter claimed.
* * * * *