POLYCRYSTALLINE DIAMOND ASSEMBLIES WITH CAST MOUNTING ELEMENTS

A retention mechanism for a PCD insert includes an expansion bolt inserted through a mounting element into a bore of the PCD insert. The bore of the PCD insert has an opening diameter that is greater than a terminal diameter at a terminal end of the bore. The expansion anchor is expanded in the bore, and an interference of the expanded expansion bolt with the body of the PCD insert secures the PCD insert to the mounting element.

BACKGROUND

In order to meet consumer and industrial demand for natural resources, companies search for and extract oil, natural gas, and other subterranean resources from the earth. Once a desired subterranean resource is discovered, drilling and production systems are employed to access and extract the resource. These systems may be located onshore or offshore depending on the location of a desired resource. Production systems may include a variety of flow control devices to control a flow rate, a pressure, other fluid properties, or a combination thereof, of fluid flowing through the production system. For example, choke valves may be used to control the flow of production fluid (e.g., oil, natural gas, etc.) from a well.

Certain choke valves (e.g., needle valves) include a seat and a needle movable relative to the seat. While the needle is engaged with the seat, the flow of fluid through the choke valve is substantially blocked. As the needle moves away from the seat, a cross-sectional area of an orifice formed by the seat and the needle progressively increases, thereby increasing the flow rate of the fluid through the choke valve. An actuator coupled to the needle may drive the needle to move relative to the seat. In certain applications, the fluid may contain a significant amount of abrasive material (e.g., sand, rock particles, etc.). Over time, flow of the abrasive material through the choke valve may cause the needle to wear, thereby changing the shape of the needle. As a result, the performance of the choke valve may be altered, and/or the operational effectiveness of the choke valve may be reduced.

SUMMARY

In some embodiments, a polycrystalline diamond (PCD) insert includes a body with a retention end and a working end. The body defines a bore extending from the retention end into the body toward the working end. An opening of the bore has an opening diameter that is less than a terminal diameter of the terminal end of the bore.

In some embodiments, a kit for a PCD assembly includes a PCD insert having a body. The body has a retention end and a working end. The body defines a bore extending from the retention end into the body toward the working end. The kit includes a mounting element. The kit includes an expansion anchor having a tightening head and an expansion head. The expansion head is configured to be inserted through the mounting element and into the bore. The expansion head is expandable to secure the PCD insert to the mounting element.

In some embodiments, inserting an expansion anchor through the mounting element and into a bore in the PCD insert. The expansion anchor is expanded until at least a portion of the expansion anchor engages an inner wall of the bore.

This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.

DETAILED DESCRIPTION

This disclosure generally relates to devices, systems, and methods for securing a tip portion of a needle in a choke valve to a base portion of the needle using an expansion anchor. The tip portion may be a PCD insert or PCD element and the base portion may be formed from steel or a steel alloy. The body of the tip portion includes a bore having an opening with an opening diameter that is greater than a terminal diameter of a terminal end of the bore. An expansion anchor may be inserted through the base portion, with the expansion head being inserted into the bore of the tip portion. The expansion head may be expanded such that an expanded diameter of the expansion head is greater than the opening diameter. The interference of the expanded expansion head with the body of the tip portion may secure the tip portion to the base portion.

FIG.1-1is a perspective view of an embodiment of a choke valve assembly10. As illustrated, the choke valve assembly10includes a body12having an inlet14and an outlet16. While the choke valve assembly10is in an open state, fluid flow through the body12from the inlet14to the outlet16is enabled. In addition, while the choke valve assembly10is in a closed state, fluid flow through the body12is blocked. In the illustrated embodiment, the choke valve assembly10includes a handle18configured to transition the choke valve assembly10between the open and closed states via manual actuation of the handle18. In other embodiments, the choke valve assembly may include an actuator (e.g., alone or in addition to the handle), such as a hydraulic actuator, a pneumatic actuator, an electromechanical actuator, another suitable actuator, or a combination thereof, configured to drive the choke valve assembly between the open and closed states. The choke valve assembly10may be used within a production system to control a flow rate of fluid from a well, or within any other suitable system to control fluid flow. For example, the choke valve assembly10may be used to vary the flow rate of fluid pumped into a well, e.g., while drilling.

As may be seen inFIG.1-2, the choke valve assembly10includes a needle configured to move along a longitudinal axis of the choke valve assembly. With the choke valve assembly in the closed state, the needle is engaged with a seat of the choke valve assembly, thereby blocking flow of the fluid through the body12. Movement of the needle away from the seat along the longitudinal axis forms an orifice between the needle and the seat, thereby transitioning the choke valve assembly to the open state and facilitating flow of the fluid through the body12. In certain embodiments, the needle includes a base portion formed from a first non-superhard material and a tip portion formed from a superhard material.

FIG.1-2is a cross-sectional view of the choke valve assembly10ofFIG.1-1. As previously discussed, the body12of the choke valve assembly includes an inlet14and an outlet16. Fluid (e.g., from a well, etc.) may enter the inlet14and flow through an inlet passage20of the body12along an inlet flow direction22(e.g., along a radial axis24of the choke valve assembly10). The fluid entering the inlet14may be at a relatively high pressure (e.g., greater than 500 psi (3.45 MPa), greater than 1000 psi (6.89 MPa), greater than 5000 psi (34.47 MPa), greater than 10,000 psi (68.95 MPa), greater than 15,000 psi (103.42 MPa), greater than 20,000 psi (137.90 MPa), greater than 25,000 psi (172.37 MPa), greater than 30,000 psi (206.84 MPa), or any range between the foregoing), and a significant amount of abrasive material (e.g., sand, particles, etc.) may be entrained within the fluid. For example, the fluid may enter the inlet14after being used for fracking a reservoir and may, therefore, include a significant amount of sand. The fluid flows through the inlet14along the inlet flow direction22to a cavity26within the body12.

As illustrated, the choke valve assembly10includes a needle28and a seat assembly30(e.g., forming a choke trim). In the illustrated embodiment, the seat assembly30includes a housing32and a seat34(e.g., forming a positive bean). The housing32includes an internal passage, and the seat34is disposed within the internal passage of the housing32. In addition, the seat34has a flow passage extending through the seat34. With the choke valve assembly10in the illustrated closed state, the needle28is engaged with the seat34, thereby blocking flow of the fluid from the cavity26to an outlet passage36that extends to the outlet16. Movement of the needle28away from the seat assembly30along a longitudinal axis38of the choke valve assembly10forms an orifice between the needle28and the seat34, thereby facilitating flow of the fluid from the cavity26, through the flow passage of the seat34, and into the outlet passage36. The fluid then flows through the outlet passage36along an outlet flow direction40(e.g., along the longitudinal axis38) to the outlet16. Due to the shape of the needle28, the cross-sectional area of the orifice increases as the needle28moves away from the seat34. Accordingly, the flow rate of the fluid through the choke valve assembly10may be controlled by controlling the position of the needle28relative to the seat34.

As illustrated, the needle28is coupled to a shaft42(e.g., by a threaded connection, a press-fit connection, a shrink-fit connection, a brazed connection, an adhesive connection, etc.), and the shaft42supports the needle28within the body12of the choke valve assembly10. In addition, the shaft42is configured to drive the needle28to move along the longitudinal axis38, thereby controlling the position of the needle28relative to the seat34. In the illustrated embodiment, the handle18of the choke valve assembly10is coupled to the shaft and configured to drive the shaft42to move along the longitudinal axis38. While the shaft42is driven to move by the handle18in the illustrated embodiment, in other embodiments, the shaft may be driven to move by another suitable actuator (e.g., alone or in addition to the handle), such as a hydraulic actuator, a pneumatic actuator, an electromechanical actuator, another suitable actuator, or a combination thereof.

Press-fitting includes coupling components to one another via engagement of a protrusion of one component with a recess of the other component (e.g., in which a cross-sectional area of the protrusion is greater than or equal to the cross-sectional area of the recess). Components may be coupled by press-fitting while the components are at an ambient temperature via application of an external force. Furthermore, shrink-fitting includes coupling components to one another via adjusting the temperature of at least one component, engaging a protrusion of one component with a recess of the other component, and enabling the at least one component to return to the ambient temperature. For example, the components may be coupled by shrink-fitting via heating the component with the recess to expand the recess, disposing the protrusion within the recess, and enabling the heated component to return to the ambient temperature. Additionally or alternatively, in certain embodiments, the components may be coupled by shrink-fitting via cooling the component with the protrusion to contract the protrusion, disposing the protrusion within the recess, and enabling the cooled component to return to the ambient temperature. In addition, brazing includes disposing a brazing material (e.g., wire, paste, solder, foil, etc.) between components, heating the brazing material (e.g., to at least partially melt the brazing material and to promote wetting between the brazing material and the components), and enabling the brazing material to cool to couple the components to one another. Furthermore, bonding includes disposing an adhesive (e.g., cement, high performance thermoplastic(s) (e.g., polyether (ether) ketone (P(E)EK), polysulfone, polyphenylene sulfide), epoxy resin, etc.) between components to couple the components to one another.

In the illustrated embodiment, the needle28includes a base portion44and a tip portion46. As illustrated, the base portion44is coupled to the shaft42(e.g., by a threaded connection, a mechanical connection, a press-fit connection, a shrink-fit connection, a brazed connection, an adhesive connection, etc.), and the tip portion46is coupled to the base portion44. The base portion44is formed from a non-superhard material (such as steel, steel alloys, or any other non-superhard material), the tip portion is formed from a superhard material, and a tip48of the needle28is formed by the tip portion46.

As used herein, “superhard” refers to a material having a hardness of greater than or equal to 20 GPa based on Vickers hardness testing, and/or a material having a hardness of greater than or equal to 4500 Hardness Brinell (B) on the Brinell scale. Superhard materials may include diamond (e.g., PCD) or other superhard material(s), such as cubic boron nitride. Forming the tip portion46of the needle28from superhard material may substantially increase the longevity of the needle28(e.g., as compared to a needle in which the tip portion is formed from a non-superhard material). For example, a significant amount of abrasive material (e.g., sand, particles, etc.) may be entrained within the fluid flowing through the choke valve assembly10(e.g., while the choke valve assembly is in the open state). The abrasive material may flow through the orifice, which is formed by the tip portion46of the needle28and the seat34, at a substantial speed. However, because the tip portion46of the needle28is formed from superhard material, wear/abrasion of the tip portion46may be substantially reduced (e.g., as compared to a needle having a tip portion formed from a non-superhard material), thereby increasing the longevity of the needle.

Furthermore, in certain embodiments, the seat34of the seat assembly30may be formed from superhard material (e.g., diamond, etc.). As previously discussed, the orifice is formed by the tip portion46of the needle28and the seat34, and fluid containing a significant amount of abrasive material may flow through the orifice at a substantial speed. Because the seat34is formed from superhard material, wear/abrasion of the seat34may be substantially reduced (e.g., as compared to a seat formed from a non-superhard material), thereby increasing the longevity of the seat34. Furthermore, in the illustrated embodiment, the needle has an angled seat-engaging surface, and the seat has an angled needle-engaging surface. In certain embodiments, the angle of the seat-engaging surface of the needle and the angle of the needle-engaging surface of the seat may be substantially equal, thereby establishing an effective seal while the choke valve assembly is in the closed state.

While the tip portion46of the needle28and the seat34of the seat assembly30are formed from superhard material in the illustrated embodiment, in other embodiments, the tip portion and/or the seat may be formed from a non-superhard material. Furthermore, the seat assembly housing32may be formed from a superhard material or a non-superhard material. In addition, while the seat assembly30includes a seat34and a housing32in the illustrated embodiment, in other embodiments, the housing may be omitted (e.g., the seat may couple to the body of the choke valve assembly). Furthermore, while the needle28includes the tip portion46and the base portion44in the illustrated embodiment, in other embodiments, the needle may include more or fewer portions (e.g., 1, 3, 4, or more). In addition, the tip portion46of the needle28may be removably coupled to the base portion44of the needle28, the needle28may be removably coupled to the shaft42, the seat34may be removably coupled to the seat assembly housing32, the seat assembly housing32may be removably coupled to the body12of the choke valve assembly10, or a combination thereof. Accordingly, the tip portion46of the needle28, the needle28, the seat34, the seat assembly30, or a combination thereof, may be removed and replace (e.g., due to wear of component(s), to establish different orifice configurations for different applications, etc.).

As used herein, a component “formed from” superhard material refers to a component in which at least relevant surface(s) of the component (e.g., fluid-engaging, bearing, etc. surfaces) are formed entirely by the superhard material. For example, the component may include a shell having outer layer(s) formed entirely of superhard material, in which the shell is coupled to a base/core of the component (e.g., by a brazed connection, an adhesive connection, a press-fit connection, a shrink-fit connection, a mechanical connection, a fastener connection, a threaded connection, other suitable connection(s), or a combination thereof) or formed on the base/core of the component (e.g., by a CVD process). Notably, a superhard material is not required to be based on each individual constituent. For instance, a polycrystalline diamond may include diamond particles, sintering aids, and catalyst materials. The sintering aids and catalyst materials themselves may not be considered superhard materials; however, when the components are sintered together, the resulting diamond lattice including the diamond, sintering aid, and catalyst material may exhibit superhard properties.

Accordingly, a component having a surface or outer layer formed entirely of superhard material may be formed as a single element (e.g., by a molding process, by a high-pressure high-temperature (HPHT) sintering process, by a machining/engraving/ablation process, by other suitable process(es), or a combination thereof). For example, diamond particles (e.g., diamond particle waste, etc.), powdered material (e.g., tungsten, silicon, etc.), and a metal (e.g., a cobalt alloy) may be formed into a desired shape within a press. The pressed elements may then be subjected to HPHT sintering to form a component having a core formed from the material (e.g., which may be chemically altered, such as forming tungsten carbide from the tungsten, forming silicon carbide from the silicon, etc.) and a diamond-containing shell (which can include sintering aids, catalyst materials, tungsten, carbide, etc.). The HPHT sintering process includes applying high pressure (e.g., greater than 5 GPa) and high temperature (e.g., greater than 1400° C.) to the elements to establish a polycrystalline diamond component. In certain embodiments, the pressed elements are reshaped within the HPHT sintering process, or the pre-HPHT forming step may be omitted, and the elements may be formed into the desired shape during the HPHT sintering process. Additionally or alternatively, a diamond-containing component (e.g., a polycrystalline diamond component, a natural diamond component formed entirely of diamond, a synthetic diamond component formed entirely of diamond, etc.) may be shaped via a laser ablation process, a machining process, an electrical discharge machining/grinding (EDM/EDG) process, or a combination thereof.

In a chemical vapor deposition (CVD) process, a diamond cover layer/shell may be grown onto the base/core. For example, layers of diamond are grown onto the base/core until a diamond cover layer/shell having a desired thickness is established. The layers closest to the core may include a mixture of the non-superhard material of the base/core and diamond. For example, a layer closest to the non-superhard material of the base/core may be substantially non-superhard material with a small amount of diamond. As additional layers are added/grown, the content of diamond relative to the base/core material increases until entirely diamond layers are formed (e.g., which establishes a diamond gradient). While growing layers of diamond onto a base/core using a CVD process is disclosed above, in certain embodiments, layers of diamond (e.g., including the diamond gradient) may be formed onto a base/core using the HPHT sintering process disclosed above. Furthermore, in certain embodiments, a shell may be formed separately from a base/core using the CVD process or the HPHT sintering process and coupled to the base/core.

According to some aspects, the tip portion46of the needle28is brazed to the base portion44, or the tip portion46is connected to the base portion44with a brazed connection. As the needle28increases in size, including a diameter of the needle28and/or a length of the needle28, the brazed connection may have a decreased effectiveness. This may be due, at least in part, to manufacturing tolerances between the tip portion46and the base portion44, size changes due to differences in thermal expansion, the amount of braze material, the size of the gap between the brazed portions, any other reason, and combinations thereof. This may weaken the brazed connection, thereby increasing the likelihood that the brazed connection breaks and fails, resulting in failure of the choke valve assembly10.

In accordance with at least one embodiment of the present disclosure, the needle28may be assembled by securing the tip portion46to the base portion44with a mechanical fastener. The tip portion46may include a bore in the body of the tip portion46. An opening end of the bore may have an opening diameter that is larger than a terminal area of a terminal end of the bore. An expansion anchor may be inserted through the base portion44and into the bore. The head of the expansion anchor may be expanded so that the head engages the inner walls of the bore. This may create an interlocked connection with the expansion anchor. In this manner, the tip portion46may be removed from the base portion44by fracturing the tip portion46, the base portion44, the expansion anchor, and combinations thereof.

In some embodiments, the expansion anchor may be tightened so that the tip portion46is firmly secured to the base portion44. This may place the base portion44in compression, and at least part of the tip portion46in tension. Superhard materials, such as polycrystalline diamond (PCD), may be relatively weak in tension. Surprisingly, it has been found that securing the PCD (or other superhard material) tip portion46to the base portion44with an expandable anchor placing a part of the PCD insert in tension may result in a more secure connection than a braze. In this manner, one or more embodiments of the present disclosure may increase the operational lifetime of the needle (or other PCD insert).

FIG.2-1is a cross-sectional view of a PCD assembly250, according to at least one embodiment of the present disclosure. The PCD assembly250includes a PCD insert252secured to a mounting element254with an expansion anchor256. The PCD insert252includes a body258having a retention end259and an operating end260. The body258defines a bore261. The bore261extends from the retention end259toward the operating end260. In accordance with at least one embodiment of the present disclosure, the bore261is a blind bore. Put another way, the bore261extends partially through the body258. In some embodiments, the bore261does not extend all the way through the body258to the operating end260. The bore261has an opening262and a terminal end263.

The bore261has an opening diameter268at the retention end259. The opening diameter268may be the size of the opening of the bore261. In some embodiments, the opening diameter268may be in a range having a lower value, an upper value, or lower and upper values including any of 0.125 in. (3.2 mm), 0.25 in. (6.4 mm), 0.375 in. (9.5 mm), 0.5 in. (12.7 mm), 0.625 in. (15.9 mm), 0.75 in. (19.1 mm), 0.875 in. (22.2 mm), 0.938 in. (23.8 mm), 1.0 in. (25.4 mm), 2.0 in. (50.8 mm) or any value therebetween. For example, the opening diameter268may be greater than 0.125 in. (3.2 mm). In another example, the opening diameter268may be less than 1.0 in. (25.4 mm). In yet other examples, the opening diameter268may be any value in a range between 0.125 in. (3.2 mm) and 2.0 in. (50.8 mm). In some embodiments, it may be critical that the opening diameter268is between 0.25 in. (6.35 mm) and 0.938 in. (23.8 mm) to provide an opening for entry of the expansion anchor256. In some embodiments, it may be critical that the opening diameter268is 50% or less of the diameter of the insert diameter272to retain strength in the body of the insert diameter272.

The bore261has a bore length270, which may be the distance between the opening262and the terminal end263. In some embodiments, the bore length270may be in a range having a lower value, an upper value, or lower and upper values including any of 0.125 in. (3.2 mm), 0.25 in. (6.4 mm), 0.375 in. (9.5 mm), 0.5 in. (12.7 mm), 0.625 in. (15.9 mm), 0.75 in. (19.1 mm), 0.875 in. (22.2 mm), or any value therebetween. For example, the bore length270may be greater than 0.125 in. (3.2 mm). In another example, the bore length270may be less than 0.875 in. (22.2 mm). In yet other examples, the bore length270may be any value in a range between 0.125 in. (3.2 mm) and 0.875 in. (22.2 mm). In some embodiments, it may be critical that the bore length270is between 0.25 in. (6.4 mm) and 0.75 in (19.1 mm) to retain the PCD insert252without weakening it.

The bore261has a terminal diameter269at the terminal end263of the bore261. In some embodiments, the terminal diameter269may be in a range having a lower value, an upper value, or lower and upper values including any of 0.25 in. (6.4 mm), 0.375 in. (9.5 mm), 0.5 in. (12.7 mm), 0.625 in. (15.9 mm), 0.75 in. (19.1 mm), 0.875 in. (22.2 mm), 1.0 in. (25.4 mm), 1.125 in. (28.6 mm), or any value therebetween. For example, the terminal diameter269may be greater than 0.25 in. (6.4 mm). In another example, the terminal diameter269may be less than 1.125 in. (28.6 mm). In yet other examples, the terminal diameter269may be any value in a range between 0.25 in. (6.4 mm) and 1.125 in. (28.6 mm). In some embodiments, it may be critical that the terminal diameter269is greater than 0.875 in. (22.2 mm) to allow the expansion anchor256to expand within the bore261.

The bore261has an inner wall that extends between the opening262and the terminal end263. The inner wall may extend at a bore angle271. In some embodiments, the bore angle271may be in a range having a lower value, an upper value, or lower and upper values including any of 2.0°, 2.5°, 3.0°, 4.0°, 5.0°, 7.5°, 10°, 12.5°, 15°, 20°, 25°, or any value therebetween. For example, the bore angle271may be greater than 2.0°. In another example, the bore angle271may be less than 25°. In yet other examples, the bore angle271may be any value in a range between 2° and 25°. In some embodiments, it may be critical that the bore angle271is between 5.0° and 15° to expand the diameter of the bore261sufficiently for the expansion anchor256to suitably grip the inner wall of the PCD insert252.

The PCD insert252has an insert diameter272. In some embodiments, the insert diameter272may be the largest diameter of the PCD insert252. In some embodiments, the insert diameter272may be the diameter of the PCD insert252at the retention end259. In some embodiments, the insert diameter272may be in a range having a lower value, an upper value, or lower and upper values including any of 0.75 in. (19.1 mm), 0.875 in. (22.2 mm), 1.0 in. (25.4 mm), 1.125 in. (28.6 mm), 1.25 in. (31.8 mm), 1.375 in. (34.9 mm), 1.5 in. (38.1 mm), or any value therebetween. For example, the insert diameter272may be greater than 0.75 in. (19.1 mm). In another example, the insert diameter272may be less than 1.5 in. (38.1 mm). In yet other examples, the insert diameter272may be any value in a range between 0.75 in. (19.1 mm) and 1.5 in. (38.1 mm). In some embodiments, it may be critical that the insert diameter272is at least 0.75 in. (19.1 mm) to provide a mechanism to secure the PCD insert252to the mounting element254that does not include braze material.

In accordance with at least one embodiment of the present disclosure, the bore261may be formed in the PCD insert252in any manner. For example, the bore261may be formed by casting, by machining, using multi-axis laser ablation, EDM sinking, grinding, any other manufacturing method, and combinations thereof.

The mounting element254includes a mount bore264. The mount bore264may extend through the mounting element254. To assemble the PCD assembly250, the body258may be placed next to the mounting element254such that the bore261and the mount bore264are aligned. The expansion anchor256may be extended through the mounting element254. For example, a shaft265may be inserted through the mount bore264and into the bore261. An expansion head266of the expansion anchor256may be inserted into the bore261. The expansion head266includes an expansion element267.

In the view shown inFIG.2-1, the expansion head266, and the expansion element267, is in a retracted configuration. In the retracted configuration, the head diameter of the expansion head266may be less than an opening diameter268of the opening262, thereby allowing the expansion head266to fit through the opening262of the bore261. This may allow the expansion head266and the expansion element267to be inserted into the bore261.

In accordance with at least one embodiment of the present disclosure, the opening diameter268may be smaller than or less than the terminal diameter269. This may allow the expansion anchor256to expand within the bore261until an expanded diameter of the expansion head266is greater than the opening diameter268, as may be seen inFIG.2-2with the expansion head266in the expanded position. Expanding the expansion head266until its expanded diameter is larger than the opening diameter268may prevent removal of the expansion anchor256from the bore261.

As may be seen inFIG.2-2, when the expansion head266is expanded into the expanded state, the expansion element267may engage the inner wall of the bore261. As may be seen, the expanded diameter of the expansion element267is larger than the opening diameter268of the bore261. In this manner, if a removal force (e.g., a force to the right in the view shown) is applied to the PCD insert252, the contact of the expansion element267with the inner wall of the bore261, thereby preventing separation of PCD insert252from the mounting element254.

In some embodiments, a radially outward force may be applied to the expansion element267to place the expansion head266in the expanded position. In some embodiments, the expansion force may be applied until the expansion element267contacts the inner wall of the bore261. In some embodiments, the expansion force may be applied after the expansion element267engages the inner wall of the bore261. This may increase the friction force of the expansion head266against the PCD insert252.

In some embodiments, the expansion head266may create an interference connection with the body258of the PCD insert252at the bore261. The interference connection may prevent the removal of the PCD insert252from the mounting element254without the body258deforming or fracturing, the mounting element254deforming or fracturing, and/or the expansion anchor256deforming or fracturing.

The expansion force may cause the expansion element267to deform. In some embodiments, the expansion element267may deform at least partially to the profile of the inner wall of the bore261. In some embodiments, the expansion element267may deform to an entirety of the profile of the inner wall of the bore261. In some embodiments, deforming to the profile of the bore261may help to improve the retention capacity of the expansion head266. For example, deforming to the profile of the bore261may increase the contact area of the expansion head266against the profile of the inner surface of the bore261.

In accordance with at least one embodiment of the present disclosure, the expansion force on the expansion head266may be applied in any manner. For example, a tightening head273of the expansion anchor256may be rotated, thereby rotating the shaft265. The shaft265may be threaded, and rotation of the threaded shaft265may apply a force longitudinal force on an expansion mechanism. The expansion mechanism may convert the longitudinal force into a radial force, which may be applied to the expansion element267. For example, the expansion mechanism may be the buckling of beam members. In some embodiments, tightening the tightening head273may place the shaft265in tension, compressing the mounting element254between the tightening head273and the PCD insert252.

As may be understood, applying the expansion force to the expansion head266may apply an outward force against the body258of the PCD insert252. This may place the body258in tension. As may be understood, PCD may be brittle in tension. But, despite placing the PCD insert252in tension, the expansion anchor256securing the PCD insert252to the mounting element254may generate a stronger connection than a brazed connection, especially for PCD insert252having an insert diameter272that is greater than or equal to 0.75 in. (19.1 mm).

In accordance with at least one embodiment of the present disclosure, the PCD assembly250may include a kit for a PCD assembly. The kit for the PCD assembly may include the PCD insert252, the mounting element254, and the expansion anchor256. Different manufacturers or suppliers may provide the various elements of the kit. For example, a first supplier may supply the PCD insert252, a second supplier may supply the mounting element254, and a third supplier may supply the expansion anchor256. In some embodiments, as discussed herein, the PCD assembly250may only include, or may consist or consist essentially of, the PCD insert252, the mounting element254, and the expansion anchor256. As may be understood, the PCD insert252may be secured to the mounting element254only using the expansion anchor256.

FIG.3is a cross-sectional view of a PCD assembly350having a PCD insert352secured to a mounting element354, according to at least one embodiment of the present disclosure. In the embodiment shown, the PCD insert352is secured to the mounting element354using both an expansion anchor356and a press-fit connection. The expansion anchor356may secure the PCD insert352to the mounting element354as discussed herein with respect toFIG.2-1andFIG.2-2.

In accordance with at least one embodiment of the present disclosure, the mounting element354may include a press-fit cavity374. A retention end359of the PCD insert352may be inserted into the press-fit cavity374. In some embodiments, the retention end359may be inserted into the press-fit cavity374with a press-fit connection, as described herein. In some embodiments, the retention end359may be inserted into the press-fit cavity374with a shrink-fit connection. In some embodiments, the retention end359may be inserted into the press-fit cavity374with any other type of connection, including the connections discussed herein.

In some embodiments, the PCD insert352may be secured to the mounting element354with both a press-fit connection (or any other connection) and an expansion anchor356. In some embodiments, the press-fit connection may provide additional strength to the connection between the PCD insert352and the mounting element354. In some embodiments, the expansion anchor356may provide a retention force against longitudinal removal of the PCD insert352from the mounting element354(e.g., to the right and left in the view shown). In some embodiments, the press-fit connection may help to laterally secure the PCD insert352to the mounting element354(e.g., to the top and bottom in the view shown). In this manner, the combination of the press-fit connection and the expansion anchor356may increase the strength of the connection between the PCD insert352and the mounting element354.

In some embodiments, the press-fit connection may help to align the PCD insert352with the mounting element354. This may help to maintain the alignment and position of the PCD insert352during operation. In some embodiments, the press-fit connection may help to align an opening362of a bore361in the body358of the PCD insert352with a mount bore364in the mounting element354. This may help to prevent lateral motion of the PCD insert352from apply a shear force to a shaft365the expansion anchor356. A shear force on the shaft365may increase the likelihood that the shaft365is broken, and therefore preventing lateral motion of the PCD insert352may help to prevent damage to the shaft365

In some embodiments, the PCD insert352may be press-fit to the mounting element354before the expansion anchor356is inserted through the mounting element354and into the bore361. In some embodiments, tightening of the expansion anchor356may draw the PCD insert352into the press-fit cavity374.

In some embodiments, the expansion anchor356may help to reduce a depth that the PCD insert352may be press-fit into the mounting element354. For example, as discussed herein, press-fitting the PCD insert352to the mounting element354may help to align the PCD insert352to the mounting element354. Because the expansion anchor356provides the retention force for the PCD insert352, the press-fit connection may be reduced. In some embodiments, the press-fit connection may be less than an industry recommended depth.

FIG.4is a cross-sectional view of a needle428having a base portion444secured to a tip portion446, according to at least one embodiment of the present disclosure. In some embodiments, the needle428may be used in a choke valve, such as the choke valve assembly10ofFIG.1-1andFIG.1-2. For example, the tip portion446may be configured to engage with a seat, and a longitudinal position of the tip portion446with respect to the seat may adjust the flow through the choke valve. In some embodiments, the base portion444may be configured to be secured to a shaft, such as with a threaded connection or other connection.

In some embodiments, the tip portion446may be secured to the base portion444with an expansion anchor456. The expansion anchor456may include a shaft465. The shaft465of the expansion anchor456may be inserted through the base portion444, such as through a mount bore464. The mount bore464may extend through an entirety of the base portion444. The mount bore464may be aligned with a bore461in a body458of the tip portion446. As the shaft465is inserted through the base portion444, an expansion head466of the expansion anchor456may be inserted into the bore461of the body458of the tip portion446.

The bore461may have an opening462with an opening diameter that is less than a terminal diameter of a terminal end463of the bore461. After the expansion head466is inserted into the bore461, the expansion head466may be expanded until an expanded diameter of the expansion head466is greater than the opening dimeter of the opening462. In this manner, the tip portion446may be secured to the base portion444.

FIG.5-1throughFIG.5-6are cross-sectional views of PCD inserts (collectively552) having a bore (collectively561) in a body (collectively558) thereof, according to example embodiments of the present disclosure. As discussed herein, the bores561of the PCD inserts552may have an opening diameter that is smaller than a terminal diameter.

The bore561may have any shape or profile. For example, inFIG.5-1, a first PCD insert552-1may have a first bore561-1in a first body558-1. The first bore561-1has a first inner surface575-1. InFIG.5-1, the first inner surface575-1is straight from a first opening562-1to a first terminal end563-1. In this manner, the first bore561-1may have a conical or frustoconical shape.

InFIG.5-2, a second PCD insert552-2may have a second bore561-2in a second body558-2. The second bore561-2has a second inner surface575-2. InFIG.5-2, the second inner surface575-2has an irregular shape. The irregular shape of the second inner surface575-2may include a straight section and an angled section. In the embodiment shown, the second inner surface575-2has a straight section closer to an opening562-2. The second inner surface575-2has an angled section closer to a terminal end563-2of the second bore561-2. The straight section may help to strengthen the second body558-2near the opening562-2, while the angled section may receive an expansion anchor to secure the second PCD insert552-2to a mounting element.

InFIG.5-3, a third PCD insert552-3may have a third bore561-3in a third body558-3. The third bore561-3has a third inner surface575-3. InFIG.5-3, the third inner surface575-3has an irregular shape. The irregular shape of the third inner surface575-3may include a straight section and an angled section. In the embodiment shown, the third inner surface575-3has an angled section closer to an opening562-3of the third bore561-3. The third inner surface575-3has a straight section closer to a terminal end563-3of the third bore561-3. The angled section of the third inner surface575-3may help the expansion head of an expansion bolt to grab or hold the third PCD insert552-3to a mounting element.

InFIG.5-4, a fourth PCD insert552-4may have a fourth bore561-4in a fourth body558-4. The fourth bore561-4has a fourth inner surface575-4. InFIG.5-4, the fourth inner surface575-4has an irregular shape. The irregular shape of the fourth inner surface575-4may be stepped or tiered. For example, the fourth inner surface575-4shown includes a first step having a first diameter at the fourth opening562-4. A second step has a second dimeter, larger than the first step and the first diameter. A third step at the fourth terminal end563-4may have a third diameter, with the third diameter being larger than the first and second diameters. The stepped profile of the fourth bore561-4may provide multiple ledges or lips for the expansion head of the expansion anchor to grip, thereby improving the connection of the expansion anchor to the fourth PCD insert552-4.

InFIG.5-5, a fifth PCD insert552-5may have a fifth bore561-5in a fifth body558-5. The fifth bore561-5has a fifth inner surface575-5. InFIG.5-5, the fifth inner surface575-5has a curved profile. The curved profile may be any type of curve, such as a parabolic curve, a hyperbolic curve, a circular curve, an elliptical curve, any other type of curve, and combinations thereof. In the embodiment shown inFIG.5-5, the fifth inner surface575-5has a profile that is concave between a fifth opening562-5and a fifth terminal end563-5. This may increase the strength of the connection of the expansion anchor to the fifth PCD insert552-5.

InFIG.5-6, a sixth PCD insert552-6may have a sixth bore561-6in a sixth body558-6. The sixth bore561-6has a sixth inner surface575-6. InFIG.5-6, the sixth inner surface575-6has a curved profile. The curved profile may be any type of curve, such as a parabolic curve, a hyperbolic curve, a circular curve, an elliptical curve, any other type of curve, and combinations thereof. In the embodiment shown inFIG.5-6, the sixth inner surface575-6has a profile that is convex between a sixth opening562-6and a sixth terminal end563-6. This may increase the strength of the sixth body558-6between the expansion anchor and the mounting element.

FIG.6is a flowchart of a method676for securing a PCD insert to a mounting element, according to at least one embodiment of the present disclosure. To secure the PCD insert to the mounting element, an expansion anchor is inserted through the mounting element and into a bore of the PCD insert at677. The expansion anchor may be expanded until at least a portion of the expansion anchor engages an inner wall of the bore at678.

In some embodiments, the PCD insert may be press-fit to the mounting element. In some embodiments, expanding the expansion anchor places at least a portion of the PCD insert in tension. In some embodiments, expanding the expansion anchor includes conforming an expansion head of the expansion anchor to a profile of the inner wall of the bore. In some embodiments, expanding the expanding anchor secures the PCD insert to the mounting element without brazing the PCD insert to the mounting element, or without using any braze material.

FIG.7-1is a cross-sectional view of a PCD assembly779, according to at least one embodiment of the present disclosure. The PCD assembly779includes a PCD insert780and a mounting element781. In some embodiments, the mounting element781may be cast to the PCD insert780. Casting the mounting element781to or around the PCD insert780may allow the mounting element781to mold to the profile of an outer surface782of the PCD insert780. In this manner, the PCD insert780may be secured to the mounting element781by casting the PCD insert780to the mounting element781.

In some embodiments, the PCD insert780may include one or more retention features783. The retention features783extend from the outer surface782. In some embodiments, the retention features783may extend radially from the outer surface782, or perpendicular to a longitudinal axis784of the PCD insert780. The retention features783may include a protrusion, a knob, a tab, any other retention feature783, and combinations thereof. In the embodiment shown, the PCD insert780has a single retention feature783. However, it should be understood that the PCD insert780may include any number of retention features783. For example, the PCD insert780may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more retention features783.

The retention features783may be spaced around a circumference of the outer surface782. In some embodiments, the retention features783may be spaced evenly around the circumference of the outer surface782. In some embodiments, the retention features783may be spaced unevenly with one or more different circumferential offsets or spacings around the circumference of the outer surface782. In some embodiments, one or more, and potentially all, of the retention features783may be longitudinally aligned, and thus at the same axial position along the length of the PCD insert780. In some embodiments, one or more of the retention features783may be located at different axial positions along the length of the PCD insert780.

In some embodiments, the retention features783may be integrally formed in the PCD insert780. For example, the retention features783may be formed with the PCD insert780when the PCD insert780is manufactured or cast. In some examples, the retention features783may be machined, ground, or otherwise added to the PCD insert780after formation. While the retention features783shown are shown extending away from the outer diameter of the outer surface782, it should be understood that the retention features783may include holes, indentations, detents, or other sections that extend into the outer surface782of the PCD insert780.

In some embodiments, the mounting element781may be cast around the circumference of the PCD insert780. In this manner, the mounting element781may surround or envelop at least a portion of the PCD insert780. In some embodiments, the mounting element781may be cast around the retention features783. Casting the mounting element781around the retention features783may help to retain the mounting element781on the PCD insert780. For example, the mounting element781may be cast on lateral or circumferential sides of the retention features783. In this manner, an interference of the cast mounting element781with the retention features783may help to prevent rotation of the PCD insert780relative to the mounting element781.

In some embodiments, the mounting element781may be cast on an upper and lower surface of the retention features783. This may help to prevent longitudinal removal of the PCD insert780from the mounting element781(e.g., removal in a direction parallel to the longitudinal axis784). In some embodiments, the mounting element781may be cast around an entirety of the retention features783, thereby preventing both rotation and longitudinal removal of the PCD insert780with respect to the mounting element781.

In some embodiments, the mounting element781may be cast around a portion of the circumference or outer perimeter of the PCD insert780. In some embodiments, the mounting element781may be cast around an entire circumference or outer perimeter of the PCD insert780. Casting the mounting element781around the entire circumference or outer perimeter of the PCD insert780may help to strengthen the connection of the PCD insert780to the mounting element781.

In some embodiments, the mounting element781may be cast along a portion of the longitudinal length of the PCD insert780. For example, the mounting element781may be cast at a retention end of the PCD insert780, thereby allowing a working end of the PCD insert780to be exposed. The working end of the PCD insert780may be the end of the PCD insert780that engages a working surface. For example, the working end of the PCD insert780may include the tapered end of a needle for a choke valve. In some examples, the working end of the PCD insert780may include the contact surface of a cutting element. In some examples, the working end of the PCD insert780may be the working surface of any PCD insert780that is configured to come into contact with another element. The working end of the PCD insert780may be opposite the retention end259. In some embodiments, the mounting element781may be cast along an entirety of a length of the PCD insert780, thereby improving the strength of the connection of the PCD insert780to the mounting element781.

In accordance with at least one embodiment of the present disclosure, the mounting element781may be cast directly onto the surface of the PCD insert780. For example, the PCD insert780may be placed in a mold and the mounting element781may be cast onto the PCD insert780while the PCD insert780is in the mold. The mounting element781may be cast in any casting manner, such as powder metallurgy, sintering, laser cladding, melting and casting, any other metallurgical process, and combinations thereof. In some embodiments, the casting process may occur at an elevated temperature. The material of the mounting element781may have a different coefficient of thermal expansion than the PCD insert780. As the mounting element781cools, the mounting element781may shrink or otherwise reduce in volume more than the PCD insert780. This may cause the mounting element781to be secured to the PCD insert780with a shrink fit connection, in addition to being cast around the retention features783. In some embodiments, the shrink fit connection may help to secure the mounting element781to the retention features783.

In accordance with at least one embodiment of the present disclosure, the mounting element781may be made from a machinable material. For example, the mounting element781may be made from a metal or a metallic alloy, such as zinc, iron, steel, aluminum, any other metal or metallic alloy, and combinations thereof. In some embodiments, after the mounting element781is cast around the PCD insert780, an outer surface785of the mounting element781may be processed or machined into a final shape or a final geometry.

In the embodiment shown inFIG.7-2, the outer surface785has been machined or processed into outer threads of a threaded connection. By machining or processing the mounting element781with a connection mechanism, the mounting element781may be connected to another element, such as the shaft42of the choke valve assembly10shown inFIG.1-2. In this manner, the PCD insert780may be secured to the shaft42using the connection mechanism machined into the outer surface785of the mounting element781. While the connection mechanism shown in a threaded connection, it should be understood that any other connection mechanism may be utilized.

FIG.8-1is a cross-sectional view of a PCD assembly879having a mounting element881cast onto a PCD insert880, according to at least one embodiment of the present disclosure. The PCD insert880includes a bore886extending into a body887of the PCD insert880. The bore886may be a blind bore, or may not extend all the way through the body887of the PCD insert880. In some embodiments, the bore886may be located in a center of the body887. For example, the bore886may be centered along a longitudinal axis884of the PCD insert880.

One or more retention features883may extend into the bore886from the body887. The retention features883may protrude or extend inward from an inner surface of the bore886. In some embodiments, the retention features883may include a protrusion, a knob, a tab, any other element extending from the inner surface of the bore886, and combinations thereof. In some embodiments, the retention features883include a hollow, a bore, a hole, a detent, any other feature that extends into the body887from the bore886, and combinations thereof.

In some embodiments, the mounting element881may be cast onto the PCD insert880. The mounting element881may be cast into the bore886. In some embodiments, the mounting element881may be directly cast onto the PCD insert880. For example, the PCD insert880may be placed in a mold and the mounting element881may be cast onto the PCD insert880while the PCD insert880is in the mold. The mounting element881may be cast in any casting manner, such as powder metallurgy, sintering, laser cladding, melting and casting, any other metallurgical process, and combinations thereof.

In some embodiments, the mounting element881may be cast directly onto the retention features883. In some embodiments, the mounting element881may be cast around the circumferential sides of the retention features883. This may help to prevent the mounting element881from rotating within the bore886. In some embodiments, the mounting element881may be cast around an upper and lower surface of the retention features883. This may help to prevent the mounting element881from being laterally removed from the bore886, such as in a direction parallel to the longitudinal axis884. In some embodiments, the mounting element881may be cast onto circumferential and upper and lower surfaces of the retention features883to prevent both rotation and lateral removal of the mounting element881from the bore886.

In accordance with at least one embodiment of the present disclosure, the mounting element881may be made from a machinable material. For example, the mounting element881may be made from a metal or a metallic alloy, such as zinc, iron, steel, aluminum, any other metal or metallic alloy, and combinations thereof. After the mounting element881is cast in the bore886, the mounting element881may be machined into a final shape.

InFIG.8-2, the mounting element881has been machined with a mounting element bore888. The mounting element bore888may extend into the bore886. The mounting element881may be machined with a connection mechanism889. The connection mechanism889may include internal threads. The internal threads may be used to connect the PCD assembly879to another element. For example, the internal threads of the connection mechanism889may be used to connect the PCD assembly879to a shaft of a choke valve assembly, such as the shaft42of the choke valve assembly10ofFIG.1-2.

In accordance with at least one embodiment of the present disclosure, the mounting element881may be machined into any type of connection mechanism889. Because the mounting element881is formed from a machinable material, the connection mechanism889may take any machinable form. In some embodiments, the mounting element881may be more easily machined than the body887of the PCD insert880. This may allow the mounting element881to form various types of connection mechanisms889.

In accordance with at least one embodiment of the present disclosure, the connection mechanism889may be used to connect the PCD assembly879to any element or structure. In this manner, the PCD assembly879may be any type of PCD assembly879that may be connected to another structure. For example, the PCD assembly879may include one or more of a needle for a choke valve, other pump parts, a cutting element, a pick head, any other PCD assembly879, and combinations thereof.

In the embodiment shown inFIG.8-1andFIG.8-2, the bore886has a cylindrical shape. However, it should be understood that the bore886may have any shape discussed herein. For example, the bore886may have any shape discussed and/or illustrated with respect toFIG.5-1throughFIG.5-6. In some embodiments, a bore886having an opening diameter that is less than a terminal diameter of the terminal end may help to reduce the removal of the mounting element881from the bore886.

In accordance with at least one embodiment of the present disclosure, a PCD assembly may include a mounting element that is cast to both the bore and the outer surface of the PCD insert. This may allow for a machined connection inside both the bore and an outer surface of the PCD insert.

FIG.9is a flowchart of a method990for forming a PCD assembly, according to at least one embodiment of the present disclosure. The method990may include preparing a PCD insert with a retention feature at991. In some embodiments, the retention feature may be formed on an outer surface of the PCD insert. In some embodiments, the retention feature may be formed on an inner surface of a bore in the PCD insert. In some embodiments, a mounting element may be cast onto the PCD insert. The mounting element may be cast directly to the PCD insert at992. In some embodiments, the mounting element may be cast around all surfaces of the retention feature. In some embodiments, casting the mounting element to the PCD insert may include cooling the mounting element on the PCD insert. This may cause a shrink-fit that at least partially connects the mounting element to the PCD insert. In some embodiments, casting the mounting element to the PCD insert may include casting the mounting element around an entirety of the PCD insert.

The mounting element may be machined into a final shape at993. In some embodiments, the final shape may include external threads on an outer surface of the mounting element. In some embodiments, the final shape may include internal threads on an inner surface of a mounting bore. In some embodiments, the internal threads may extend into the bore of the PCD insert. In some embodiments, the machining the final shape may include machining the final shape, such as the threaded connection, across the retention features. In some embodiments, the PCD assembly formed by the PCD insert and the mounting element may be connected to a structure, such as the shaft of a choke valve assembly.

The following are example embodiments in accordance with the present disclosure:A1. A polycrystalline diamond (PCD) assembly, comprising:a PCD insert, the PCD insert having a body and an outer surface, the outer surface including a retention feature; anda mounting element molded to the PCD insert around at least a portion of the outer surface of body and the retention feature.A2. The retention mechanism of A1, the mounting element being directly cast on the PCD insert.A3. The retention mechanism of A1 or A2, the mounting element being formed from a machinable material.A4. The retention mechanism of any of A1-A3, the mounting element being machined with a connection mechanism.A5. The retention mechanism of A4, wherein the connection mechanism includes external threads of a threaded connection.A6. The retention mechanism of any of A1-A5, wherein the retention feature includes a protrusion extending from the outer surface.A7. The retention mechanism of any of A1-A6, wherein the mounting element is molded around an entirety of the retention feature.B1. A polycrystalline diamond (PCD) assembly, comprising:a PCD insert, the PCD insert having a body defining a bore, the bore including an anti-rotation feature; anda mounting element molded to the PCD insert inside the bore and around the anti-rotation feature.B2. The retention mechanism of B1, the mounting element being directly cast into the bore.B3. The retention mechanism of B1 or B2, the mounting element being formed from a machinable material.B4. The retention mechanism of any of B1-B3, the mounting element being machined with a connection mechanism.B5. The retention mechanism of B4, wherein the connection mechanism includes internal threads of a threaded connection.B6. The retention mechanism of any of B1-B5, wherein the anti-rotation feature includes a protrusion protruding into the bore.B7. The retention mechanism of any of B1-B6, wherein the mounting element is molded around an entirety of the anti-rotation feature.C1. A method, comprising:preparing a polycrystalline diamond (PCD) insert with a retention feature on an outer surface of a body of the PCD insert;casting a mounting element to the PCD insert, the mounting element being cast around the retention feature; andmachining the mounting element into a final shape.C2. The method of C1, wherein machining the mounting element into a final shape includes machining a threaded connection onto the mounting element.C3. The method of C1 or C2, wherein casting the mounting element to the PCD insert includes casting the mounting element around an entirety of the retention feature.C4. The method of any of C1-C3, wherein casting the mounting element to the PCD insert includes cooling the mounting element on the PCD insert, the cooled mounting element applying a compressive force to the PCD insert.C5. The method of any of C1-C4, wherein machining the mounting element into the final shape includes machining the final shape across the retention feature.C6. The method of any of C1-C5, further comprising connecting the PCD insert and the mounting element to a shaft of a choke valve assembly.

The embodiments of the PCD assemblies have been primarily described with reference to choke valves; however, the PCD assemblies described herein may be used in applications used in drilling, production, or characterization of a wellbore, subterranean formation, or natural resource. In other embodiments, PCD assemblies of the present disclosure can be used in entirely different industries. Thus, PCD assemblies according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources, including in a borehole used for other purposes, such as placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.