Patent Publication Number: US-2023151698-A1

Title: Earth boring tools including brazed cutting elements and related methods

Description:
BACKGROUND 
     Polycrystalline diamond compact (“PDC”) cutters have been used in a variety of industrial applications, including downhole drill bits for use in forming boreholes in subterranean formations, such as wellbores. PDC cutters are cutting elements that include cutting faces of a polycrystalline diamond material which is then bonded to a substrate. 
     Cutting elements are typically mounted on a drill bit body by brazing. The drill bit body is formed with recesses, which are often referred to in the art as “cutter pockets,” for receiving a substantial portion of the cutting element in a manner which presents the PDC layer at an appropriate location and orientation for cutting in accordance with the drill bit design. A surface of the volume of polycrystalline diamond material defines a cutting face and/or cutting edge of the cutter. In such cases, a brazing compound is applied to the surface of a substrate of the PDC cutting element to which the PDC layer is bonded and/or in the recess in the bit body in which the cutting element is to be bonded. The cutting elements are installed in their respective recesses in the bit body and heat is applied to each cutting element to raise the temperature to a point that is high enough to melt the brazing compound, after which the brazing compound is allowed to cool and solidify to bond the cutting elements to the bit body within the cutter pockets. 
     In downhole operations, drill bits and the cutters attached to them are subjected to extreme forces and heat while the cutting through the subterranean formation. In these extreme conditions, the cutting elements attached to the bit body are sometimes fractured or broken off from the drill bit body, which can result in damage to other downhole equipment, reduction of drilling efficiency, and other adverse consequences for the drilling operation. 
     BRIEF SUMMARY 
     In some embodiments, an earth boring tool includes a bit body where at least one surface of the bit body defines a cutting element recess in an outer surface of the bit body. The earth-boring tool may also include a cutting element where the cutting element is secured within the cutting element recess by a braze material at an interface between the bit body and the cutting element. The cutting element may include a generally cylindrical substrate that has at least one outer surface that defines a braze recess as well as a polycrystalline diamond compact included on the generally cylindrical substrate. The braze material is disposed between the cutting element and at least one surface of the bit body defining the cutting element recess, including within the braze recess of the generally cylindrical substrate. The bit body does not include a surface defining a feature on the bit body complementary to the braze recess in the generally cylindrical substrate. 
     A method of securing a cutting element to an earth-boring tool includes disposing a generally cylindrical cutting element within a cutting element recess defined by at least one surface of a bit body where the generally cylindrical cutting element has at least one outer surface defining a braze recess, disposing a braze material between the generally cylindrical cutting element and at least one surface of the bit body defining the cutting element recess, including within the braze recess in at least one outer surface of the generally cylindrical cutting element, and where the bit body does not include a surface defining feature on the bit body complementary to the braze recess in at least one outer surface of the cutting element. 
     In other embodiments, a method of securing a cutting element to an earth-boring tool includes removing material from at least one outer surface of the cutting element to define a braze recess where removing material includes using conventional machining techniques. The cutting element includes a substrate where at least one outer surface of the substrate defines a braze recess. The braze recess may be defined in a lateral surface and/or a base surface of the substrate. 
     In other embodiments, a method of securing a cutting element to an earth-boring tool includes rotating a generally cylindrical cutting element relative to a bit body while the generally cylindrical cutting element is disposed within a cutting element recess and a braze material is disposed between the generally cylindrical cutting element and at least one surface of the cutting element recess. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of the example embodiments of the disclosure when reading in conjunction with the accompanying drawings, in which: 
         FIG.  1    illustrates an earth-boring rotary drill bit comprising cutting elements secured to the bit body by brazing in accordance with embodiments of the present disclosure; 
         FIG.  2 A  is a simplified perspective side view of a substrate of a cutting element used in an earth-boring tool; 
         FIG.  2 B  is a simplified end view of the substrate of  FIG.  2 A ; 
         FIG.  3 A  is a simplified perspective side view of a second substrate of a cutting element used in an earth-boring tool; 
         FIG.  3 B  is a simplified end view of the substrate of  FIG.  3 A ; 
         FIG.  4    is a simplified perspective view of a third substrate of a cutting element used in an earth-boring tool; 
         FIG.  5 A  is a simplified perspective view of a fourth substrate of a cutting element us ed in an earth boring tool; 
         FIG.  5 B  is a simplified end view of the substrate of  FIG.  5 A ; 
         FIG.  6 A  is a simplified perspective view of a fifth substrate of a cutting element used in an earth boring tool; 
         FIG.  6 B  is a simplified end view of the substrate of  FIG.  6 A ; 
         FIG.  7 A  is a simplified perspective view of a sixth substrate of a cutting element used in an earth boring tool; 
         FIG.  7 B  is a simplified end view of the substrate of  FIG.  7 A ; 
         FIG.  8 A  is a simplified perspective view of a seventh substrate of a cutting element used in an earth boring tool; 
         FIG.  8 B  is a simplified end view of the substrate of  FIG.  8 A ; 
         FIG.  9 A  is a simplified perspective view of an eighth substrate of a cutting element used in an earth boring tool; 
         FIG.  9 B  is a simplified end view of the substrate of  FIG.  9 A ; 
         FIG.  10    is a simplified perspective view of a ninth substrate of a cutting element used in an earth boring tool; 
         FIG.  11    is a cross section view of the substrate of  FIG.  4   ; 
         FIG.  12    is a detailed cross sectional end view of  FIG.  5 A ; and 
         FIG.  13    is a side view of the substrate of  FIG.  10    disposed in an earth boring tool. 
     
    
    
     DETAILED DESCRIPTION 
     The illustrations presented herein are not actual views of any particular cutting element, insert, or drill bit, but are merely idealized representations employed to describe embodiments of the present disclosure. Additionally, elements common between figures may retain the same numerical designations. 
     As used herein, the term “hard material” means and includes any material having a Knoop hardness value of about 1,000 Kg/mm 2  (9,807 MPa) or more. Hard materials include, for example, diamond, cubic boron nitride, boron carbide, tungsten carbide, etc. 
     As used herein, the term “intergranular bond” means and includes any direct atomic bond (e.g., covalent, metallic, etc.) between atoms in adjacent grains of material. 
     As used herein, the term “polycrystalline hard material” means and includes nay material comprising a plurality of grains or crystals of the material that are bonded directly together by intergranular bonds. The crystal structures of the individual grains of polycrystalline hard material may be randomly oriented in space within the polycrystalline hard material. 
     As used herein, the term “polycrystalline compact” means and includes any structure comprising intergranular bonds formed by a process that involves application of pressure (e.g., compaction) to the precursor material or materials used to form the polycrystalline hard material. 
     As used herein, the term “earth-boring tool” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore and includes, for example, rotary drill bits, percussion bits, core bits, eccentric bits, bi-center bits, reamers, mills, drag bits, roller-cone bits, hybrid bits, and other drilling bits and tools known in the art. 
     Any reference to an element herein using a designation such as “first,” “second,” and so forth does not limit the quantity or order of those elements, unless such limitation is explicitly stated. Rather, these designations may be used herein as a convenient method of distinguishing between two or more elements or instances of an element. Thus, a reference to first and second elements does not mean that only two elements may be employed there or that the first element must precede the second element in some manner. In addition, unless stated otherwise, a set of elements may include one or more elements. 
     Any reference to the terms “braze process,” “brazing process,” or “brazing” means any type of process involving binding two objects together using a metal filler. This process may include, for example, furnace brazing, torch brazing, or any other method of brazing known in the art. 
     As used herein, the term “generally” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as, for example, within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is generally met, the parameter, property, or condition may be at least 90% met, at least 95% met, or even at least 99% met. 
     PDC cutters of a down-hole drill bit are often secured to a drill bit body through a brazing process. The brazing process bonds objects together using a metal filler, such as aluminum-silicon alloys, silver-base alloys, and copper-zinc alloys. Additionally, a chemical flux may be used in conjunction with the metal filler in order to facilitate a strong braze. Flux can be used in a paste or a powder form and coated either on the joint to be brazed or coated on the metal filler used for brazing. Flux aids the brazing process by absorbing oxides that otherwise form on the surfaces of the joint when the metal filler is melted and applied thereon. Oxides prevent the metal filler from wetting and adhering to the surfaces of the joint. However, too much flux can also inhibit the wettability of the metal filler and left over flux residue may additionally act as a corrosive material that may lead to damage to the surface it is applied and, as a result, may lead to a weakening of the braze joint. Because of this, excess flux may need to be evacuated during the brazing process in order to ensure a strong braze. 
     Polycrystalline hard material itself is difficult to braze because the material has poor wettability as well as other factors. Because of this, polycrystalline hard material is conventionally attached to a substrate made from a material, such as tungsten carbide, more suitable for brazing due to, for instance, greater wettability. For example, a flux may be applied to the surfaces of a recess on the bit body in which the cutting element is received. The cutting elements are installed in their respective recesses in the bit body and heat is applied to each cutting element as well as a metal filler to raise the temperature to a point which is high enough to melt the filler and braze the cutting elements to the bit body using the metal filler. In order to promote wettability, the cutting element may be rotated while in the recess to allow the metal filler to fully cover the cutting element substrate as well as the surfaces of the recess. However, because of the typically smooth cylindrical shape of the substrate, the substrate may be difficult to grip and may be difficult to spin in the recess making the brazing process more cumbersome and challenging. 
     Moreover, because of the forces applied to the cutting element during drilling, in combination with the severe heat and pressure that each cutting element of a drill bit undergoes within the wellbore, the bond formed by brazing the cutting element to the drill bit may fail, leading to cutting elements being forcibly removed from their respective recesses which can result in damage to other downhole equipment, reduction of drilling efficiency, and other adverse consequences for the drilling operation. 
       FIG.  1    illustrates earth-boring tool  100  in the form of a fixed cutter rotary drill bit. The earth-boring tool  100  includes a bit body  102 . One or more cutting elements  104  as described herein may be mounted on the bit body  102  of the earth-boring tool  100 , such as on blades  106 . The cutting elements  104  may optionally be secured within a cutting element recess formed in the outer surface of the bit body  102  where at least one surface of the bit body defines the cutting element recess in the outer surface of the bit body. Other types of earth-boring tools, such as roller cone bits, percussion bits, hybrid bits, reamers, etc., also may include cutting elements  104  as described herein. 
     The cutting elements  104  may include a polycrystalline hard material  108 . Typically, the polycrystalline hard material  108  may be or include polycrystalline diamond, but may include other hard materials instead of or in addition to polycrystalline diamond. For example, the polycrystalline hard material  108  may be or include cubic boron nitride. Optionally, cutting elements  104  may also include substrates  110  to which the polycrystalline hard material  108  is bonded, or on which the polycrystalline hard material  108  is formed. For example, a substrate  110  may include a generally cylindrical body of cobalt-cemented tungsten carbide material, although substrates of different geometries and compositions may also be employed. The polycrystalline hard material  108  may be in the form of a table (i.e., a layer) of polycrystalline hard material  108  on the substrate  110 , as shown in  FIG.  1   . The polycrystalline hard material  108  may be provided on (e.g., formed on or secured to) a surface of the substrate  110 . The cutting elements  104  may be referred to as “polycrystalline compacts,” or, if the polycrystalline hard material  108  includes diamond, as “polycrystalline diamond compacts.” 
     The substrate  110  in  FIG.  1    may include at least one outer surface that defines a braze recess and which may be secured to the bit body  102  using a braze material disposed between the cutting element and at least one surface of the bit body defining the cutting element recess, including within the braze recess of the substrate  110 . Though earth-boring tool  100  is shown having a cutting element  104  with substrate  110 , any cutting element or substrate described with respect to the other figures may be used. 
     In accordance with the present disclosure, cutting elements are described that include a substrate and braze recess located in at least one surface of the substrate. In at least one aspect of the present disclosure, the braze recess allows a greater surface area of the substrate to interface with a braze material order to facilitate improved mechanical retention of the cutting element to the earth-boring tool without necessitating complicated formation of complementary mating surfaces on both the bit body and the cutting element. Moreover, having a braze recess on the cutting element with no complementary features on the earth-boring tool may allow for the cutting element to optionally be rotated during the brazing process and also optionally allowing rotating or removing the cutting element without obstruction after reheating the braze material for maintenance or replacement purposes. 
       FIG.  2 A  illustrates one embodiment of substrate  110  in a simplified perspective side view. The substrate  110  may be generally cylindrical in shape and may include a lateral surface  112  as well as base surfaces  114   a  and  114   b . In some embodiments, when substrate  110  is disposed within a recess of the bit body  102 , base surface  114   a  faces a back surface of a cutting element recess of the bit body  102  and a polycrystalline hard material (e.g., a polycrystalline diamond compact) may be provided on base surface  114   b . The cutting element may be placed within a cutting element recess in the bit body  102  in such a way so as to allow the polycrystalline hard material to face outward from the bit body  102 . 
     Substrate  110  may include at least one outer surface defining a braze recess  120 . For example, as shown in  FIG.  2 A , braze recess  120  may be defined in base surface  114   a . In other embodiments, braze recess  120  may be defined in other surfaces of substrate  110  as shown at least in the example embodiments discussed below. Substrate  110  may be secured to a bit body  102  by placing substrate  110  in a recess of bit body  102  and then brazing the substrate  110  to bit body  102 . Brazing a cutting element to a bit body may be accomplished by disposing a cutting element  104 , including substrate  110 , inside of a cutting element recess of bit body  102  and providing a liquefied braze material between the cutting element and at least one surface of the bit body defining a cutting element recess. The braze recess  120  may allow the liquefied braze material to fill the braze recess  120  as the braze material is disposed between the cutting element and the cutting element recess of the bit body  102 . The geometry created by the braze recess  120  may allow for a greater surface area of the substrate  110  to come into contact with the braze material as it is secured within the cutting element recess of bit body  102  than conventional substrate geometries. By allowing the greater surface area of substrate  110  including braze recess  120  to interface with the braze material, the mechanical retention of the braze joint between the substrate  110  and the cutting element recess of bit body  102  may be increased. Furthermore, the braze recess  120  may allow for greater flux evacuation than conventional substrate constructions because the braze recess  120  may provide a path for flux to evacuate after the braze material and the flux have been heated to a liquid state and disposed between the cutting element recess of the bit body  102  and the substrate  110  of the cutting element  104 . Allowing flux to evacuate may prevent an excess of flux from being disposed in the braze joint, which may lead to a stronger braze joint between substrate  110  and the cutting element recess. 
     Though substrate  110  is depicted as generally cylindrical, other geometries capable of being disposed within a recess of bit body  102  may be employed. Moreover, braze recess  120 , or any braze recess disclosed herein, may be defined in any surface of the employed geometry. Furthermore, the braze recess  120  may cover at least a portion of the surface it is defined in up to and including the entirety of the surface. The braze recess  120  may have a generally rectangular profile as shown, for example, in  FIG.  2 A , or may have other configurations, such as a triangular or rounded (elliptical) profile. Though the braze recess  120  depicted in  FIG.  2 A  shows uniform braze recess profiles, braze recess  120  may combine different profile shapes. 
     The braze recess  120  may be formed on substrate  110  by removing material from substrate  110 . The removal of material may be accomplished using conventional machining methods including lathing, broaching, milling, boring, drilling, etc. Additionally, braze recess  120  may be formed as a result of the process of forming the substrate. For example, braze recess  120  may be formed by being predefined by a mold where material is disposed within the mold and then hardened to form the substrate  110 , thus forming the braze recess  120  in at least one outer surface of the substrate  110  simultaneously with the substrate  110 . In another example, the substrate  110  may be formed through a sintering process using a mold with a predefined braze recess  120 . In yet another example, the braze recess  120  may be formed initially though additive manufacturing where the substrate  110  is additively manufactured with the braze recess  120  already defined in at least one surface of substrate  110 . 
     With continued reference to  FIG.  2 A , Substrate  110  may have a braze recess  120  in the form of multiple grooves that are arranged in various ways on the surfaces of the substrate  110 . For example, as shown in  FIG.  2 A , the substrate  110  may have a braze recess  120  in the form of two grooves extending orthogonally in relation to each other creating a cross pattern on the base surface  114   a . In other embodiments, the braze recess  120  on base surface  114   a  may be in the form of one or a plurality of grooves where the one or more grooves may be irregular in shape and, in the case of having a plurality of grooves, each groove may be at any angle in relation to the other grooves. In some embodiments, braze recess  120  may be in the form of a plurality of grooves extending across base surface  114   a . For example, in some embodiments, the plurality of grooves may extend generally parallel to each other across base surface  114   a . As another example, in some embodiments the plurality of grooves may be in the form of two sets of grooves, the first set of grooves extending generally parallel to each other across base surface  114   a  and the second set of grooves extending generally parallel to each other across base surface  114   a  at an angle from about 15 to about 90 degrees relative to the first set of grooves, thus defining a plurality of crossing patterns in base surface  114   a . In other embodiments, the braze recess  120  defined in the base surface  114   a  of substrate  110  may comprise one or more concentric circles or spirals. 
     Still referring to  FIG.  2 A , in some embodiments, the braze recess  120  may extend to a depth  116  into substrate  110  from a surface thereof, where depth  116  is in a range extending from about 0.020 to about 0.120 inches. In other embodiments, the braze recess  120  may extend to a depth  116  into substrate  110  from a surface thereof, where depth  116  may be in a range extending from about 0.002 to about 0.010 inches 
       FIG.  2 B  is a simplified end view of substrate  110  facing base surface  114   a  and displaying a width  118  of the braze recess  120 . In some embodiments, the braze recess  120  may extend to a width  118  extending across a surface of substrate  110  in a range extending from 0.020 to about 0.120 inches. In other embodiments, the braze recess  120  may extend to a width  118  extending across a surface of substrate  110  in a range extending from about 0.002 to about 0.010 inches. 
       FIG.  3 A  and  FIG.  3 B  illustrate a simplified perspective and end view of an embodiment of substrate  180  having a braze recess  122 . The substrate  180  may be identical to substrate  110  but for the configuration of braze recess  122  being in the form of three grooves disposed on a base surface  112   a  and arranged in a crossing pattern where each groove is angled generally equidistant in relation to each of the other grooves. 
       FIG.  4    is a simplified perspective view of an example embodiment of substrate  190  having a braze recess  124  defined in lateral surface  112  of the substrate  190  where the braze recess  124  is in the form of a groove extending helically around at least a portion of the substrate  190 . In the embodiment of  FIG.  4   , the groove extends helically around an entirety of the substrate  190 . In other embodiments the braze recess  124  may be in the form of a groove extending only partially around a portion of the substrate  190 . In yet other embodiments, the braze recess  124  may be in the form of one or more grooves extending circumferentially around a portion or an entirety of the substrate. As used herein, the reference to a “braze recess” includes one or more grooves or other recesses which may or may not be contiguous or intersecting. 
     When brazing a cutting element to an earth-boring tool, once the cutting element has been placed inside the recess with the braze material inside, the substrate of the cutting element may optionally be rotated to help wet the substrate with the braze material and enable a strong braze joint between the bit body and the substrate. Braze recess  124  may allow the braze material to fill the braze recess  124  as the braze material is disposed between the cutting element and at least one surface of the cutting element recess of the bit body  102 . When the cutting element is optionally rotated within the cutting element recess with the braze material disposed therein, the helical construction of braze recess  124  may allow for the braze material to more easily fill braze recess  124  as a result of the rotating motion, thereby making it easier to wet the substrate  190  with the braze material. Moreover, as a result of the geometry of braze recess  124  creating more surface area on lateral surface  112 , a greater surface area of the substrate  190  may come into contact with the braze material as it is secured within the cutting element recess of bit body  102  compared to conventional substrates that do not include braze recess  124 . By allowing the greater surface area of substrate  190  including braze recess  124  to interface with the braze material, the strength of the braze joint between the substrate  190  and the cutting element recess of bit body  102  may be increased. Furthermore, braze recess  124  may allow for greater flux evacuation because braze recess  124  may provide a path for flux to evacuate after the braze material and the flux have been heated to a liquid state and disposed between the cutting element recess of the bit body  102  and substrate  190  of the cutting element. Allowing flux to evacuate may prevent an excess of flux from being disposed in the braze joint, which may lead to a stronger braze joint between substrate  190  and the cutting element recess. Additionally, the braze recess  124  may provide a coarse surface to lateral surface  112  that may make it easier for a person performing the brazing process to grip the substrate  190  in order to turn it during the brazing process to provide a homogeneous wetting of the surfaces of substrate  190  with the braze material. Moreover, braze recess  124  may have a width and a depth that allows a capillary action to occur between the braze recess  124  and the liquefied braze material such that the braze material will flow within the braze recess  124  without the aid of external forces. This capillary action between the braze recess  124  and the braze material may further aid in wetting the surfaces of substrate  190  with braze material and makes it easier to homogeneously wet the surfaces of substrate  190  with the braze material, including while the substrate  190  is disposed within the cutting element recess of the bit body  102 . Specifically, as a non-limiting example, the braze recess  124  may extend to a depth into substrate  190  from a surface thereof, where the depth is in a range extending from about 0.002 to about 0.010 inches. 
     The braze recess  124  may be formed on substrate  190  by removing material from substrate  190 . The removal of material may be accomplished using conventional machining methods including lathing, broaching, milling, boring, drilling, etc. Additionally, braze recess  124  may be formed as a result of the process of forming a substrate. For example, braze recess  124  may be formed by being predefined by a mold where material is disposed within the mold and then hardened to form the substrate  190 , thus forming the braze recess  124  in at least one outer surface of the substrate  190  simultaneously with the substrate  190 . In another example, the braze recess  124  may be formed through a sintering process using a substrate mold with predefined braze recesses. In yet another example, the braze recess  124  may be formed initially through additive manufacturing where the substrate  190  is additively manufactured with the braze recess  124  already defined. 
     Although the braze recess  124  is shown as being a homogenous pattern defined in lateral surface  112 , in some embodiments the substrate  190  may have any number of a variety of braze recess patterns disposed on lateral surface  112 , such as, as a non-limiting example, any of the patterns or combination of patterns disclosed in the present disclosure. Moreover, though the braze recess  124  is shown in the form of a single groove extending helically around substrate  190 , the braze recess  124  may be in the form of a plurality of grooves where, in one embodiment, the grooves may be disposed on lateral surface  112  as a one or more longitudinally spaced, circular rings around substrate  190  where the rings are generally orthogonal to the longitudinal axis of substrate  190 . In  FIG.  4   , braze recess  124  is shown as being defined in a portion of the lateral surface  112 . However, in some embodiments, braze recess  124  may be defined across the entirety of the lateral surface  112 . 
       FIG.  5 A  and  FIG.  5 B  show a perspective and end view of substrate  200 . The substrate  200  may be identical to substrate  190  but for the configuration of braze recess  126  being in the form of one or more longitudinally extending, circumferentially spaced grooves disposed on lateral surface  112  such that the one or more longitudinally extending grooves are generally parallel to the longitudinal axis of substrate  200 . Although braze recess  124  is shown in  FIG.  5 A  and  FIG.  5 B  to have the form of a plurality of grooves having a uniform width and depth, in other embodiments, the width and/or depth of each groove may vary. 
       FIG.  6 A  and  FIG.  6 B  show a perspective and end view of substrate  210  having a braze recess  128 . Substrate  210  may be identical to substrate  190  but for the configuration of braze recess  128  in the form of four lateral grooves, each generally equidistant from each other as defined on lateral surface  112  and extending generally parallel to a longitudinal axis of substrate  210 . In some embodiments, braze recess  128  may extend to a depth into substrate  210  from a surface thereof, where the depth is in a range extending from about 0.020 to about 0.120 inches. Moreover, the braze recess  128  may extend to a width extending across a surface of substrate  210  in a range extending from 0.020 to about 0.120 inches. In yet other embodiments, the braze recess  128  may extend to a depth into substrate  210  from a surface thereof, where depth  116  is in a range extending from about 0.002 to about 0.010 inches. Furthermore, the braze recess  128  may extend to a width  118  extending across a surface of substrate  210  in a range extending from about 0.002 to about 0.010 inches. Though braze recess  128  is shown in  FIG.  6 A  as having four grooves, in additional embodiments, braze recess  128  may be in the form of any number of grooves. 
       FIG.  7 A  and  FIG.  7 B  show a perspective and end view of substrate  220  having a braze recess  130 . Substrate  220  may be identical to substrate  190 , but for braze recess  130  being in the form of a first set of grooves and a second set of grooves. In some embodiments, the first set of grooves and the second set of grooves may exhibit any combination of braze recess patterns disclosed herein. In the embodiment shown in  FIG.  7 A , the first set of grooves extend generally parallel to a longitudinal axis of the substrate  220  and the second set of grooves extend helically around at least a portion of the substrate  220 . Moreover, while the first set of grooves and second set of grooves are shown in  FIG.  7 A  to overlap each other, the first set of grooves and the second set of grooves may be arranged such they are generally separate when disposed on lateral surface  112 . This separation can occur either laterally or vertically across lateral surface  112 . 
       FIG.  8 A  and  FIG.  8 B  show a perspective and end view of substrate  230  having a braze recess  132 . Substrate  230  may be identical to substrate  190 , but for braze recess  132  being in the form of at least one groove extending helically around at least a portion of substrate  230  at an angle from about 15 to about 75 degrees in relation to a longitudinal axis of substrate  230 . In the embodiment shown in  FIG.  8   , a plurality of grooves extend helically around at least a portion of substrate  230  at a generally 45 degree angle in relation to the longitudinal axis of substrate  230 . 
       FIG.  9 A  and  FIG.  9 B  show a perspective and end view of an example embodiment of substrate  240  having a braze recess  134 . Substrate  240  may be identical to substrate  110  but for having a braze recess  134  in the form of two grooves extending generally orthogonal to each other and defined in base surface  114   a  where the grooves have a generally rounded (elliptical) transverse profile. In some embodiments, braze recess  134 , or any braze recess disclosed herein, may be in the form of any number of grooves having a combination of different profile shapes including generally triangular, trapezoidal, or rectangular shapes. 
       FIG.  10    shows a perspective view of an example embodiment of substrate  250  having a braze recess  136   a  and a braze recess  136   b . Substrate  250  may combine attributes of substrate  110  shown in  FIG.  2 A  and substrate  190  shown in  FIG.  4   , having all of the related advantages of those embodiments. Substrate  240  may have at least one braze recess defined in a base surface, such as base surface  114   a , and at least one braze recess defined in lateral surface  112 .  FIG.  10    shows one example embodiment including braze recess  136   b  defined in lateral surface  112  and in the form of a groove extending helically around at least a portion of substrate  250 . Additionally, braze recess  136   a  is shown defined in base surface  114   a  and in the form of two grooves extending orthogonally in relation to each other in a cross pattern. However, in other embodiments any combination of braze recesses disposed on a base surface and a lateral surface are contemplated. 
       FIG.  11    shows a schematic cross sectional view of a substrate having a braze recess  138  which may correlate to any embodiment discussed herein. As shown, an example braze recess  138  may have a braze recess surface width  140  and a braze recess base width  142  in addition to a braze recess angle  150  that may be defined by the ratio between the braze recess surface width  140  and the braze recess base width  142 . Moreover, though the braze recess surface width  140  is depicted as being greater than the braze recess base width  142 , other embodiments may have the braze recess surface width  140  be equal to or less than the braze recess base width  142 . For example, the braze recess surface width  140  may extend across a surface of the substrate in a range extending from 0.020 to about 0.120 inches and the braze recess base width  142  may be in a range extending from 0.020 to about 0.120 inches. In other embodiments, the braze recess surface width  140  may extend across a surface of the substrate in a range extending from about 0.002 to about 0.010 inches and the braze recess base width may be in a range extending from about 0.002 to about 0.010 inches. Additionally, braze recess  138  may extend to a depth  148  into a substrate from a surface thereof, where the depth  148  is the distance from the plane defined by the lateral surface  112  to the braze recess base surface  146 . The depth  148  may be in a range extending from about 0.020 to about 0.120 inches. In other embodiments, the depth  148  may in a range extending from about 0.002 to about 0.010 inches. Furthermore, in some embodiments, braze recess  138  may be in the form of a helical groove that extends at least once around the entire circumference of a substrate and where the lateral distance between the helical groove as it extends at least once around the substrate is defined by the pitch distance  144 . In some embodiments, the pitch distance  144  is from about 0.04 to about 0.015 inches. In additional embodiments the pitch distance  144  may be any distance so long as the helical groove extends at least once around the substrate. Forming braze recess  138  in at least one surface of a substrate increases the surface area of the substrate that can interface with a braze material. The amount of surface area of a substrate with braze recess  138  is affected by each of at least the braze recess angle  150 , the depth  148 , braze recess surface width  140 , braze recess base width  142 , and the pitch distance  144 . 
       FIG.  12    shows a detailed end view illustrating a profile view of braze recess  139 , which may correlate with any embodiment herein. Braze recess  139  may be in the form of a groove defining a profile in a base surface of substrate  260  and extending a depth  162  into substrate  260 . In some embodiments, braze recess  139  may be in the form of a plurality of lateral grooves where the lateral grooves may be defined in the lateral surface  112  such that the distance (i.e., pitch) between a center of each groove of the plurality of lateral grooves is defined by the disposition angle  164 . The disposition angle  164  may in in the range from about 2 to 8 degrees of radial distance between each groove of the plurality of lateral grooves measured around the circumference of a base surface of substrate  260 . Though the disposition angle  164  is shown to be uniform across substrate  260 , in other embodiments the disposition angle  164  may vary between each lateral groove of the plurality of lateral grooves. Braze recess  139  may also have different profile shapes. For example, braze recess  139  may have a generally trapezoidal profile as shown in  FIG.  12   , or may have a generally triangular profile  160 . In other embodiments, the braze recess  139  may have a generally rounded or elliptical profile. 
       FIG.  13    shows a simplified side view illustrating how substrate  270  may be disposed in bit body  102 . Substrate  270  may be identical to substrate  250  including all related advantages discussed in relation thereto. A cutting element  180  that includes substrate  270  may be disposed within cutting element recess  170  of bit body  102  such that base surface  114   a  faces a back surface of cutting element recess  170  and a polycrystalline diamond compact included on base surface  114   b  faces outward from the bit body  102 . Braze material  172  may be disposed in cutting element recess  170  such that the braze material  172  is disposed at an interface between substrate  270  and the bit body  102  and fills the space between the substrate  270  and the cutting element recess  170  including within braze recess  174   a  and/or braze recess  174   b . In some embodiments, braze recess  174   a  and/or braze recess  174   b  may be of a size that allows for a capillary action to occur with liquefied braze material. Cutting element  180  including substrate  270  may be disposed within the cutting element recess  170  such that part of substrate  270  at least partially rises above the cutting element recess  170  whereas, in other embodiments, substrate  270  may be wholly covered by the cutting element recess  170 . 
     Braze material  172  may be composed of any material able to form a braze joint between cutting element  180  including substrate  270  and the cutting element recess  170 . In some embodiments, the braze material may include manganese (MN), aluminum (AL), phosphorus (P), silicon (Si), or zinc (Zn) alloyed with nickel (Ni), copper (Cu) or silver (Ag). 
     In some embodiments, the bit body  102  does not include a surface, such as the surfaces of cutting element recess  170 , defining a feature on the bit body complementary to a braze recess defined in at least one surface of substrate  270 . In other embodiments, the bit body  102  may include surfaces, such as the surfaces of cutting element recess  170 , that are coarse or rough to increase the wettability of the surfaces while not directly interfacing complimentarily with a braze recess defined in at least one surface of substrate  270 . 
     A brazing process where a cutting element may be secured to a downhole earth-boring tool may include disposing a cutting element within a cutting element recess defined by at least one surface of a bit body where at least one outer surface of the cutting element defines a braze recess. In some embodiments the cutting element may be generally cylindrical. In one example of this process, a braze material, including a flux compound, may be heated to a temperature sufficient to allow the braze material to bond the cutting element to a bit body. Typically, this involves heating the braze material to its melting point and then disposing the braze material and the flux compound in the cutting element recess prior to the placing of the cutting element. However, in other example processes the braze material and flux compound may be heated and disposed after the cutting element has been disposed within the cutting element recess. In the case of disposing the braze material before disposing the cutting element within the cutting element recess, once the cutting element has been placed inside the recess with the braze material disposed between the cutting element and at least one surface of the cutting element recess, the substrate of the cutting element may optionally be rotated relative to the bit body to help wet the substrate with the braze material to enable a strong braze joint between the bit body and the substrate. The braze recess defined in at least one surface of the cutting element may allow for a capillary action with the braze material such that liquefied braze material flows within the braze recess without the aid of external forces. This capillary action aids in wetting the surfaces of the cutting element and the cutting element recess with the braze material. Moreover, braze recesses defined in one or more surfaces of the cutting element may allow for greater flux evacuation as a braze recess may provide a path for flux to evacuate after the braze material and the flux have been heated and disposed between the cutting element recess of the bit body and the cutting element. 
     With regard to the cutting element, a braze recess may be defined in at least one outer surface of the cutting element. For example, a braze recess may be defined in a lateral surface of the cutting element, in a base surface of the cutting element, or both. In some embodiments, the braze recess may be formed by removing material from at least one outer surface of the cutting element. In a non-limiting example, the material may be removed from the cutting element through conventional machining methods including lathing, broaching, milling, boring, drilling, etc. In other embodiments, a braze recess may be formed simultaneously with the substrate of the cutting element. For example, in certain embodiments the braze recess may be defined in a cutting element mold such that, when material is poured into the mold and hardened the resulting cutting element will include a braze recess. In other embodiments a braze recess may be defined when using additive manufacturing to form the cutting element such that the material is additively applied defining a braze recess as part of the initially formed cutting element shape. 
     While the present disclosure has been described herein with respect to certain illustrated some embodiments, those of ordinary skill in the art will recognize and appreciate that the present invention is not so limited. Rather, many additions, deletions, and modifications to the illustrated and described some embodiments may be made without departing from the scope of the invention as hereinafter claimed along with their legal equivalents. In addition, features from one some embodiment may be combined with features of another some embodiment while still being encompassed within the scope of the invention as contemplated by the inventor.