US 12,410,104 B2
Methods of forming cutting elements
Marc W. Bird, Houston, TX (US)
Filed by Baker Hughes Holdings LLC, Houston, TX (US)
Filed on Sep. 24, 2019, as Appl. No. 16/581,152.
Application 16/581,152 is a division of application No. 15/594,174, filed on May 12, 2017, granted, now 11,292,750.
Prior Publication US 2020/0031724 A1, Jan. 30, 2020
Int. Cl. C04B 35/645 (2006.01); B22F 5/00 (2006.01); B22F 7/06 (2006.01); B23B 27/20 (2006.01); C04B 35/56 (2006.01); C04B 35/63 (2006.01); C04B 35/638 (2006.01); C22C 1/051 (2023.01); C22C 19/00 (2006.01); C22C 19/07 (2006.01); C22C 29/00 (2006.01); C22C 29/08 (2006.01); E21B 10/46 (2006.01); E21B 10/567 (2006.01)
CPC C04B 35/6455 (2013.01) [B22F 7/06 (2013.01); B23B 27/20 (2013.01); C04B 35/5626 (2013.01); C04B 35/6303 (2013.01); C04B 35/638 (2013.01); C22C 1/051 (2013.01); C22C 19/007 (2013.01); C22C 19/07 (2013.01); C22C 29/005 (2013.01); C22C 29/08 (2013.01); E21B 10/46 (2013.01); E21B 10/5673 (2013.01); B22F 2005/001 (2013.01); B22F 2998/10 (2013.01); C04B 2235/3847 (2013.01); C04B 2235/402 (2013.01); C04B 2235/404 (2013.01); C04B 2235/405 (2013.01); C04B 2235/427 (2013.01); C04B 2235/604 (2013.01); C04B 2235/85 (2013.01); C04B 2235/9607 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A method of forming a cutting element, comprising:
providing a supporting substrate comprising WC particles dispersed within a homogenized binder comprising from about 66 wt % Co to about 90 wt % Co, from about 5.0 wt % Al to about 15 wt % Al, from about 0.1 wt % C to about 0.2 wt % C, and from about 5.0 wt % W to about 30 wt % W;
depositing a powder comprising diamond particles directly on the supporting substrate;
subjecting the supporting substrate and the powder to elevated temperatures and elevated pressures to diffuse a portion of the homogenized binder of the supporting substrate into the powder and inter-bond the diamond particles; and
converting the homogenized binder within interstitial spaces between the inter-bonded diamond particles into a thermally stable material substantially free of catalytic Co, without leaching, and comprising κ-carbide precipitates.