Polycrystalline diamond bodies including one or more threads, apparatuses including the same, and methods of forming and using the same

An example PCD body includes a top surface, a bottom surface opposite the top surface, and at least one lateral surface extending between the top surface and the bottom surface. The PCD body includes one or more threads that are configured to allow the PCD body to be threadedly attached to a component, such as a substrate, a drill bit body, or a support ring. In an embodiment, the one or more threads may be formed on at least a portion of the lateral surface.

BACKGROUND

Wear-resistant, superabrasive compacts are utilized in a variety of mechanical applications. For example, polycrystalline diamond compacts (“PDCs”) are used in drilling tools (e.g., cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and in other mechanical apparatuses.

PDCs have found particular utility as superabrasive cutting elements in rotary drill bits, such as roller-cone drill bits and fixed-cutter drill bits. PDCs have also found particular utility as superhard bearing elements in bearing apparatuses, such as thrust-bearing and radial bearing apparatuses, by providing diamond surfaces that bearing against each other during use. The rotary drill bits and bearing apparatuses typically includes a number of PDCs affixed to a bit body or support ring, respectively. The PDCs are mounted to the bit body or support ring by press-fitting or brazing into a receptacle formed in the bit body or support ring. However, press-fitting or brazing the PDCs into the bit body or support ring may make repair (e.g., due to failure of the PDCs) of the rotary drill bits or bearing apparatuses that include the PDCs difficult and may cause thermal damage to the PDCs.

A PDC typically includes a superabrasive diamond layer commonly referred to as a diamond table. The diamond table may be formed and bonded to a substrate using a high-pressure, high-temperature (“HPHT”) process. The HPHT process may include placing a cemented carbide substrate into a container with a volume of diamond particles positioned adjacent to the cemented carbide substrate. A number of such cartridges may be loaded into an HPHT press. The substrates and volume of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains defining a polycrystalline diamond (“PCD”) table that is bonded to the substrate. The catalyst material is often a metal-solvent catalyst (e.g., cobalt, nickel, iron, or alloys thereof) that is used for promoting intergrowth of the diamond particles.

SUMMARY

Embodiments disclosed herein include polycrystalline diamond (“PCD”) tables including one or more threads, apparatuses including the same, and methods of forming and using the same. In an embodiment, a polycrystalline diamond body is disclosed. The polycrystalline diamond body includes a top surface, a bottom surface opposite the top surface, at least one lateral surface extending from or near the top surface to or near the bottom surface, and one or more threads formed on at least a portion of at least one surface of the polycrystalline diamond body.

In an embodiment, an apparatus is disclosed. The apparatus includes at least one polycrystalline diamond body including a top surface, a bottom surface opposite the top surface, at least one lateral surface extending from or near the top surface to or near the bottom surface, and one or more threads formed on at least a portion of at least one surface of the polycrystalline diamond body. The apparatus also includes a body including one or more body thread that are configured to interact with the one or more threads to threadedly attach the at least one polycrystalline diamond body to the body.

In an embodiment, a method of forming a polycrystalline diamond body is disclosed. The method includes forming one or more threads on at least a portion of at least one surface of a polycrystalline diamond body. The polycrystalline diamond body includes a top surface, a bottom surface opposite the top surface, and the at least one lateral surface extending from or near the top surface to or near the bottom surface.

In an embodiment, a method is disclosed. The method includes, while in a field and after a polycrystalline diamond body has spalled, detaching the polycrystalline diamond from a body. The polycrystalline diamond body includes a top surface, a bottom surface opposite the top surface, at least one lateral surface extending from or near the top surface to or near the bottom surface, and one or more threads formed on at least a portion of at least one surface of the polycrystalline diamond body. The body includes one or more body thread that are configured to interact with the one or more threads to threadedly attach the at least one polycrystalline diamond body to the body.

DETAILED DESCRIPTION

Embodiments disclosed herein include polycrystalline diamond (“PCD”) bodies including one or more threads, apparatuses including the same, and methods of forming and using the same. An example PCD body includes a top surface, a bottom surface opposite the top surface, and at least one lateral surface extending between the top surface and the bottom surface. The PCD body includes one or more threads that are configured to allow the PCD body to be threadedly attached to a component, such as a substrate, a drill bit body, or a support ring. In an embodiment, the one or more threads may be formed on at least a portion of the lateral surface.

In some applications, the threads may improve attaching the PCD body to the component compared to other conventional methods of attaching the PCD body to the component. In an embodiment, a PCD body that does not include one or more threads (“threadless PCD body”) may be metalurgically bonded or brazed to a cemented carbide substrate to form a polycrystalline diamond compact (“PDC”). Bonding and/or brazing the threadless PCD body to the cemented carbide substrate may cause several issues. For example, bonding the threadless PCD body to the cemented carbide substrate requires a catalyst (e.g., metal solvent catalyst) to at least partially occupy pores between the bonded diamond grains which may reduce the thermal stability of the threadless PCD. Brazing the threadless PCD body to the substrate may cause thermal damage to the threadless PCD body. Further, the threadless PCD body and/or a PDC that includes the threadless PCD body may be attached to a component other than the substrate (e.g., bit body or support ring) via an interference fit or brazing to form an apparatus. However, the interference fit and the brazing techniques may prevent replacement of the threadless PCD bodies in the field when the threadless PCD body fails. Instead, the apparatus may need to a specialized facility to remove and replace the failed threadless PCD body. Shipping the apparatus to the specialized facility may take a significant amount of time, require replacement apparatuses for operations while the apparatus is shipped and repair, and can be costly. Further, brazing the threadless PCD body and/or PDC that includes the threadless PCD body to the component may cause liquid metal embrittlement and cause thermal damage to the PCD body. It is noted that, as used herein, the “field” refers to a location were the apparatuses are used and is distinct from a specialized facilitate that includes equipment specially configured to braze and/or facilitate interference fit between the threadless PCD body and the component.

The PCD bodies disclosed herein that include the one or more threads which, in some embodiments, may represent an improvement over the threadless PCD body. For example, the one or more table treads allows the PCD bodies disclosed herein to be attached to a component (e.g., substrate, drill bit, or support ring) without a metallurgical bond, a braze, or an interference fit thereby preventing the issues associated with such attachment methods. Further, the threads may allow the PCD bodies to be detached from the components when the PCD bodies fail and a replacement PCD body that also includes threads to be attached to the component in the field. Thus, the PCD bodies disclosed herein that include the one or more threads may prevent some of the issues discussed above with regards to the threadless PCD body.

FIG.1Ais a side elevational view of a PCD body100, according to an embodiment. The PCD body100includes a top surface102and a bottom surface104opposite the top surface102. In the illustrated embodiment, the top surface102and the bottom surface104are illustrated as being substantially planar. However, it is noted that the top surface102and/or the bottom surface104may be non-planar (e.g., curved, dimpled, etc.). For example, the top surface102may be curved (e.g., convexly or concavely) when the PCD body100is used in a radial bearing assembly. The PCD body100also include at least one lateral surface106extending between the top surface102and the bottom surface104. In an embodiment, the PCD body100may include at least one chamfer108, for example, extending from the top surface102to the lateral surface106.

The PCD body100also includes one or more threads110formed in at least a portion of the lateral surface106. The threads110may be formed as any suitable type of thread and/or according to any standard. In an embodiment, the threads110may be formed as 60° V threads, API threads, UNEF threads, helical profile sweep, rope threads, UNR threads, UNJ threads, ACME threads, Whitworth threads, ball screw threads, worm threads, NPT threads, NPTF threads, BSPT threads, buttress thread, UTS threads, British standard threads, or any other type of thread. In an embodiment, the threads110may exhibit a generally triangular cross-sectional shape, such as a generally isometric triangular cross-sectional shape. (as shown). In an embodiment, the threads110may exhibit a generally square cross-sectional shape, a generally trapezoidal cross-sectional shape, or any other suitable cross-sectional shape. In an embodiment, the threads110may be right-handed threaded or left-handed threaded, depending on whether forces applied to the PCD body100during use are expected to apply a clockwise or counter-clockwise rotation to the PCD body100.

The threads110may be formed on all of or only a portion of the lateral surface106. For example, the threads110may be formed on about 5% to about 20%, about 10% to about 30%, about 20% to about 40%, about 30% to about 50%, about 40% to about 60%, about 50% to about 70%, about 60% to about 80%, about 70% to about 90%, about 80% to about 99%, or all of the lateral surface106of the PCD body100. The percentage of the lateral surface106that includes the threads110formed thereon may depend on a variety of factors. In an embodiment, the percentage of the lateral surface106that includes the threads110may be selected based on the length of the lateral surface106measured along the screw axis116of the threads110, the pitch of the threads110, and/or the expected force that is applied to the PCD body100during use. For instance, increasing the force applied to the PCD body100and decreasing the pitch of the threads110increases the likelihood that the threads110become damaged. However, increasing the percentage of the lateral surface106that includes the threads110decreases the likelihood that the threads110become damaged. In an embodiment, the percentage of the lateral surface106that includes the threads110may be selected to be as small as possible because it is difficult to form the threads110in the lateral surface106due to the hardness of the PCD body100. In an embodiment, the percentage of the lateral surface106that includes the threads110may depend on how much of the lateral surface106is exposed (e.g., extends above) when the PCD body100is attached to the component. Generally, it is desirable to reduce the quantity of the threads110that are exposed when the PCD body100is attached to the component during high stress and/or high wear applications. For instance, the valleys114of the threads110may form stress concentrators that increase the likelihood that the PCD body100prematurely fails and the threads110may increase the surface area of the lateral surface106that may wear. In some embodiments, the threads110may be formed on a surface other than the lateral surface106, such as on at least a portion of the chamfer108.

The threads110may be a single start thread or a multiple start thread. A start refers to the number of distinct threads that are formed on the lateral surface106. For example, the single start thread includes a single helical thread (e.g., helically extending ridge) along the lateral surface106whereas the multiple start thread that includes a plurality of intertwined threads. When the threads110are a multiple start thread, the threads110may include any number of starts, such as 2-4, 3-5, 4-6, 5-7, 6-8, 7-9, 8-10, 9-11, 10-12, 11-13, 12-14, 13-15, 14-16, 15-17, 16-18, 17-19, 18-20, 19-21, or more than 20 starts. Generally, increasing the number of starts makes attaching the PCD body100to a component quicker. For example, rotating the PCD body100360° advances the PCD body100into the base by a distance that is equal to the pitch of the threads110times the number of starts. However, increasing the number of starts of the threads110may decrease the distance between adjacent peaks112which may make the threads110more likely to be damaged. As such, the number of starts may be selected to be smaller when larger forces are expected to be applied to the PCD body100compared to a PCD body100that is expected to have smaller forces applied thereto.

The threads110exhibit a pitch that is the distance between adjacent peaks112. The pitch of the threads110may be selected to be greater than about 0.3 mm, greater than about 0.4 mm, greater than about 0.5 mm, greater than about 0.6 mm, greater than about 0.7 mm, greater than about 0.8 mm, greater than about 0.9 mm, greater than about 1 mm, greater than about 1.2 mm, greater than about 1.4 mm, greater than about 1.6 mm, greater than about 1.8 mm, greater than about 2 mm, greater than about 2.25 mm, greater than about 2.5 mm, greater than about 2.75 mm, greater than about 3 mm, greater than about 3.5 mm, greater than about 4 mm, greater than about 5 mm, greater than about 6 mm, greater than about 7 mm, greater than about 8 mm, greater than about 10 mm, greater than about 12.5 mm, greater than about 15 mm, greater than about 20 mm, or in ranges of about 0.3 mm to about 0.5 mm, about 0.4 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, about 0.8 mm to about 1 mm, about 0.9 mm to about 1.2 mm, about 1 mm to about 1.4 mm, about 1.2 mm to about 1.6 mm, about 1.4 mm to about 1.8 mm, about 1.6 mm to about 2 mm, about 1.8 mm to about 2.25 mm, about 2 mm to about 2.5 mm, about 2.25 mm to about 2.75 mm, about 2.5 mm to about 3 mm, about 2.75 mm to about 3.5 mm, about 3 mm to about 4 mm, about 3.5 mm to about 5 mm, or about 4 mm to about 6 mm, about 5 mm to about 7 mm, about 6 mm to about 8 mm, about 7 to about 10 mm, about 8 to about 12.5 mm, about 10 mm to about 15 mm, or about 12.5 mm to about 20 mm. The pitch of the table threads110may be selected to be greater than about 1% the minor or major diameter of the table threads110, such as greater than about 5%, greater than about 10%, greater than about 20%, greater than about 30%, greater than about 40%, greater than about 50%, greater than about 60%, greater than about 80%, greater than about 100%, greater than about 125%, greater than about 150%, greater than about 200%, greater than about 250%, greater than about 300%, or in ranges of about 1% to about 10%, about 5% to about 20%, about 10% to about 30%, about 20% to about 40%, about 30% to about 50%, about 40% to about 60%, about 50% to about 80%, about 60% to about 100%, about 80% to about 125%, about 100% to about 150%, about 125% to about 200%, about 150% to about 250%, or about 200% to about 300% the minor or major diameter of the table threads110.

The pitch may be selected based on a number of factors. In an example, the pitch of the threads110may be selected based on the hardness of the threads formed on the component. The pitch of the threads110match the pitch of the threads of the component to which the PCD body100is configured to be attached. The likelihood that the threads110and the threads of the component become damaged depends, at least to some extent, on the hardness of the material that forms the threads of the component. Generally, the hardness of the threads110are greater than the hardness of the threads of the component. Thus, the hardness of the threads of the component may limit the pitch of the threads110. In an example, the pitch of the threads110may depend on the application that the PCD body100is configured to be used in and, more particularly, the force that is expected to be applied to the PCD body100in such an application. As previously discussed, the likelihood that the threads110and/or the threads of the component become damaged depends on the magnitude of the force applied to the PCD body100(e.g., increasing the force increases the likelihood of damage and vice versa). As such, in one non-limiting example, the pitch of the threads110may be relatively coarse (e.g., greater than about 1 mm) when the PCD body100is used in a subterranean drilling application or a high load bearing assembly. However, in another non-limiting example, the pitch of the threads110may be relatively fine (e.g., less than 1.5 mm or less than 1 mm) when used in a low load bearing assembly. In an example, the pitch may be selected depending on how fine of adjustments (e.g., adjusting distance that the top surface102extends from the component, etc.) and how quickly the PCD body100is attached to the component is desired. For instance, decreasing the pitch allows for more fine adjustments while increasing the pitch allows for quicker attachment of the PCD body100to the component.

The threads110may exhibit any suitable major diameter (e.g., the maximum diameter of a cylinder that touches the peaks112) and any suitable minor diameter (e.g., the minimum diameter of a cylinder that touches the valleys114). The major and minor diameters of the threads110may be selected independently to be greater than about 0.5 cm, greater than about 0.75 cm, greater than about 1 cm, greater than about 1.25 cm, greater than about 1.5 cm, greater than 1.75 cm, greater than about 2 cm, greater than about 2.5 cm, greater than about 3 cm, greater than about 3.5 cm, greater than about 4 cm, greater than about 4.5 cm, greater than about 5 cm, or in ranges of about 0.5 cm to about 1 cm, about 0.75 cm to about 1.25 cm, about 1 cm to about 1.5 cm, about 1.25 cm to about 1.75 cm, about 1.5 cm to about 2 cm, about 1.75 cm to about 2.5 cm, about 2 cm to about 3 cm, about 2.5 cm to about 3.5 cm, about 3 cm to about 4 cm, about 3.5 cm to about 4.5 cm, or about 4 cm to about 5 cm. The major and minor diameter of the threads110may be selected based on the maximum lateral dimension of the PCD body100, the size of the cavity that is configured to receive the PCD body100, the pitch of the threads110, and whether the PCD body100includes a protrusion (as shown inFIG.2).

The depth of the threads110is the difference between the major and minor diameters of the threads110. The depth may be selected to be about 0.05 mm to about 0.15 mm, about 0.1 mm to about 0.2 mm, about 0.15 mm to about 0.25 mm, about 0.2 mm to about 0.3 mm, about 0.25 mm to about 0.35 mm, about 0.3 mm to about 0.4 mm, about 0.35 mm to about 0.45 mm, about 0.4 mm to about 0.5 mm, about 0.45 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, about 0.8 mm to about 1 mm, about 0.9 mm to about 1.2 mm, about 1 mm to about 1.5 mm, about 1.25 mm to about 1.75 mm, about 1.5 mm to about 2 mm, about 1.75 mm to about 2.5 mm, about 2 mm to about 3 mm, about 2.5 mm to about 3.5 mm, about 3 mm to about 4 mm, about 3.5 mm to about 6 mm, about 5 mm to about 7 mm, or about 6 mm to about 8 mm. The depth of the threads110may be selected based on the pitch of the threads110and the angle that the surfaces of the thread110extend relative to the screw axis116. The depth of the threads110may also be selected based on whether the threads110are truncated. The threads110are truncated when the outermost and innermost portions of the peaks112and valleys114, respectively, are not sharp angles and are instead, for example, rounded or flat. Truncating the threads110may decrease the depth of the threads110which may increase the likelihood that the threads110and/or the threads of the component become damaged. However, truncating the threads110may make manufacturing of the threads110easier and quicker and reduces wear on the device that forms the threads (e.g., electrodes or grinding wheel).

Generally, the PCD body100exhibits a generally circular shape (e.g., a generally cylindrical shape) where the lateral surface106includes the threads110. The generally circular cross-sectional shape allows the PCD body100to be threadedly attached to the component while reducing gaps between the lateral surface106PCD body100and surface of the component that contacts the lateral surface106. However, the generally circular shape may make gripping the PCD body100difficult when tightening or loosening the PCD body100. For instance, the generally circular cross-sectional shape may prevent or limit pliers or wrenches from mechanically gripping the PCD body100. As such, in some examples, the portions of the PCD body100(e.g., portions that do not include the threads110) may exhibit a generally non-circular cross-sectional shape (e.g., a generally non-cylindrical shape), such as a cross-sectional shape that exhibits at least one flat side, an elongated cross-sectional shape, a generally rectangular (e.g., square) cross-sectional shape, or a generally hexagonal cross-sectional shape. Such non-circular cross-sectional shapes may facilitate gripping the PCD body100with pliers, wrench, or other tools which facilitate tightening and loosening the PCD body100with such tools. In other examples, one or more recesses may be formed in the top surface102that allow the PCD body100to be tightened or loosened with a screwdriver. Examples of such recesses include a single straight recess, a generally square recess, a hexagonal recess, a generally triangular recess, two intersecting recesses in the form of a cross, or a recess exhibiting the shape of a 6-pointed star. In some embodiments, the PCD body100exhibits a generally non-circular shape where the lateral surface106includes the table threads110, such as a generally tri-lobed shape.

FIG.1Bis a schematic illustration of an embodiment of a method for fabricating the PCD body100, according to any embodiment. It is noted that the method illustrated inFIG.1Bmay be used to form any of the PCD bodies disclosed herein. Referring toFIG.1B, a mass of diamond particles118is positioned adjacent to a substrate120. The mass of diamond particles118may exhibit an average particle size of about 0.1 μm to about 150 μm (e.g., about 50 μm or less, about 30 μm or less, about 20 μm or less, about 15 μm or less, about 10 μm or less, about 5 μm to about 15 μm, about 10 μm to about 20 μm, about 18 μm to about 20 μm, or about 15 μm to about 18 μm). The diamond particle size distribution of the mass of diamond particles118may exhibit a single mode, or may exhibit a bimodal or greater grain size distribution. In an embodiment, the plurality of diamond particles may include a relatively larger size and at least one relatively smaller size. As used herein, the phrases “relatively larger” and “relatively smaller” refer to particles sizes determined by any suitable method, which differ by at least a factor of two (e.g., 40 μm and 20 μm). In various embodiments, the diamond particles118may include a portion exhibiting a relatively larger size (e.g., 100 μm, 90 μm, 80 μm 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm) and another portion exhibiting at least one relatively smaller size (e.g., 30 μm, 20 μm, 10 μm, 15 μm, 12 μm, 10 μm, 8 μm, 4 μm, 2 μm, 1 μm, 0.5 μm, less than 0.5 μm, 0.1 μm, less than 0.1 μm). Of course, the diamond particles118may also include three or more different sizes (e.g., one relatively larger size and two or more relatively smaller sizes), without limitation. Examples of diamond particle size distributions for the diamond particles118are disclosed in U.S. Pat. No. 10,501,998 and U.S. Pat. No. 9,346,149. The disclosure of each of the foregoing patent applications is incorporated herein, in its entirety, by this reference.

In order to effectively HPHT sinter the mass of diamond particles118, the mass of diamond particles118may be placed adjacent a surface of the substrate120to form an assembly122. In an embodiment, the substrate120may be omitted and the assembly122include a disc of the catalyst material disposed adjacent to the mass of diamond particles118, the mass of diamond particles118includes the catalyst material mixed therein, or no catalyst material is used. The assembly122may be placed in a pressure transmitting medium, such as a refractory metal can, graphite structure, pyrophyllite, combinations thereof, or another suitable container or supporting element. The pressure transmitting medium, including the assembly122, may be subjected to an HPHT process at a temperature of at least about 1000° C. (e.g., about 1100° C. to about 2200° C., or about 1200° C. to about 1450° C.) and a pressure in the pressure transmitting medium of at least about 5 GPa (e.g., at least about 7.5 GPa, at least about 9.0 GPa, at least about 10.0 GPa, at least about 11.0 GPa, at least about 12.0 GPa, at least about 14.0, or about 7.5 GPa to about 9.0 GPa) for a time sufficient to sinter the diamond particles118and form a PCD body100bonded to the substrate120thereby forming the PDC150.

During the HPHT process, the presence of a catalyst facilitates intergrowth between the mass of diamond particles118and forms the PCD body100including directly bonded-together diamond grains (e.g., exhibiting sp3bonding) defining a plurality of interstitial regions. In the illustrated embodiment, the PDC350may be formed by sintering the mass of diamond particles118on the substrate120, which may be a cobalt-cemented tungsten carbide substrate. For example, cobalt and/or a cobalt alloy from the substrate120liquefies during the HPHT process and infiltrates into the mass of diamond particles118to catalyze formation of the PCD body100. In such an example, some tungsten and/or tungsten carbide (metallic infiltrants) from the substrate120may dissolve in or otherwise transfer or alloy with the catalyst. However, in other embodiments, the catalyst may be mixed with the mass of diamond particles118, provided from a thin foil, another external source, combinations of the foregoing, or no catalyst at all. Additionally, the catalyst and the metallic infiltrants may react with the mass of diamond particles118to form carbides. As such, the interstitial regions of the PCD body100may be at least partially occupied by at least one interstitial constituent (e.g., at least one of a metal-solvent catalyst, a metallic infiltrant, one or more formed carbides etc.).

The PCD body100so formed may include an interfacial surface124bonded to the substrate120. Examples of interfacial surface geometries for the substrate120that may be bonded to the interfacial surface124are disclosed in U.S. Pat. No. 8,297,382, the disclosure of which is incorporated herein, in its entirety, by this reference. In an embodiment, the sintered grains of the PCD body100may exhibit an average grain size of about 20 μm or less or about 30 μm or less. For example, the average grain size and grain size distribution of the PCD body100may be substantially similar or the same as the average diamond particle size and distribution of the mass of diamond particles118.

Examples of suitable HPHT process conditions that may be used to form any of the PDC embodiments disclosed herein are disclosed in U.S. Pat. No. 7,866,418 which is incorporated herein, in its entirety, by this reference.

When the HPHT sintering pressure is about 7.5 GPa in combination with the precursor average diamond particle size being less than 30 μm, at least an unleached portion of the PCD body100defined collectively by the bonded diamond grains and the metal-solvent catalyst may exhibit a coercivity of about 115 Oe or more and a metal-solvent catalyst content of less than about 7.5 wt % as indicated by a specific magnetic saturation of about 15 G·cm3/g or less. In a more detailed embodiment, the coercivity may be about 115 Oe to about 250 Oe and the specific magnetic saturation of the PCD body100(prior to being leached) may be greater than 0 G·cm3/g to about 15 G·cm3/g. In an even more detailed embodiment, the coercivity may be about 115 Oe to about 175 Oe and the specific magnetic saturation of the PCD body100may be about 5 G·cm3/g to about 15 G·cm3/g. In yet an even more detailed embodiment, the coercivity and specific magnetic saturation of the PCD body100(prior to being leached) may be about 155 Oe to about 175 Oe and about 10 G·cm3/g to about 15 G·cm3/g, respectively. The specific permeability (i.e., the ratio of specific magnetic saturation to coercivity) of the unleached portions of the PCD body100may be about 0.10 or less, such as about 0.060 G·cm3/g Oe to about 0.090 G·cm3/g Oe. In some embodiments, despite the average grain size of the bonded diamond grains being less than about 30 μm, the metal-solvent catalyst content in the PCD body100(prior to being leached) may be less than about 7.5 wt % (e.g., about 3 wt % to about 6 wt % or about 1 wt % to about 3 wt %) resulting in a desirable thermal stability.

After the HPHT process, the PCD body100may be at least partially leached to remove at least a portion of the at least one interstitial constituent therefrom. In an embodiment, the PDC350may be at least partially immersed in and/or exposed to a leaching agent (e.g., hydrofluoric acid, nitric acid, a supercritical fluid, a gaseous leaching agent, another suitable leaching agent, or combinations thereof) to at least partially remove at least one interstitial constituent from the PCD body100to form a leached region. Removing at least a portion of the at least one interstitial constituent from the PCD body100may improve the wear resistance, heat resistance, thermal stability, or combinations thereof of the PCD body100, particularly in situations where the PCD body100may be exposed to elevated temperatures. In an embodiment, the PCD body100may only be partially leached to maintain the metallurgical bond between the substrate120and the PCD body100. However, in other embodiments, a PCD body100may be removed from a substrate120to which it was bonded during HPHT sintering. Such a configuration may allow the PCD body100to be completely leached, which may improve the thermal stability of the PCD body100.

Explaining further, after the HPHT process, the substrate120may be removed from the PCD body100. The substrate120may be removed from the PCD body100before, during, or after at least one of leaching the PCD body100and/or forming the threads110on the PCD body100. The substrate120may be removed from the PCD body100by one or more of dissolving the substrate120(e.g., while leaching the PCD body100), grinding away the substrate120, electro-discharge machining (“EDM”) processes (wire EDM or plunge EDM), laser ablation, grinding, and/or any other suitable technique. In some embodiments, the substrate120may not be removed from the PCD body100.

The threads110may be formed in the PCD body100using any suitable technique. In an embodiment, the threads110may be at least partially formed during the HPHT process. In an example, the pressure transmitting medium or other container that the mass of diamond particles118are disposed in may be configured as a mold. The surfaces of the mold that contact the mass of diamond particles118may include a negative of the threads110. In other words, the surfaces of the mold that contact the mass of diamond particles118may include valleys and peaks that form the peaks112and valleys114, respectively, of the threads110. For instance, the mass of diamond particles118may form a shape that corresponds to at least the contours of the surfaces of the mold. During the HPHT process, the diamond grains are bonded together which locks the shape of the mass of diamond particles118thereby forming the threads110. In an example, the assembly122includes a sacrificial material disposed in the pressure transmitting medium along with the mass of diamond particles118. The sacrificial material may form and fill at least the valleys114of the threads110. In other words, the PCD body100includes the sacrificial material disposed in the valleys114of the threads110. The sacrificial material may be configured to be more easily removed from the PCD body100than the bonded diamond grains. For instance, the sacrificial material may include a material that is less hard than the diamond grains which makes the sacrificial material easier to remove from the PCD body100during machining techniques (e.g., mechanical machining, grinding, EDM, or laser ablation) or may be formed from a material that is easily dissolved during the leaching process. Examples of sacrificial materials include tungsten carbide, refractory metals, ceramics, or other materials used in HPHT processes.

In an embodiment, the threads110may be formed using a machining process after the HPHT process. In an example, the threads110may be formed using plunge electrical discharge machining (“EDM”). In such an example, an electrode exhibiting a shape that generally corresponds to the valleys114may move towards the PCD body100to remove portions of the PCD body100. The portions removed from the PCD body100may form at least the valleys114. The PCD body100may be mounted on a device that rotates and otherwise moves the PCD body100relative to the electrode since it may be easier to rotate and otherwise move the PCD body100than the device that includes the electrode. In an example, the threads110may be formed suing an electrical discharge grinder. In such an example, an electrode in the forms of a spinning wheel may be moved proximate to portions of the PCD body100that are to be removed therefrom. The spinning wheel may include one or more protrusions that correspond in shape to the valleys114. The spinning wheel may cause an electrical discharge that removes portions of the PCD body100to form at least the valleys114. The PCD body100may be mounted on a device that rotates and otherwise moves the PCD body100relative to the spinning wheel since it may be easier to rotate and other move the PCD body100than the device that includes the spinning wheel. In an example, the threads110may be formed using a grinding or “turning the thread” technique. However, forming the threads110using grinding or “turning the thread” techniques may be difficult since, due to the hardness of the diamond grains of the PCD body100, the machining medium is likely to be removed at the same or greater rate than the PCD body100. In an example, the threads110may be formed using water jetting or wire EDM.

In an embodiment, the threads110may be formed in the PCD body100by lasing the PCD body100with a laser device to remove portions therefrom. In an example, the laser device may be positioned such that a laser omitted thereby predominately cuts portions of the PCD body100. The laser may cut portions of the PCD body100when the laser is generally oriented parallel (±30°) to the surface of the PCD body100that the laser illuminates. In an example, the laser may be configured to remove portions of the PCD body100by predominately ablating portions of the PCD body100. The laser may ablate portions of the PCD body100when the laser is generally oriented perpendicular (±30°) to the surface of the PCD body100that the laser illuminates. It is noted that the laser may neither predominately cut or ablate the PCD body100(e.g., the angle that the laser illuminates the PCD body100is neither generally parallel or perpendicular to a surface of the PCD body100). Further examples of techniques that may be used to lase the PCD body100are disclosed in U.S. patent application Ser. No. 16/084,469, and U.S. Pat. No. 9,062,505, the disclosures of each of which is incorporated herein, in its entirety, by this reference.

In an example, the PCD body100may be mounted to a device that rotates or otherwise moves the PCD body100relative to the laser device. In an example, the laser device may be configured to rotate relative to the PCD body100. In either example, the angle between the laser and the surface of the PCD body100may remain relatively constant (e.g., ±20°). Maintaining the angle constant may improve the accuracy that the laser removes portions of the PCD body100since the mode (e.g., cut or ablate) of removing the PCD body100may not change.

In an example, the portions of the lateral surface106that includes the threads110formed thereon may be divided into sections and the laser device may be configured to remove portions of the PCD body100from one section before removing portions of the PCD body100in another section. Dividing the lateral surface106into sections may improve the accuracy of the laser device removing portions of the PCD body100. For example, the lateral surface106may be divided into 2 or more sections, 3 or more sections, 4 or more sections, 5 or more sections, 6 or more sections, 7 or more sections, 8 or more sections, 9 or more sections, 10 or more sections, or in ranges of about 2-4 sections, 3-5 sections, 4-6 sections, 5-7 sections, 6-8 sections, 7-9 sections, or 8-10 sections. The number of portions that the lateral surface106is divided into may depend on the laser device, the mode that the laser device uses to remove portions of the PCD body100, and the desired accuracy. In an example, each section may include a portion of the circumference of the lateral surface106.

In an embodiment, any technique (or any combination of techniques) disclosed herein for forming the threads110may be used to shape and/or polish portions of the PCD body100that are distinct from the threads110.

In an embodiment, the PCD body100may include a bottom chamfer117extending from the bottom surface104to the lateral surface106. The bottom chamfer117may facilitate insertion of the PCD body100into a recess since there is no corner between the bottom surface104and the lateral surface106that may catch on the component when attaching the PCD body100to the component. The bottom chamfer117may or may not include one or more threads110formed thereon.

The PCD bodies disclosed herein may exhibit a shape other than the shape illustrated inFIGS.1A and1B. For example,FIG.2is a side elevational view of a PCD body200, according to an embodiment. Except as otherwise disclosed herein, the PCD body200may include one or more features that are the same or substantially similar to any of the PCD bodies disclosed herein. For example, the PCD body200may include a top surface202, a bottom surface204opposite the top surface202, and a plurality of diamond grains bonded together.

The illustrated embodiment, the PCD body200includes at least one first lateral surface206aand at least one second lateral surface206b. The first lateral surface206aextends from or near the top surface202and the second lateral surface206bextends from or near the bottom surface204. The PCD body200also include at least one intermediate surface226extending between the first and second lateral surfaces206a,206b.

The PCD body200includes a main body230and a protrusion232extending therefrom. The main body230of the PCD body200is partially defined by the top surface202, the first lateral surface206a, and the intermediate surface226. The main body230exhibits a first lateral dimension (e.g., diameter) extending between opposing portions of the first lateral surface206a. The protrusion232is partially defined by the bottom surface204and the second lateral surface206b. The protrusion232exhibits a second maximum lateral dimension (e.g., diameter) measured between opposing portions of the second lateral surface206b. The second lateral dimension is smaller than the first lateral dimension. In some embodiments, the second lateral dimension is larger than the first lateral dimension.

At least a portion (e.g., all) of second lateral surface206bmay include one or more threads210formed thereon. The threads210allow the PCD body200to be threadedly attached to a component. The threads210may include one or more features that are the same or substantially similar to any of the threads disclosed herein and may be formed according to any of the methods disclosed herein. The first lateral surface206amay also include one or more threads formed thereon (not shown).

The protrusion232may be formed using any suitable technique. In an example, the protrusion232may be formed by disposing the mass of diamond particles that form the PCD body200into a mold (e.g., pressure transmitting medium or other container) that exhibits a shape that generally corresponds to the negative shape of the PCD body200. In such an embodiment, the protrusion232and the PCD body200are integrally formed with each other. For instance, the mold may include a wider region that corresponds to the main body230, a narrower region that corresponds to the protrusion232, and a step therebetween that corresponds to the intermediate surface226. In an example, the protrusion232may be formed using a sacrificial material. In an example, the protrusion232may be formed by removing portions of the PCD body200to form the protrusion232using machining (e.g., EDM, grinding, lasing, etc.) techniques.

The protrusion232may reduce the quantity of diamond particles that are required to form the PCD body200relative to a substantially cylindrical PCD body that exhibits the same maximum lateral dimension as the first maximum lateral dimension of the main body230. The protrusion232may also facilitate attachment of the PCD body200to the component. For example, the protrusion232may be inserted into cavities formed in the component that are too small to receive a substantially cylindrical PCD body that exhibits the same maximum lateral dimension as the first maximum lateral dimension of the main body230. The smaller cavities that are configured to receive the protrusion232may be easier to form since a smaller quantity of the component needs to be removed to receive the protrusion232. The protrusion232may also allow for greater flexibility in the selection of the PCD body200that is attached to the component. For example, the cavity of the component may be configured to receive a substantially cylindrical PCD body. However, it may be desirable to use a PCD body that exhibits a larger top surface than the substantially cylindrical PCD body. The protrusion232allows the size of the top surface to be increased without modifying the cavity of the component.

The intermediate surface226(e.g., intermediate annular surface) may abut a surface of the component when the PCD body200is attached to the component, for example, to prevent over-insertion of the PCD body200into the component and/or to provide additional support for the PCD body200. As such, the intermediate surface226may generally correspond to the shape of a portion of the component that receives that PCD body200. In an example, the intermediate surface226may be generally parallel to the top surface202when the surface of the component that abuts the intermediate surface226. In an example, the intermediate surface226may be curved when the surface of the component that abuts the intermediate surface226is curved (e.g., the component is a support ring for a radial bearing assembly). In some embodiments, the intermediate surface226may not correspond to the shape of the surface of the component that abuts the intermediate surface226.

Any corner of the PCD body200may exhibit a radius, fillet, or chamfer. For example, at least one of the corner where the top surface202meets the lateral surface206a, the corner where the lateral surface206ameets the intermediate surface226, the corner where the lateral surface206bmeets the intermediate surface226, or the corner where the bottom surface204meets the lateral surface206bmay exhibit a radius, fillet, or chamfer.

As previous discussed, the PCD body disclosed herein may be configured to be attached to a component. The component may include, for example, a substrate (e.g., cemented carbide substrate), a bit body, a support ring, or any other structure that may receive a PCD body. For example,FIG.3Ais an isometric view of a substrate334that is configured to receive any of the PCD bodies disclosed herein. The substrate334is configured to be attached to any of the PCD bodies disclosed herein to form a PDC (shown inFIGS.3B and3C). Threadedly attaching the PCD body to the substrate334may mitigate issues caused by metallurgically bonding or brazing the PCD body to the substrate, as previously discussed herein.

The substrate334may be configured to indirectly attach the PCD body to secondary component. The secondary component may include any component that a PDC may be attached to that is distinct from the substrate334. Examples of the secondary component includes a drilling bit body or a support ring. Indirectly attaching the PCD body to the secondary component via the substrate334may allow the PCD body to be attached to a secondary component that is configured to receive conventional PDCs (e.g., PDCs that include a threadless PCD body) while also allowing the PCD body to be easily detached from the substrate334. The substrate334may be threadedly attached to (e.g., the substrate334includes component threads), interference fitted, or brazed to the secondary component

The substrate334includes a substrate top surface336, a substrate bottom surface338opposite the substrate top surface336, and at least one substrate lateral surface340extending between the substrate top surface336and the substrate bottom surface338. The substrate334may optionally include one or more chamfers. In an embodiment, the substrate334may be formed from a cemented carbide substrate, such as a cobalt-cemented tungsten carbide substrate. In an embodiment, the substrate334may be formed from a material other than a cemented carbide substrate (e.g., steel) since the substrate334is not metallurgically bonded to the PCD body.

The substrate334defines a cavity342that is sized and shape to receive at least a portion of any of the PCD bodies disclosed herein. The cavity342may extend from the substrate top surface336of the substrate334and into the substrate334. The cavity342may be partially defined by at least one cavity lateral surface344and, when the cavity342does not extend completely through the substrate334, a substrate bottom surface346. The substrate bottom surface346may be spaced from the substrate top surface336and the cavity lateral surface344may extend from or near the substrate top surface336of the substrate334to or near the substrate bottom surface346.

The substrate334exhibits a thickness between the substrate lateral surface340and the cavity lateral surface344(i.e., a portion of the cavity lateral surface344that does not include the component threads348or from the peaks of the component threads348), as previously discussed herein. The thickness between the substrate lateral surface340and the cavity lateral surface344may be about 1 mm to about 3 mm, about 2 mm to about 4 mm, about 3 mm to about 5 mm, about 4 mm to about 6 mm, about 5 mm to about 7 mm, about 6 mm to about 8 mm, about 7 mm to about 9 mm, about 8 mm to about 1 cm, about 9 mm to about 1.2 cm, about 1 cm to about 1.5 cm, about 1.25 cm to about 1.75 cm, about 1.5 cm to about 2 cm, about 1.75 cm to about 2.5 cm, or greater than about 2 cm. The thickness of the substrate334between the substrate lateral surface340and the cavity lateral surface344may depend on the depth of the component threads348and the expected forces that are to be applied to the PCD body attached to the substrate334during use.

At least a portion of the cavity lateral surface344may include one or more component threads348. The component threads348are configured to correspond to and be threadedly attached to the threads of a PCD body (e.g., the PCD body100as show inFIG.3Band/or the PCD body100as shown inFIG.3C). For example, the component threads348may include a plurality of peaks and valleys. The peaks of the component threads348are configured to be positioned within the valleys of the threads and the valleys of the component threads348are configured to receive the peaks of the threads. The properties of the component threads348may be selected to match or generally correspond to the properties of the threads that the component threads348are configured to be threadedly attached. In an example, the component threads348may exhibit a pitch, depth, truncation, and/or type (e.g., API threads) that generally corresponds to the pitch, depth, truncation, and/or type of the threads, respectively. In other words, the component threads348may exhibit any of the pitches, depth, truncations, and/or type of threads disclosed herein. The component threads348exhibit a major diameter that is the smallest diameter of a cylinder that touches the peaks of the component threads348and a minor diameter that is the largest diameter of a cylinder that touches the valleys of the component threads348. The major diameter and the minor diameter of the component threads348generally correspond to (e.g., is the same as, slightly smaller than, or slightly larger than) the minor diameter and the major diameter, respectively, of the threads to which the substrate334is configured to be attached.

FIG.3Bis a cross-sectional schematic of a PDC350b(e.g., an apparatus) that includes the PCD body100illustratedFIG.1Athreadedly attached to the substrate334illustrated inFIG.3A, according to an embodiment. As illustrated, the PCD body100is disposed in the cavity342(shown inFIG.3A) defined by the substrate334. The threads110and the component threads348interact with each other such that the PCD body100is securely attached to the substrate334.

In an embodiment, the top surface102of the PCD body100may be generally level or substantially coplanar with the substrate top surface336. In an embodiment, the top surface102of the PCD body100may be spaced from the substrate top surface336by a distance d which may decrease the amount of wear on the substrate334than if the top surface102of the PCD body100was even with the substrate top surface336. The distance d also allows the PCD body100to be gripped with pliers, wrenches, or other tools. The distance d may be selected to be greater than about 1 mm, greater than about 2 mm, greater than about 3 mm, greater than about 4 mm, greater than about 5 mm, greater than about 6 mm, greater than about 8 mm, greater than about 1 cm, greater than about 1.25 cm, greater than about 1.5 cm, greater than about 1.75 cm, greater than about 2 cm, or in ranges of about 1 mm to about 3 mm, about 2 mm to about 4 mm, about 3 mm to about 5 mm, about 4 mm to about 6 mm, about 5 mm to about 8 mm, about 6 mm to about 1 cm, about 8 mm to about 1.25 cm, about 1 cm to about 1.5 cm, about 1.25 cm to about 1.75 cm, or about 1.5 cm to about 2 cm. In some embodiments, the distance d may be less than 1 mm, such as 0 mm when the top surface102of the PCD body100is flush with the top surface336of the substrate334.

In the illustrated embodiment, the PCD body100exhibits a first maximum lateral dimension DTand the substrate334exhibits a second maximum lateral dimension DS. As illustrated, the first maximum lateral dimension DTis less than the second maximum lateral dimension DS. The second maximum lateral dimension DSis greater than the first maximum lateral dimension DTbecause the substrate334requires a thickness between the substrate lateral surface340and the cavity lateral surface344, as previously discussed herein. The fact that the first maximum lateral dimension DTis less than the second maximum lateral dimension DScauses a portion substrate top surface336to be exposed during operation. Exposing a portion of the substrate top surface336may increase wear on the substrate334.

FIG.3Cis a schematic cross-sectional view of a PDC350c(e.g., an apparatus) that include the PCD body200illustrated inFIG.2threadedly attached to the substrate334illustrated inFIG.3A, according to an embodiment. As illustrated, the protrusion232the PCD body200is disposed in the cavity342(shown inFIG.3A) defined by the substrate334. The threads210and the component threads348interact with each other such that the PCD body200is securely attached to the substrate334.

The PCD body200exhibits a first maximum lateral dimension DTand the substrate334exhibits a second maximum lateral dimension DS. In an embodiment, as illustrated, the first maximum lateral dimension DTand the second maximum lateral dimension DSare substantially the same. As such, the PCD body200covers substantially all of the substrate top surface336thereby minimizing wear on the substrate334during operation. In an embodiment, not shown, the second maximum lateral dimension DSmay be greater than the first maximum lateral dimension DT. In such an embodiment, the substrate top surface336may be exposed during use which may increase the wear on the substrate334. In an embodiment, the first maximum lateral dimension DTis greater than the second maximum lateral dimension DS. These three embodiments illustrate how the protrusion232of the PCD body200allows the PCD body200to be attached to different components that may not be specifically configured to receive such a PCD body200.

In some embodiments, the PCD bodies disclosed herein may be non-threadedly attached to a substrate. For example,FIG.4is schematic cross-section of a PDC450, according to an embodiment. The PDC450includes a PCD body400and a substrate434. Except as otherwise disclosed herein the PCD body400and the substrate434are the same or substantially similar to any of the PCD bodies and substrates, respectively, disclosed herein. The PCD body400is metallurgically bonded or brazed to the substrate434along an interfacial surface424thereof. The PDC450includes a top surface402, a bottom surface438opposite the top surface402, at least one lateral surface406extending between the top and bottom surfaces402,438, and, optionally, at least one chamfer408.

The PDC450includes one or more threads452formed on at least a portion of the lateral surface406. The threads452are configured to threadedly attach the PDC450to a secondary component that is distinct from the substrate434, such as a drill bit body or a support ring. For example, the secondary component may include one or more component threads that are configured to interact with the threads452, thereby threadedly attaching the PDC450to the secondary component.

The threads452may include one or more threads410formed on at least a portion of the lateral surface406defined by the PCD body400and/or one or more substrate threads448formed on at least a portion of the lateral surface406defined by the substrate434. The threads410and the substrate threads448may include one or more features that are the same or substantially similar to any of the threads disclosed herein. The threads410and the substrate threads448may be aligned with and exhibit complementary geometries (e.g., pitch, major diameter, etc.) as each other which allows the threads410and the substrate threads448to interact with the same threads on the secondary component. The threads452(e.g., at least one of the threads410or the substrate threads448) may be formed using any of the techniques (or combinations thereof) disclosed herein.

Except as otherwise disclosed herein, the PDC450may be formed according to any of the methods disclosed herein. For example, an assembly is disposed in a pressure transmitting medium. The assembly includes a mass of diamond particles and, optionally, a substrate. The assembly may include at least one catalyst material (e.g., metal-solvent catalyst, alkali metal carbonates, alkaline earth metal carbonates, etc.) at least one of disposed in the substrate, in the form of a disc of catalyst material, or mixed with the mass of diamond particles. The assembly is then subjected to an HPHT process configured to cause diamond-to-diamond bonding. In an embodiment, when the assembly includes the substrate434, the HPHT process may metallurgically bond the substrate434to the PCD body400thereby forming the PDC450. In an embodiment, the substrate disposed in the assembly is distinct from the substrate434of the PDC450. In such an embodiment, the substrate that was disposed in the assembly may be removed from the PCD body400, for example, via grinding. The PCD body400may then be attached to the substrate434in a second HPHT process or via brazing to form the PDC450. In an embodiment, the assembly does not include a substrate. In such an embodiment, the PCD body400may be attached to the substrate434in a second HPHT process or via brazing to form the PDC450.

As previously discussed, the component to which any of the PCD bodies disclosed herein may be attached may be distinct from the substrate. In an embodiment, the component to which any of the PCD bodies disclosed herein are attached to may include a PCD component that is distinct from the PCD body. For example,FIG.5is an exploded isometric view of an apparatus550that includes at least two PCD materials, according to an embodiment. Except as otherwise disclosed herein, the at least two PCD materials of the apparatus550may be the same as or substantially similar to any of the PCD materials (i.e., PCD bodies) disclosed herein. For simplicity and brevity, the top PCD material will be referred to as the PCD body500and the bottom PCD material will be referred to as the PCD component554. As such, as discussed herein, the PCD body500includes the male threaded connector and the PCD component554includes the female threaded connector. However, it is noted that the top PCD material may be the PCD component554and the bottom PCD material may be the PCD body500.

The PCD body500includes a top surface502, a bottom surface504opposite the top surface502, at least one lateral surface506, and, optionally, at least one chamfer508. The PCD body500also includes at least one threads510formed on at least a portion of the at least one lateral surface506. In an embodiment, as illustrated, the PCD body500includes a main body530and a protrusion532extending from the main body530, similar to the PCD body200illustrated inFIG.2. In an embodiment, the PCD body500may exhibit a generally cylindrical shape (i.e., does not include the protrusion532extending from the main body530) similar to the PCD body100illustrated inFIG.1A.

The PCD component554includes a component top surface536, a component bottom surface538, at least one component lateral surface540extending between the component top surface536and the component bottom surface538, and, optionally, at least one chamfer (not shown). The PCD component554defines a cavity542. The cavity542is partially defined by at least one cavity lateral surface544that extends from or near the component top surface536towards the body bottom surface538. At least a portion of the cavity lateral surface544includes one or more component threads548formed thereon. The component threads548are configured to interact with the threads510such that the PCD body500may be threadedly attached to the PCD component554. In an embodiment, as illustrated, the cavity542only extends partially through the PCD component554. In such an embodiment, the cavity542is also partially defined by a cavity bottom surface546that is spaced from the component top surface536and the body bottom surface538and the cavity lateral surface544extends from or near the component top surface536to or near the cavity bottom surface546. In an embodiment, the cavity542extends completely through the PCD component554.

The PCD component554may be formed using any of the methods disclosed herein. For example, the PCD component554may be formed according to the method illustrated inFIG.1B. In such an example, a mass of diamond particles may be disposed in a pressure transmitting assembly and subject to an HPHT process. The cavity542and the component threads548may be formed using a mold, a sacrificial material, plunge EDM, grinding, or any other suitable method.

Threadedly attaching the PCD body500to the PCD component554may help resolve several issues associated with the manufacturing of PCD materials. In an example, as previously discussed, conventional PCD bodies are often metallurgically bonded to substrates which may adversely affect the thermal stability of the conventional PCD body. The PCD component554may be metallurgically bonded to a substrate (not shown) and, thus, the PCD component554may include an infiltrant disposed therein that compromises the thermal stability of the PCD component554. The PCD body500may have be substantially free of infiltrants that compromise the thermal stability thereof (e.g., leached). The threads510and component threads548allows the PCD body500to be threadedly attached to the PCD component554and the substrate without re-introducing infiltrants into the PCD body500or requiring brazing the PCD body500to the PCD component554. As previously discussed, the PCD body500and the PCD component554may be reversed. As such, the PCD body500may be metallurgically bonded to the substrate and the PCD component554may be substantially devoid of infiltrants.

In an example, the apparatus550(e.g., PCD body500and the PCD component554collectively) may exhibit a thickness that is greater than is possible with a single PCD material. For example, using an HPHT process, a single PCD material may exhibit a maximum thickness of 24 mm measured from a top surface to a bottom surface thereof. Further, increasing the width (e.g., diameter) of the single PCD material that is measured between lateral surface(s) thereof a may also require a decrease in the thickness of the single PCD material. For instance, a single PCD material exhibiting a width of about 75 mm may exhibit a maximum thickness of about 5 mm and a PCD material exhibiting a width of about 13 mm may exhibit a maximum thickness of about 18 mm. However, apparatus550may exhibit a thickness that is greater than about 5 mm, greater than about 10 mm, greater than about 15 mm, greater of about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 50 mm, greater than about 60 mm, greater than about 70 mm, greater than about 80 mm, greater than about 100 mm, such as in ranges of about 5 mm to about 15 mm, about 10 to about 20 mm, about 15 mm to about 25 mm, about 20 mm to about 30 mm, about 25 mm to about 35 mm, about 30 mm to about 40 mm, about 35 mm to about 50 mm, about 40 mm to about 60 mm, about 50 mm to about 80 mm, or about 60 mm to about 100, even when the width of at least a portion of the apparatus550is greater than 10 mm, greater than about 15 mm, greater than about 20 mm, greater than about 30 mm, greater than about 40 mm, greater than about 50 mm, greater than about 60 mm, greater than 70 mm, or in ranges of about 10 mm to about 20 mm, about 15 mm to about 30 mm, about 20 mm to about 40 mm, about 30 mm to about 50 mm, about 40 mm to about 60 mm, or about 50 mm to about 70 mm.

It is noted that the apparatus550may include three or more PCD materials configured to be threadedly attached together. For example, at least one of the PCD body500or the PCD component554may define an additional cavity or protrusion. The additional or protrusion may allow the PCD body500and/or PCD component554to be threadedly attached to another PCD material.

As previously discussed, the PCD bodies disclosed herein may be threadedly attached to other bodies. For example,FIG.6is a cross-sectional schematic of a portion of an apparatus650, according to an embodiment. The apparatus650includes a PCD body600that is threadedly attached to a component634. Except as otherwise disclosed herein, the PCD body600may include one or more features that are the same or substantially similar to any of the PCD bodies disclosed herein. For example, the PCD body600may include a top surface602, a bottom surface604, and at least one lateral surface606that includes one or more threads610formed on at least a portion thereof.

Except as otherwise disclosed herein, the component634may include one or more features that are the same or substantially similar to any of the components disclosed herein. For example, the component634may include a component top surface636and a cavity642. The cavity642may be partially defined by a cavity bottom surface646spaced from the component top surface636and at least one cavity lateral surface644extending between the component top surface636and the cavity bottom surface646. The component634may include one or more component threads648formed on at least a portion of the cavity lateral surface644. The component threads648may be configured as any of the component threads disclosed herein and may be further configured to interact with the threads610.

The component634may be a drill bit body, a support ring of a bearing assembly, or any other component that may be attached to the PCD body600. The component634may be formed from any suitable material. For example, the component634may be formed from steel (e.g., stainless steel), another metal, a carbide material (e.g., tungsten carbide), another ceramic, or combinations thereof. The material that forms the component634may depend on the device that includes the component634. For example, the component634may be formed from a relatively hard material, such as hardened steel or tungsten carbide when the component634forms part of a drill bit body due to the abrasive environment that component634is exposed.

In the embodiments disclosed above, the PCD body form a male threaded attachment and the components form a female threaded attachment. In such embodiments, the PCD body may form a male threaded attachment since it may be easier to form a cavity in the softer component than the harder PCD body. However, any of the PCD bodies disclosed herein may form a female threaded attachment and any of the components disclosed herein may form a male threaded attachment. For example,FIG.7is an exploded cross-sectional schematic of a portion of an apparatus750, according to an embodiment. The apparatus750includes a PCD body700and a component734. The PCD body700and the component734are configured to be threadedly attached together. Except as otherwise disclosed herein, the PCD body700and the component734may include one or more features that are the same or substantially similar to any of the PCD bodies and components, respectively, disclosed herein. For example, the PCD body700may include a top surface702, a bottom surface704, and at least one lateral surface706extending between the top and bottom surfaces702. The component734is illustrated as being similar to the component634(e.g., a bit body or a support ring) illustrated inFIG.6. However, it is noted that the component734may include any of the components disclosed herein (e.g., a substrate or a PCD component).

The PCD body700defines a cavity742extending inwardly from bottom surface704. The cavity742may include a cavity top surface746that is spaced from the bottom surface704and at least one cavity lateral surface744extending between the bottom surface704and the cavity top surface746. The PCD body700includes one or more threads710formed on at least a portion of the cavity lateral surface744. Accordingly, the one or more embodiments disclosed herein that a polycrystalline diamond body may comprise internal (as shown inFIGS.5and7) and/or external threads (as shown inFIGS.1A-2and4-6), without limitation.

The component734includes a protrusion732extending from the component top surface736. The protrusion732is sized and shaped to fit within the cavity742defined by the PCD body700. The protrusion732may be partially defined by a protrusion top surface756and at least one protrusion lateral surface758. The component734includes one or more component threads748formed on at least a portion of the protrusion lateral surface758. The component threads748are configured to interact with the threads710. Thus, the PCD body700may be threadedly attached to the component734by inserting the protrusion732into the cavity742and rotating the PCD body700relative to the protrusion732such that the threads710and component threads748interact with each other.

The disclosed PCD bodies and PDC embodiments may be used in a number of different applications including, but not limited to, use in a rotary drill bit (FIGS.8A and8B), a thrust-bearing apparatus (FIG.9), a radial bearing apparatus (FIG.10), a mining rotary drill bit (e.g., a roof bolt drill bit), and a wire-drawing die. The various applications discussed above are merely some examples of applications in which the PDC embodiments may be used. Other applications are contemplated, such as employing the disclosed PDC embodiments in friction stir welding tools.

FIG.8Ais an isometric view andFIG.8Bis a top plan view of an embodiment of a rotary drill bit800for use in subterranean drilling applications, such as oil and gas exploration, according to an embodiment. The rotary drill bit800comprises a bit body802that includes radially and longitudinally extending blades804with leading faces806, and a threaded pin connection808for connecting the bit body802to a drilling string. The bit body802defines a leading end structure for drilling into a subterranean formation by rotation about a longitudinal axis and application of weight-on-bit. At least one PCD body, configured according to any of the previously described embodiments, may be directly or indirectly (e.g., via a substrate) threadedly attached to the bit body802.

The bit body802includes a plurality of PCD cutting elements812secured to the blades804. At least one of the PCD cutting elements812includes any one of the PCD bodies disclosed herein. The PCD cutting elements812may be threadedly attached to the bit body802or otherwise attached to the bit body802when the PCD cutting elements812includes a PCD body threadedly attached to a substrate. In addition, if desired, at least one of the PCD cutting elements812may be conventional PDCs (e.g., a threadless PCD body bonded to a substrate) press fitted or brazed to the bit body802. Also, circumferentially adjacent blades804define so-called junk slots818therebetween, as known in the art. Additionally, the rotary drill bit800may include a plurality of nozzle cavities820for communicating drilling fluid from the interior of the rotary drill bit800to the PDCs812.

The rotary drill bit800may then be used in one or more subterranean drilling operations until at least one of the plurality of PCD cutting elements812spall (“spalled PCD”). Spalling of the PCD cutting elements812may be detected by sudden changes in force exerted by the plurality of PCD cutting elements812against a subterranean surface, visual inspection, audible cues, or combinations thereof, etc. After one or more PCD cutting elements812spall, the spalled PCD may be removed from the rotary drill bit800, for instance, while the rotary drill bit800is in the field. For example, the spalled PCD may be removed from the rotary drill bit800by rotating the spalled PCD relative to the bit body802. A new PCD cutting element may then be threadedly attached to the drill bit body802, for instance, while the rotary drill bit800is in the field. The rotary drill bit800may then be used in subterranean drilling operations.

FIGS.8A and8Bmerely depict one embodiment of a rotary drill bit that employs at least one PCD cutting elements812fabricated and structured in accordance with the disclosed embodiments, without limitation. The rotary drill bit800is used to represent any number of earth-boring tools or drilling tools, including, for example, core bits, roller-cone bits, fixed-cutter bits, eccentric bits, bi-center bits, reamers, reamer wings, or any other downhole tool including superabrasive compacts, without limitation.

FIG.9is an isometric cut-away view of an embodiment of a thrust-bearing apparatus900, which may utilize any of the disclosed PCD body embodiments as bearing elements, according to an embodiment. The thrust-bearing apparatus900includes respective thrust-bearing assemblies902. Each thrust-bearing assembly902includes an annular support ring904that may be fabricated from a material, such as carbon steel, stainless steel, or another suitable material. Each support ring904includes a plurality of recesses (not labeled) that receives a corresponding bearing element906. At least one of the bearing element906includes a PCD body910including a bearing surface912and, optionally, a substrate908. In an embodiment, at least one bearing element906includes the PCD body910directly threadedly attached to the support ring904(e.g., the substrate908is omitted). In an embodiment, at least one bearing element906includes the PCD body910threadedly attached to the substrate908and the substrate908may be threadedly attached, brazed, press-fitted, fastened using fasteners, or otherwise attached to the support ring904. In an embodiment, the PCD body910is bonded or brazed to the substrate908and at least the substrate908is threadedly attached to the support ring904.

In use, the bearing surfaces912of one of the thrust-bearing assemblies902bears against the opposing bearing surfaces912of the other one of the bearing assemblies902. For example, one of the thrust-bearing assemblies902may be operably coupled to a shaft to rotate therewith and may be termed a “rotor.” The other one of the thrust-bearing assemblies902may be held stationary and may be termed a “stator.”

FIG.10is an isometric cut-away view of an embodiment of a radial bearing apparatus1000, which may utilize any of the disclosed PCD body embodiments as bearing elements, according to an embodiment. The radial bearing apparatus1000includes an inner race1002positioned generally within an outer race1004. The outer race1004includes a plurality of bearing elements1006affixed thereto that have respective bearing surfaces1008. The inner race1002also includes a plurality of bearing elements1010affixed thereto that have respective bearing surfaces1012. One or more, or all of the bearing elements1006and1010may be configured according to any of the PCD body embodiments disclosed herein. For example, one or more of the bearing elements1006or1010may include a PCD body directly threadedly attached to the outer race1004or the inner race1010, respectively, a PCD body threadedly attached to a substrate, or a PCD body bonded to a substrate and that substrate is threadedly attached to one of the races. The inner race1002is positioned generally within the outer race1004and, thus, the inner race1002and outer race1004may be configured so that the bearing surfaces1008and1012may at least partially contact one another and move relative to each other as the inner race1002and outer race1004rotate relative to each other during use.

The radial-bearing apparatus1000may be employed in a variety of mechanical applications. For example, so-called “roller cone” rotary drill bits may benefit from a radial-bearing apparatus disclosed herein. More specifically, the inner race1002may be mounted to a spindle of a roller cone and the outer race1004may be mounted to an inner bore formed within a cone and that such an outer race1004and inner race702may be assembled to form a radial-bearing apparatus.

The PDCs disclosed herein may also be utilized in applications other than cutting technology. For example, the disclosed PDC embodiments may be used in wire dies, bearings, artificial joints, inserts, cutting elements, and heat sinks. Thus, any of the PDCs disclosed herein may be employed in an article of manufacture including at least one superabrasive element or compact.

Thus, the embodiments of the PCD bodies disclosed herein may be used in any apparatus or structure in which at least one conventional PDC is typically used. In one embodiment, one or more of the PCD bodies disclosed herein may be used in a downhole drilling assembly. U.S. Pat. Nos. 4,410,054; 4,560,014; 5,364,192; 5,368,398; and 5,480,233, the disclosure of each of which is incorporated herein, in its entirety, by this reference, disclose subterranean drilling systems within which bearing apparatuses utilizing any of the PCD bodies disclosed herein may be incorporated. The embodiments of PCD bodies disclosed herein may also form all or part of heat sinks, wire dies, bearing elements, cutting elements, cutting inserts (e.g., on a roller-cone-type drill bit), machining inserts, or any other article of manufacture as known in the art. Other examples of articles of manufacture that may use any of the PCD bodies disclosed herein are disclosed in U.S. Pat. Nos. 4,811,801; 4,274,900; 4,268,276; 4,468,138; 4,738,322; 4,913,247; 5,016,718; 5,092,687; 5,120,327; 5,135,061; 5,154,245; 5,460,233; 5,544,713; and 6,793,681, the disclosure of each of which is incorporated herein, in its entirety, by this reference. Examples of other articles of manufactures that the PCD bodies disclosed herein can be used in are disclosed in U.S. Provisional Patent Application No. 62/232,732; U.S. patent application Ser. Nos. 13/790,046, 14/273,360, 14/275,574, and 14/811,699.

In some embodiments, the PCD bodies disclosed herein may be formed from a superhard material other than PCD (“superhard bodies”). For example, the superhard bodies disclosed herein may be formed silicon diamond, cubic boron nitride (with or without binder), magnesium carbon diamond, or another material exhibiting a hardness greater than tungsten carbide. Except for being formed from superhard material other than PCD, the superhard bodies are the same or substantially similar to any of the PCD bodies disclosed herein. For example, the superhard bodies may include one or more threads, may be configured to be attached to any of the bodies (e.g., substrate, bit body, or support ring) disclosed herein, and may be used in any of the applications disclosed herein.

Terms of degree (e.g., “about,” “substantially,” “generally,” etc.) indicate structurally or functionally insignificant variations. In an example, when the term of degree is included with a term indicating quantity, the term of degree is interpreted to mean±10%, ±5%, or +2% of the term indicating quantity. In an example, when the term of degree is used to modify a shape, the term of degree indicates that the shape being modified by the term of degree has the appearance of the disclosed shape. For instance, the term of degree may be used to indicate that the shape may have rounded corners instead of sharp corners, curved edges instead of straight edges, one or more protrusions extending therefrom, is oblong, is the same as the disclosed shape, etc.