EP3538735A1 - Rock-cutting tool and method for mine and oil drilling - Google Patents

Rock-cutting tool and method for mine and oil drilling

Info

Publication number
EP3538735A1
EP3538735A1 EP17797619.8A EP17797619A EP3538735A1 EP 3538735 A1 EP3538735 A1 EP 3538735A1 EP 17797619 A EP17797619 A EP 17797619A EP 3538735 A1 EP3538735 A1 EP 3538735A1
Authority
EP
European Patent Office
Prior art keywords
diamond
layer
impregnation
pdc
powder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP17797619.8A
Other languages
German (de)
French (fr)
Other versions
EP3538735B1 (en
Inventor
Robert Delwiche
Etienne Lamine
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Diarotech SA
Original Assignee
Diarotech SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Diarotech SA filed Critical Diarotech SA
Publication of EP3538735A1 publication Critical patent/EP3538735A1/en
Application granted granted Critical
Publication of EP3538735B1 publication Critical patent/EP3538735B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
    • E21B10/573—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
    • E21B10/5735—Interface between the substrate and the cutting element

Definitions

  • the present invention relates to rock cutting tools for mining and petroleum drilling and their manufacturing process.
  • rockbits that is to say having a cutting head comprising three conical rotating heads, provided with teeth or pins for drilling more or less effectively any type of terrain.
  • the tricone was changed to adapt to the nature of the formation encountered, that is to say the hardness of the rock. Indeed, it is common to find oil slicks to a depth of more than one thousand meters and it is necessary to cross a succession of soft rocks, like clays, and hard rocks, like sandstones, to reach there.
  • PDC knives have been manufactured comprising a highly impact resistant backing layer, generally based on tungsten carbide (WC), on which a thinner layer of PDC has been formed by a high-pressure high process. temperature (HPHT) or chemical vapor deposition (CVD). These knives are incorporated by brazing rotary cutting heads, or blades, drilling tools, which can have various shapes.
  • WC tungsten carbide
  • HPHT high-pressure high process. temperature
  • CVD chemical vapor deposition
  • diamond impregnation knives that is to say, cutting, impregnated in their structure , usually based on carbide, a multitude of diamond particles.
  • These diamond impregnation knives are manufactured by powder metallurgy processes and are much more resistant to abrasion than a simple carbide-based structure, with each diamond particle involved in rock abrasion.
  • the combination of these diamond knives and PDC knives in so-called mixed tools did not significantly improve the drilling capabilities of the tool. Indeed, for reasons related to soldering techniques, the diamond knife is located too far from the PDC layer and therefore does not effectively enhance its action.
  • the PDC knife wears before the diamond knife can be really effective, and is therefore no longer available for a softer successive layer.
  • the Applicant has therefore sought to develop rock cutting tools having blades for effectively drilling both soft formations that hard formations, with minimal wear. It is the object of the present invention to provide a hybrid tool for cutting rocks, effective and resistant, and a method of manufacturing this tool.
  • the invention relates to a rock cutting tool with knives comprising at least one polycrystalline synthetic diamond (PDC) anterior layer, a diamond impregnation rear layer with diamond particles and bonding cobalt, characterized in that the PDC layer is supported directly, along a plane interface, on the diamond impregnation layer whose interface surface is planar by machining and on which diamond particles are exposed, and the particles of The flush diamond of the impregnating layer is covalently bonded to the polycrystalline synthetic diamond.
  • PDC polycrystalline synthetic diamond
  • alternating diamond impregnation layers and PDC layers are provided.
  • US2014 / 0223839 discloses knives having a PDC anterior layer supported on a diamond impregnation backing layer with diamond particles comprising bonding cobalt.
  • the interface between these two layers is not flat, and no diamond particle does not flush on the surface of the diamond impregnation layer.
  • the cohesion between the two layers is based on the non-planarity of the interface which increases the surface area of this interface.
  • the cohesion between the two layers is done by carbon-carbon covalent chemical bonds
  • the PDC layer is as set in the diamond impregnation layer, which significantly increases the adhesion between the two layers and makes the tool more resistant to mechanical stress resulting either from direct contact with the rock or high temperatures that may be encountered in the drilling conditions.
  • the present invention also provides a method of manufacturing a knife of a rock cutting tool according to which
  • diamond granules are prepared with a powder containing tungsten, carbon and cobalt,
  • a diamond impregnation layer is preformed by cold pressing of the granules in a mold
  • the preformed diamond impregnation layer is sintered to crimp the diamonds, the sintered diamond impregnation layer is machined to a plane surface with flush diamonds,
  • the diamond powder layer is converted to a polycrystalline synthetic diamond (PDC) layer covalently bonded to said flush diamonds.
  • PDC polycrystalline synthetic diamond
  • each granule contains only one diamond particle.
  • the sintering of the diamond impregnation layer is carried out by a hot isostatic process.
  • Figure 1 is a schematic perspective view of the tool of the invention
  • Figure 2 is a perspective view of a knife of the tool of Figure 1;
  • FIG. 3 is a perspective view of the diamond impregnation layer of the knife of Figure 2;
  • Figure 4 is a flowchart which schematically illustrates the method of the invention and
  • Figure 5 is a perspective view of an alternative embodiment of a knife of the tool of the invention.
  • a rock cutting tool 1 has three blades 2 with four knives 3 at the free end of each blade.
  • the tool 1 is intended to be rotated about its axis AA '.
  • each knife is formed of a polycrystalline synthetic diamond (PDC) front or front layer 5 and a diamond impregnation back or rear layer 6 with diamond particles 7.
  • PDC polycrystalline synthetic diamond
  • FIG. 3 the front surface 8 of the posterior layer 6, adjacent to the anterior layer 5, is flat and diamond particles 12 are flush with it.
  • Oil drilling uses tools that dig a cylindrical hole.
  • the tools used generally have a cutting head which rotates at a greater or lesser speed in one direction.
  • the tool 1 has three blades 2 which will be in contact with the rock formation to be drilled. In particular, the knives 3 will ensure the drilling of the rock formation.
  • the PDC layer 5 is very hard and forms the cutting edge that will first cut the rock formation. This layer 5, however, is relatively brittle and is supported by a layer more resistant to mechanical stress.
  • tungsten carbide support layer was used as a support, which material exhibits excellent mechanical stress resistance.
  • tungsten carbide is not very resistant to abrasion and wears relatively quickly in contact with the rock, which reduces the life of the PDC layer.
  • a diamond impregnation layer 6 is used here to support the PDC layer 5, which has at least two advantages: the diamond particles 7 present in a tungsten carbide matrix, also containing cobalt to ensure the bonding of the assembly, increase the resistance of the support to abrasion and participate actively in the drilling of the rock, on the one hand and secondly the presence of these diamond particles makes it possible to reduce the difference in coefficient of thermal expansion between the support layer 6 and the PDC layer 5, which limits the mechanical stress that appears when the tool heats to several hundred degrees when of its rotation in contact with the rock. The result is a definite improvement in tool life.
  • the method used for the manufacture of knives 3 makes it possible to provide them with other advantageous properties.
  • step 401 of granulation of a powder 9 with diamond particles 7 results in diamond granules 10 which are then molded and cold-pressed at step 402 of pre-forming the Diamond impregnation.
  • This preformed layer is then subjected, in step 403, to sintering at the end of which a diamond impregnation layer 11 is obtained.
  • This layer 11 is then machined in step 404 until the surface 8 is flattened for disclose flush diamond particles 12.
  • a layer of diamond powder 13 is deposited on the surface 8 at step 405, then a step 406 allows the conversion of the diamond powder 13 into polycrystalline synthetic diamond 5.
  • the powder 9 used in step 401 comprises carbon, tungsten and cobalt.
  • the granulation is carried out so that each diamond particle 7 is embedded in a tungsten carbide matrix, the cobalt serving as a binder, and even each granule 10 contains only one diamond particle 7.
  • the choice of the starting size of the diamond particles 7, as well as filtering tools used thereafter, determines the size of the granules 10.
  • the use of such granules 10 makes it possible to obtain excellent homogeneity of the distribution of the diamond particles 7 throughout the These particles 7 could not even touch each other, ie the average distance between two diamond particles 7 would be constant throughout the impregnation layer 11.
  • the diamond impregnation layer is therefore a layer of tungsten carbide , containing cobalt, and in which are homogeneously distributed diamond particles.
  • the sintering step 403 consists in heating the powder 9 containing the carbon and the tungsten constituting the granules 10 without reaching the fusion of these elements. The heat, however, melts the cobalt that is also present in order to weld / bind all the elements together. Cobalt acts here as a binder. Sintering techniques are well known in powder metallurgy. It is possible, for example, to carry out hot isostatic pressing sintering in a gaseous environment (hipping), which makes it possible to obtain a dense layer 11 and reinforcing the diamond particles 7 in a reinforced manner.
  • the diamond particles 7 having been introduced in the form of "encapsulated" granules, the surfaces of the impregnation layer 11 expose only tungsten carbide and cobalt.
  • a machining step 404 is carried out in order to planarize this surface 8 and to make flush diamond particles 12 crimped in the diamond impregnation layer 6.
  • machining can be achieved for example by grinding or laser.
  • the machined diamond impregnation layer 6 can then be replaced in a suitable mold where diamond powder 13 is deposited on the machined face 8 of the layer 6 and where this diamond powder 13 is converted into PDC 5.
  • the conversion of the diamond powder 13 into a PDC layer 5 consists in the formation of covalent chemical bonds between carbon atoms originating from different diamond particles constituting this powder 13, that is to say bonds which will weld the particles of the powder between them to form a single element called "polycrystalline". There is no carbon contribution at this stage, so no new diamond formation, but the binding of a multitude of diamond particles between it.
  • This conversion generally takes place at high temperature and requires a catalyst element, here cobalt. Cobalt can therefore be added to the diamond powder 13 to facilitate the reaction. However, this is not necessary here, the pressure and temperature conditions used in the conversion step 406 being such that the cobalt contained in the diamond impregnation layer 6 can migrate to the surface 8 and serve as a catalyst for the 406.
  • the cobalt used as binder in step 403 plays a second role here, that of catalyst.
  • the homogeneity of the diamond impregnation layer 6 may be advantageous to allow a homogeneous migration of cobalt to the entire surface where the diamond powder 13 has been deposited, in order to ensure the formation of a PDC which is also homogeneous and solid.
  • step 406 The conditions necessary for the conversion of step 406 are obtained for example by a high pressure-high temperature (HPHT) process well known in powder metallurgy.
  • HPHT high pressure-high temperature
  • multilayer knives 14 that is to say alternately associating several diamond impregnation layers, here the three layers 61, 62 and 63 with several layers PDC 51, 52 and 53.
  • these multilayer knives 14 repeats the same steps 401 to 406 previously described. Some of these steps can be multiplied.
  • the diamond impregnation layer 61 is machined on its two contact faces with the PDC layers 51 and 52.
  • the diamond impregnation layer 62 is also machined on its two contact faces with the PDC layers 52 and 53. Even more generally, the diamond impregnation layer can be machined on several sides until flat surfaces with flush diamonds are obtained.
  • the PDC layers 52 and 53 are each supported on either side by two impregnation layers, which further enhances their impact resistance. Each knife then has several cutting edges.
  • the knives described here have a cylindrical shape. It is nevertheless possible according to the configuration of the tool, to make knives with various shapes, more or less complex.
  • the manufacturing method described herein can make use of a wide variety of molds as needed.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

The invention concerns a rock-cutting tool and the method for manufacturing this tool that comprises cutters (3) comprising a layer (5) of synthetic polycrystalline diamond (PCD), a diamond impregnation layer (6) with diamond particles and binding cobalt, characterised by<b/>the fact that the PCD layer rests directly, along a planar interface (8), on the diamond impregnation layer, the interface surface of which is planar by means of machining and on which diamond particles (12) are located.

Description

Outil et procédé de coupe de roche pour forages miniers et pétroliers  Tool and method for cutting rock for mining and oil drilling
La présente invention concerne les outils de coupe de roches pour forages miniers et pétroliers ainsi que leur procédé de fabrication. The present invention relates to rock cutting tools for mining and petroleum drilling and their manufacturing process.
Les foreurs miniers ou pétroliers ont longtemps utilisé des outils de type tricône, dits « rockbits », c'est-à-dire ayant une tête de coupe comprenant trois têtes rotatives de forme coniques, munies de dents ou de picots pour forer plus ou moins efficacement tout type de terrain. Au fur et à mesure de la progression verticale de l'outil de forage, le tricône était changé pour s'adapter à la nature de la formation rencontrée, c'est-à-dire à la dureté de la roche. En effet, il est fréquent de trouver des nappes pétrolières à une profondeur de plus de mille mètres et il faut traverser une succession de roches tendres, comme des argiles, et de roches dures, comme des grès, pour y accéder. Mining or petroleum drillers have long used tricone-type tools, called "rockbits", that is to say having a cutting head comprising three conical rotating heads, provided with teeth or pins for drilling more or less effectively any type of terrain. As the vertical progression of the drilling tool, the tricone was changed to adapt to the nature of the formation encountered, that is to say the hardness of the rock. Indeed, it is common to find oil slicks to a depth of more than one thousand meters and it is necessary to cross a succession of soft rocks, like clays, and hard rocks, like sandstones, to reach there.
Dans les années 60, la mise au point des diamants synthétiques polycristallins (PDC) et leur incorporation aux outils de forage en remplacement des dents et picots ont permis d'améliorer drastiquement l'efficacité de forage, en particulier au niveau des roches plus tendres et a conduit à l'abandon des outils « rockbits ».  In the 1960s, the development of polycrystalline synthetic diamonds (PDC) and their incorporation into drill tools to replace teeth and spikes greatly improved drilling efficiency, particularly in the softer and softer rocks. led to the abandonment of "rockbits" tools.
En pratique, des couteaux PDC ont été fabriqués comprenant une couche de support très résistante au chocs, généralement à base de carbure de tungstène (WC), sur laquelle a été formée une couche plus fine de PDC, par un procédé à haute pression-haute température (HPHT) ou par dépôt chimique en phase vapeur (CVD). Ces couteaux sont incorporés par brasage aux têtes de coupe rotatives, ou lames, des outils de forage, pouvant avoir des formes variées.  In practice, PDC knives have been manufactured comprising a highly impact resistant backing layer, generally based on tungsten carbide (WC), on which a thinner layer of PDC has been formed by a high-pressure high process. temperature (HPHT) or chemical vapor deposition (CVD). These knives are incorporated by brazing rotary cutting heads, or blades, drilling tools, which can have various shapes.
Cependant, ces couteaux PDC présentent plusieurs inconvénients. D'une part, la résistance à l'usure de la couche PDC dépend fortement de la couche qui la supporte. La grande différence de coefficient d'expansion thermique entre le PDC (coefficient faible) et le support en carbure (coefficient élevé) induit un stress mécanique qui est particulièrement élevé à haute température. Or, lors du forage, les températures atteignent, au niveau de la tête de coupe, plusieurs centaines de degrés. Cela peut induire la formation de craquelures dans la couche PDC et réduire notablement sa longévité. D'autre part, la faible résistance à l'usure par abrasion de la couche de support ainsi qu'une élasticité des roches induisent un talonnage et limitent fortement son action de soutien au PDC qui va se casser sous l'action du stress mécanique. Ces inconvénients réduisent donc l'application du PDC aux formations tendres. Il a alors été proposé, pour renforcer les lames, d'ajouter sur les têtes rotatives de forage, dans l'épaisseur de la lame, des couteaux d'imprégnation diamantés, c'est-à-dire des taillants, imprégnés dans leur structure, généralement à base de carbure, d'une multitude de particules de diamants. Ces couteaux d'imprégnation diamantée sont fabriqués par des procédés de métallurgie des poudres et sont beaucoup plus résistants à l'abrasion qu'une simple structure à base de carbure, chaque particule de diamant participant à l'abrasion de la roche. La combinaison de ces couteaux diamantés et des couteaux PDC dans des outils dits mixtes n'a cependant pas permis d'améliorer notablement les capacités de forage de l'outil. En effet, pour des raisons liées aux techniques de brasage, le couteau diamanté est situé trop loin de la couche PDC et ne permet donc pas de renforcer efficacement son action. En présence d'une couche de formation dure, le couteau PDC s'use avant que le couteau diamanté ne puisse être vraiment efficace, et il n'est donc plus disponible pour une couche successive plus tendre. Or il est extrêmement long et coûteux de ressortir du forage une tête de coupe afin d'en remplacer l'outil. However, these PDC knives have several disadvantages. On the one hand, the wear resistance of the PDC layer strongly depends on the layer that supports it. The large difference in coefficient of thermal expansion between the PDC (low coefficient) and the carbide support (high coefficient) induces a mechanical stress which is particularly high at high temperature. However, during drilling, the temperatures reach, at the cutting head, several hundred degrees. This can induce the formation of cracks in the PDC layer and significantly reduce its longevity. On the other hand, the low abrasion wear resistance of the support layer and elasticity of the rocks induce a tailgating and strongly limit its action of supporting the PDC which will break under the action of mechanical stress. These disadvantages therefore reduce the application of the PDC to soft formations. It was then proposed, for reinforcing the blades, to add to the rotary drilling heads, in the thickness of the blade, diamond impregnation knives, that is to say, cutting, impregnated in their structure , usually based on carbide, a multitude of diamond particles. These diamond impregnation knives are manufactured by powder metallurgy processes and are much more resistant to abrasion than a simple carbide-based structure, with each diamond particle involved in rock abrasion. The combination of these diamond knives and PDC knives in so-called mixed tools, however, did not significantly improve the drilling capabilities of the tool. Indeed, for reasons related to soldering techniques, the diamond knife is located too far from the PDC layer and therefore does not effectively enhance its action. In the presence of a hard forming layer, the PDC knife wears before the diamond knife can be really effective, and is therefore no longer available for a softer successive layer. However, it is extremely long and expensive to remove a cutting head from the bore in order to replace the tool.
La demanderesse a donc cherché à développer des outils de coupe de roches ayant des lames permettant de forer efficacement aussi bien des formations tendres que des formations dures, avec une usure minimale. C'est le but de la présente invention de proposer un outil hybride de coupe des roches, efficace et résistant, ainsi qu'un procédé de fabrication de cet outil. The Applicant has therefore sought to develop rock cutting tools having blades for effectively drilling both soft formations that hard formations, with minimal wear. It is the object of the present invention to provide a hybrid tool for cutting rocks, effective and resistant, and a method of manufacturing this tool.
Solution de l'invention Solution of the invention
A cet effet, l'invention concerne un outil de coupe de roches avec des couteaux comprenant au moins une couche antérieure de diamant synthétique polycristallin (PDC), une couche postérieure d'imprégnation diamantée avec des particules de diamant et du cobalt de liaison, caractérisé par le fait que la couche PDC s'appuie directement, le long d'une interface plane, sur la couche d'imprégnation diamantée dont la surface d'interface est plane par usinage et sur laquelle affleurent des particules de diamant, et les particules de diamant affleurantes de la couche d'imprégnation sont liées de façon covalente avec le diamant synthétique polycristallin. To this end, the invention relates to a rock cutting tool with knives comprising at least one polycrystalline synthetic diamond (PDC) anterior layer, a diamond impregnation rear layer with diamond particles and bonding cobalt, characterized in that the PDC layer is supported directly, along a plane interface, on the diamond impregnation layer whose interface surface is planar by machining and on which diamond particles are exposed, and the particles of The flush diamond of the impregnating layer is covalently bonded to the polycrystalline synthetic diamond.
Dans une forme de réalisation intéressante, il est prévu en alternance des couches d'imprégnation diamantée et des couches PDC.  In an interesting embodiment, alternating diamond impregnation layers and PDC layers are provided.
US2014/0223839 décrit des couteaux ayant une couche antérieure de PDC s'appuyant sur une couche postérieure d'imprégnation diamantée avec des particules de diamants comprenant du cobalt de liaison. Cependant, l'interface entre ces deux couches n'est pas plane, et aucune particule de diamant n'affleure à la surface de la couche d'imprégnation diamantée. La cohésion entre les deux couches est basée sur la non-planarité de l'interface qui augmente la superficie de cette interface. US2014 / 0223839 discloses knives having a PDC anterior layer supported on a diamond impregnation backing layer with diamond particles comprising bonding cobalt. However, the interface between these two layers is not flat, and no diamond particle does not flush on the surface of the diamond impregnation layer. The cohesion between the two layers is based on the non-planarity of the interface which increases the surface area of this interface.
Dans les couteaux de l'outil de la présente invention, la cohésion entre les deux couches se fait par des liaisons chimiques covalentes carbone-carbone, la couche PDC est comme sertie dans la couche d'imprégnation diamanté, ce qui augmente notablement l'adhésion entre les deux couches et rend l'outil plus résistant aux stress mécaniques résultant soit du contact direct avec la roche, soit des hautes températures pouvant être rencontrées dans les conditions de forage.  In the knives of the tool of the present invention, the cohesion between the two layers is done by carbon-carbon covalent chemical bonds, the PDC layer is as set in the diamond impregnation layer, which significantly increases the adhesion between the two layers and makes the tool more resistant to mechanical stress resulting either from direct contact with the rock or high temperatures that may be encountered in the drilling conditions.
La présente invention propose également un procédé de fabrication d'un couteau d'un outil de coupe de roche suivant lequel The present invention also provides a method of manufacturing a knife of a rock cutting tool according to which
on prépare des granulés de diamant avec une poudre contenant du tungstène, du carbone et du cobalt,  diamond granules are prepared with a powder containing tungsten, carbon and cobalt,
on préforme une couche d'imprégnation diamanté par pression à froid des granulés dans un moule,  a diamond impregnation layer is preformed by cold pressing of the granules in a mold,
la couche d'imprégnation diamantée préformée est frittée pour sertir les diamants, on usine la couche d'imprégnation diamantée frittée jusqu'à obtention d'une surface plane avec des diamants affleurants,  the preformed diamond impregnation layer is sintered to crimp the diamonds, the sintered diamond impregnation layer is machined to a plane surface with flush diamonds,
on dépose une couche de poudre de diamant sur ladite surface plane et  depositing a layer of diamond powder on said flat surface and
- on convertit la couche de poudre de diamant en une couche de diamant synthétique polycristallin (PDC) liée de façon covalente auxdits diamants affleurants.  - The diamond powder layer is converted to a polycrystalline synthetic diamond (PDC) layer covalently bonded to said flush diamonds.
Avantageusement, chaque granulé ne contient qu'une particule de diamant. Advantageously, each granule contains only one diamond particle.
Dans une forme de mise en œuvre du procédé de l'invention, le frittage de la couche d'imprégnation diamantée est réalisé par un procédé isostatique à chaud. In one form of implementation of the process of the invention, the sintering of the diamond impregnation layer is carried out by a hot isostatic process.
II est clair que l'outil de l'invention et le procédé de fabrication d'un couteau, produit intermédiaire de l'outil, sont liés par un concept inventif, du fait de leurs mêmes caractéristiques essentielles destinées à résoudre le même problème. It is clear that the tool of the invention and the method of manufacturing a knife, intermediate product of the tool, are linked by an inventive concept, because of their same essential characteristics intended to solve the same problem.
L'invention sera mieux comprise à l'aide de la description suivante de plusieurs formes de réalisation de l'invention, en référence au dessin en annexe sur lequel :  The invention will be better understood with the aid of the following description of several embodiments of the invention, with reference to the drawing in the appendix, in which:
la figure 1 est une vue schématique en perspective de l'outil de l'invention ; Figure 1 is a schematic perspective view of the tool of the invention;
la figure 2 est une vue en perspective d'un couteau de l'outil de la figure 1 ; Figure 2 is a perspective view of a knife of the tool of Figure 1;
la figure 3 est une vue en perspective de la couche d'imprégnation diamantée du couteau de la figure 2 ; la figure 4 est un organigramme qui illustre schématiquement le procédé de l'invention et la figure 5 est une vue en perspective d'une variante de réalisation d'un couteau de l'outil de l'invention. En référence à la figure 1, un outil 1 de coupe de roches possède trois lames 2 avec quatre couteaux 3 à l'extrémité libre de chaque lame. L'outil 1 est destiné à être animé d'un mouvement de rotation autour de son axe AA'. En référence à la figure 2, chaque couteau est formé d'une couche avant ou antérieure 5 en diamant synthétique polycristallin (PDC) et d'une couche arrière ou postérieure 6 d'imprégnation diamantée avec des particules de diamant 7. En référence à la figure 3, la surface avant 8 de la couche postérieure 6, adjacente à la couche antérieure 5, est plane et des particules de diamant 12 y affleurent. Figure 3 is a perspective view of the diamond impregnation layer of the knife of Figure 2; Figure 4 is a flowchart which schematically illustrates the method of the invention and Figure 5 is a perspective view of an alternative embodiment of a knife of the tool of the invention. Referring to Figure 1, a rock cutting tool 1 has three blades 2 with four knives 3 at the free end of each blade. The tool 1 is intended to be rotated about its axis AA '. With reference to FIG. 2, each knife is formed of a polycrystalline synthetic diamond (PDC) front or front layer 5 and a diamond impregnation back or rear layer 6 with diamond particles 7. With reference to FIG. 3, the front surface 8 of the posterior layer 6, adjacent to the anterior layer 5, is flat and diamond particles 12 are flush with it.
Le forage pétrolier utilise des outils qui creusent un trou de forme cylindrique. Les outils utilisés ont généralement une tête de coupe qui tourne à plus ou moins grande vitesse selon une direction. L'outil 1 possède trois lames 2 qui vont être en contact avec la formation rocheuse à forer. En particulier, les couteaux 3 vont assurer le forage de la formation rocheuse. Oil drilling uses tools that dig a cylindrical hole. The tools used generally have a cutting head which rotates at a greater or lesser speed in one direction. The tool 1 has three blades 2 which will be in contact with the rock formation to be drilled. In particular, the knives 3 will ensure the drilling of the rock formation.
La couche PDC 5 est très dure et forme l'arête de coupe qui va venir tailler en premier la formation rocheuse. Cette couche 5 est cependant relativement cassante et elle est supportée par une couche plus résistante au stress mécanique.  The PDC layer 5 is very hard and forms the cutting edge that will first cut the rock formation. This layer 5, however, is relatively brittle and is supported by a layer more resistant to mechanical stress.
Usuellement, une couche de support en carbure de tungstène était utilisée pour servir de support, ce matériau présentant une excellente résistance au stress mécanique. Cependant, le carbure de tungstène est peu résistant à l'abrasion et s'use relativement vite au contact de la roche, ce qui réduit la durée de vie de la couche PDC. Bien qu'a priori moins résistante au stress mécanique, à cause de sa nature bi-phasique, une couche d'imprégnation diamantée 6 est ici utilisée pour supporter la couche PDC 5, ce qui présente au moins deux avantages : les particules de diamant 7 présentes dans une matrice de carbure de tungstène, contenant également du cobalt pour assurer la liaison de l'ensemble, augmentent la résistance du support à l'abrasion et participent activement au forage de la roche, d'une part et, d'autre part, la présence de ces particules de diamant permet de réduire la différence de coefficient d'expansion thermique entre la couche de support 6 et la couche PDC 5, ce qui limite le stress mécanique qui apparaît lorsque l'outil chauffe à plusieurs centaines de degrés lors de sa rotation au contact de la roche. Il en résulte une amélioration certaine de la durée de vie de l'outil. Le procédé utilisé pour la fabrication des couteaux 3 permet de leur apporter d'autres propriétés avantageuses. Usually, a tungsten carbide support layer was used as a support, which material exhibits excellent mechanical stress resistance. However, tungsten carbide is not very resistant to abrasion and wears relatively quickly in contact with the rock, which reduces the life of the PDC layer. Although a priori less resistant to mechanical stress, because of its bi-phasic nature, a diamond impregnation layer 6 is used here to support the PDC layer 5, which has at least two advantages: the diamond particles 7 present in a tungsten carbide matrix, also containing cobalt to ensure the bonding of the assembly, increase the resistance of the support to abrasion and participate actively in the drilling of the rock, on the one hand and secondly the presence of these diamond particles makes it possible to reduce the difference in coefficient of thermal expansion between the support layer 6 and the PDC layer 5, which limits the mechanical stress that appears when the tool heats to several hundred degrees when of its rotation in contact with the rock. The result is a definite improvement in tool life. The method used for the manufacture of knives 3 makes it possible to provide them with other advantageous properties.
En référence à la figure 4, l'étape 401 de granulation d'une poudre 9 avec des particules de diamants 7 aboutit à des granulés diamantés 10 qui sont ensuite moulés et comprimés à froid à l'étape 402 de préformation de la couche d'imprégnation diamantée. Cette couche préformée est ensuite soumise, à l'étape 403, à un frittage au terme duquel on obtient une couche d'imprégnation diamantée 11. Cette couche 11 est ensuite usinée à l'étape 404 jusqu'à rendre plane la surface 8 pour y découvrir des particules de diamants affleurantes 12. Une couche de poudre de diamant 13 est déposée sur la surface 8 à l'étape 405, puis une étape 406 permet la conversion de la poudre de diamant 13 en diamant synthétique polycristallin 5. With reference to FIG. 4, step 401 of granulation of a powder 9 with diamond particles 7 results in diamond granules 10 which are then molded and cold-pressed at step 402 of pre-forming the Diamond impregnation. This preformed layer is then subjected, in step 403, to sintering at the end of which a diamond impregnation layer 11 is obtained. This layer 11 is then machined in step 404 until the surface 8 is flattened for disclose flush diamond particles 12. A layer of diamond powder 13 is deposited on the surface 8 at step 405, then a step 406 allows the conversion of the diamond powder 13 into polycrystalline synthetic diamond 5.
La poudre 9 utilisée à l'étape 401 comprend du carbone, du tungstène et du cobalt. La granulation est réalisée de telle sorte que chaque particule de diamant 7 soit enrobée dans une matrice de carbure de tungstène, le cobalt servant de liant, et même, que chaque granulé 10 ne contienne qu'une particule de diamant 7. Le choix de la taille de départ des particules de diamant 7, ainsi que des outils de filtrage utilisés ensuite, détermine la dimension des granulés 10. L'utilisation de tels granulés 10 permet d'obtenir une excellente homogénéité de la répartition des particules de diamant 7 dans toute la couche d'imprégnation diamantée 11. Ces particules 7 pourraient même ne pas se toucher entre elles, c'est-à-dire que la distance moyenne entre deux particules de diamant 7 serait constante dans toute la couche d'imprégnation 11. The powder 9 used in step 401 comprises carbon, tungsten and cobalt. The granulation is carried out so that each diamond particle 7 is embedded in a tungsten carbide matrix, the cobalt serving as a binder, and even each granule 10 contains only one diamond particle 7. The choice of the starting size of the diamond particles 7, as well as filtering tools used thereafter, determines the size of the granules 10. The use of such granules 10 makes it possible to obtain excellent homogeneity of the distribution of the diamond particles 7 throughout the These particles 7 could not even touch each other, ie the average distance between two diamond particles 7 would be constant throughout the impregnation layer 11.
Ces granulés 10 sont introduits dans un moule, dont la forme correspond à la forme de la couche d'imprégnation diamantée 11 désirée, puis compressés à froid pour préformer cette couche 11. La couche d'imprégnation diamantée est donc une couche de carbure de tungstène, contenant du cobalt, et dans laquelle sont réparties, de façon homogène, des particules de diamant.  These granules 10 are introduced into a mold, whose shape corresponds to the shape of the desired diamond impregnation layer 11 and then cold-pressed to preform this layer 11. The diamond impregnation layer is therefore a layer of tungsten carbide , containing cobalt, and in which are homogeneously distributed diamond particles.
L'étape de frittage 403 consiste à chauffer la poudre 9 contenant le carbone et le tungstène constituant les granulés 10 sans atteindre la fusion de ces éléments. La chaleur permet toutefois de faire fondre le cobalt qui y est également présent afin de souder/lier tous les éléments entre eux. Le cobalt joue ici un rôle de liant. Les techniques de frittage sont bien connues en métallurgie des poudres. On peut par exemple procéder au frittage par compression isostatique à chaud en ambiance gazeuse (hipping), ce qui permet d'obtenir une couche 11 dense et sertissant de façon renforcée les particules de diamant 7. A ce stade, les particules de diamant 7 ayant été introduites sous forme de granulés « encapsulées », les surfaces de la couche d'imprégnation 11 exposent seulement du carbure de tungstène et du cobalt. Avant de former la couche PDC 5 sur l'une de ces surfaces, une étape 404 d'usinage est réalisée afin de planariser cette surface 8 et de faire affleurer des particules de diamant 12 serties dans la couche d'imprégnation diamantée 6. L'usinage peut être réalisé par exemple par meulage ou laser. The sintering step 403 consists in heating the powder 9 containing the carbon and the tungsten constituting the granules 10 without reaching the fusion of these elements. The heat, however, melts the cobalt that is also present in order to weld / bind all the elements together. Cobalt acts here as a binder. Sintering techniques are well known in powder metallurgy. It is possible, for example, to carry out hot isostatic pressing sintering in a gaseous environment (hipping), which makes it possible to obtain a dense layer 11 and reinforcing the diamond particles 7 in a reinforced manner. At this stage, the diamond particles 7 having been introduced in the form of "encapsulated" granules, the surfaces of the impregnation layer 11 expose only tungsten carbide and cobalt. Before forming the PDC layer 5 on one of these surfaces, a machining step 404 is carried out in order to planarize this surface 8 and to make flush diamond particles 12 crimped in the diamond impregnation layer 6. machining can be achieved for example by grinding or laser.
La couche d'imprégnation diamantée usinée 6 peut alors être replacée dans un moule adéquat où de la poudre de diamant 13 est déposée sur la face usinée 8 de la couche 6 et où cette poudre de diamant 13 est convertie en PDC 5.  The machined diamond impregnation layer 6 can then be replaced in a suitable mold where diamond powder 13 is deposited on the machined face 8 of the layer 6 and where this diamond powder 13 is converted into PDC 5.
La conversion de la poudre de diamant 13 en une couche PDC 5 consiste en la formation de liaisons chimiques covalentes entre des atomes de carbone provenant de particules de diamant différentes constituant cette poudre 13, c'est-à-dire des liaisons qui vont souder les particules de la poudre entre elles pour former un seul élément dit « polycristallin ». Il n'y a pas à cette étape d'apport de carbone, donc pas de nouvelle formation de diamant, mais la liaison d'une multitude de particules de diamant entre elle. Cette conversion a généralement lieu à haute température et nécessite un élément catalyseur, ici le cobalt. Du cobalt peut donc être ajouté à la poudre de diamant 13 pour faciliter la réaction. Cela n'est cependant pas ici nécessaire, les conditions de pression et de température utilisée à l'étape de conversion 406 étant telles que le cobalt contenu dans la couche d'imprégnation diamantée 6 peut migrer vers la surface 8 et servir de catalyseur à la conversion 406. Le cobalt utilisé comme liant à l'étape 403 joue ici un second rôle, celui de catalyseur. L'homogénéité de la couche d'imprégnation diamantée 6 peut être intéressante pour permettre une migration homogène du cobalt vers toute la surface où la poudre de diamant 13 a été déposée, afin d'assurer la formation d'un PDC également homogène et solide. The conversion of the diamond powder 13 into a PDC layer 5 consists in the formation of covalent chemical bonds between carbon atoms originating from different diamond particles constituting this powder 13, that is to say bonds which will weld the particles of the powder between them to form a single element called "polycrystalline". There is no carbon contribution at this stage, so no new diamond formation, but the binding of a multitude of diamond particles between it. This conversion generally takes place at high temperature and requires a catalyst element, here cobalt. Cobalt can therefore be added to the diamond powder 13 to facilitate the reaction. However, this is not necessary here, the pressure and temperature conditions used in the conversion step 406 being such that the cobalt contained in the diamond impregnation layer 6 can migrate to the surface 8 and serve as a catalyst for the 406. The cobalt used as binder in step 403 plays a second role here, that of catalyst. The homogeneity of the diamond impregnation layer 6 may be advantageous to allow a homogeneous migration of cobalt to the entire surface where the diamond powder 13 has been deposited, in order to ensure the formation of a PDC which is also homogeneous and solid.
Les conditions nécessaires à la conversion de l'étape 406 sont obtenues par exemple par un procédé haute pression-haute température (HPHT) bien connu dans la métallurgie des poudres. The conditions necessary for the conversion of step 406 are obtained for example by a high pressure-high temperature (HPHT) process well known in powder metallurgy.
Lors de cette conversion, non seulement les particules de la poudre de diamant 13 vont se lier entre elles, mais des liaisons vont également pouvoir se former entre des particules de la poudre de diamant 13 et les particules de diamant affleurantes 12 de la couche d'imprégnation 6. La couche PDC 5 va donc être très fortement arrimée à sa couche de support 6, grâce à l'étape d'usinage qui a permis de faire affleurer à l'interface 8 entre les deux couches des particules de diamants 12. Cela confère à l'ensemble du couteau une résistance supplémentaire au stress mécanique, la couche PDC 5 n'allant pas avoir tendance à se désolidariser de sa couche de support 6 sous l'effet de chocs ou de l'élévation de la température lors du forage. La durée de vie de l'outil est donc notablement améliorée ainsi que son efficacité face à une grande variété de formations rocheuses aussi bien tendres que dures. During this conversion, not only the particles of the diamond powder 13 will bond with each other, but bonds will also be formed between particles of the diamond powder 13 and the flush diamond particles 12 of the diamond layer. impregnation 6. The PDC layer 5 will therefore be very strongly attached to its support layer 6, thanks to the machining step which made it possible to be flush with the interface 8 between the two layers of the diamond particles 12. This gives the knife assembly additional resistance to mechanical stress, the PDC layer 5 not tending to dissociate from its support layer 6 under the effect of shocks or the rise in temperature during drilling. The life of the tool is significantly improved and its effectiveness against a wide variety of rock formations both soft and hard.
Selon la profondeur à forer ainsi que la nature des roches qui vont être rencontrées, la forme de l'outil peut être variée, de même que la forme de ses lames ainsi que leur nombre. Dans certains cas, il peut être intéressant d'utiliser des couteaux multicouches 14 (figure 5), c'est-à- dire associant en alternance plusieurs couches d'imprégnation diamantée, ici les trois couches 61, 62 et 63 avec plusieurs couches PDC 51, 52 et 53.  Depending on the depth to be drilled and the nature of the rocks that will be encountered, the shape of the tool can be varied, as well as the shape of its blades and their number. In some cases, it may be advantageous to use multilayer knives 14 (FIG. 5), that is to say alternately associating several diamond impregnation layers, here the three layers 61, 62 and 63 with several layers PDC 51, 52 and 53.
Le procédé de fabrication de ces couteaux multicouches 14 reprend les mêmes étapes 401 à 406 précédemment décrites. Certaines de ces étapes peuvent être multipliées. Par exemple, la couche d'imprégnations diamantées 61 est usinée sur ses deux faces de contact avec les couches PDC 51 et 52. La couches d'imprégnation diamantée 62 est également usinée sur ses deux faces de contact avec les couches PDC 52 et 53. Encore plus généralement, la couche d'imprégnation diamantée peut être usinée sur plusieurs faces jusqu'à obtention de surfaces planes avec des diamants affleurants.  The manufacturing process of these multilayer knives 14 repeats the same steps 401 to 406 previously described. Some of these steps can be multiplied. For example, the diamond impregnation layer 61 is machined on its two contact faces with the PDC layers 51 and 52. The diamond impregnation layer 62 is also machined on its two contact faces with the PDC layers 52 and 53. Even more generally, the diamond impregnation layer can be machined on several sides until flat surfaces with flush diamonds are obtained.
Dans cette configuration multicouche, les couches PDC 52 et 53 sont supportées chacune de part et d'autre par deux couches d'imprégnation, ce qui renforce encore leur résistance aux chocs. Chaque couteau a alors plusieurs arêtes de coupes.  In this multilayer configuration, the PDC layers 52 and 53 are each supported on either side by two impregnation layers, which further enhances their impact resistance. Each knife then has several cutting edges.
Les couteaux décrits ici ont une forme cylindrique. Il est néanmoins possibles selon la configuration de l'outil, de fabriquer des couteaux ayant des formes diverses, plus ou moins complexes. Le procédé de fabrication décrit ici peut faire usage d'une grande variété de moules selon les besoins.  The knives described here have a cylindrical shape. It is nevertheless possible according to the configuration of the tool, to make knives with various shapes, more or less complex. The manufacturing method described herein can make use of a wide variety of molds as needed.

Claims

Revendications claims
1. Outil de coupe de roches avec des couteaux (3) comprenant au moins une couche antérieure (5) de diamant synthétique polycristallin (PDC), une couche postérieure1. Rock cutting tool with knives (3) comprising at least one anterior layer (5) of polycrystalline synthetic diamond (PDC), a posterior layer
(6) d'imprégnation diamantée avec des particules de diamant (7) et du cobalt de liaison, caractérisé par le fait que la couche PDC s'appuie directement, le long d'une interface plane(8), sur la couche d'imprégnation diamantée dont la surface d'interface (8) est plane par usinage et sur laquelle affleurent des particules de diamant (12), et les particules de diamant affleurantes (12) de la couche d'imprégnation (6) sont liées de façon covalente avec le diamant synthétique polycristallin (5). (6) Diamond impregnation with diamond particles (7) and cobalt bonding, characterized in that the PDC layer is supported directly along a plane interface (8) on the coating layer. diamond impregnation whose interface surface (8) is planar by machining and on which diamond particles (12) are exposed, and the flush diamond particles (12) of the impregnating layer (6) are covalently bonded with polycrystalline synthetic diamond (5).
2. Outil selon la revendication 1, dans lequel il est prévu en alternance des couches d'imprégnations diamantées (61, 62, 63) et des couches PDC (51, 52, 53). 2. Tool according to claim 1, wherein alternating layers of diamond impregnations (61, 62, 63) and PDC layers (51, 52, 53) are provided.
3. Outil selon l'une des revendications 1 et 2, dans lequel les particules de diamant3. Tool according to one of claims 1 and 2, wherein the diamond particles
(7) de la couche d'imprégnation diamantée (6) sont réparties de façon homogène et ne sont pas en contact les unes avec les autres. (7) of the diamond impregnation layer (6) are homogeneously distributed and not in contact with one another.
4. Outil selon l'une des revendications 1 à 3, dans lequel la couche d'imprégnation diamanté (6) comprend du carbure de tungstène. 4. Tool according to one of claims 1 to 3, wherein the diamond impregnation layer (6) comprises tungsten carbide.
5. Procédé de fabrication d'un couteau d'un outil de coupe de roche suivant lequel5. A method of manufacturing a knife of a rock cutting tool according to which
- on prépare des granulés (10) de diamant avec une poudre (9) contenant du tungstène, du carbone et du cobalt, diamond granules (10) are prepared with a powder (9) containing tungsten, carbon and cobalt,
- on préforme une couche d'imprégnation diamanté (11) par pression à froid des granulés (10) dans un moule,  a diamond impregnation layer (11) is preformed by cold pressing of the granules (10) in a mold,
- la couche d'imprégnation diamantée préformée est frittée pour sertir les diamants (7),  the preformed diamond impregnation layer is sintered to crimp the diamonds (7),
- on usine la couche d'imprégnation diamantée frittée (11) jusqu'à obtention d'une surface plane (8) avec des diamants affleurants (12),  the sintered diamond impregnation layer (11) is machined until a plane surface (8) is obtained with flush diamonds (12),
- on dépose une couche de poudre de diamant (13) sur ladite surface plane (8) et - on convertit la couche de poudre de diamant (13) en une couche de diamant synthétique polycristallin (PDC) (5) liée de façon covalente auxdits diamants affleurants (12). a layer of diamond powder (13) is deposited on said flat surface (8) and - The diamond powder layer (13) is converted into a polycrystalline synthetic diamond (PDC) layer (5) covalently bonded to said flush diamonds (12).
6. Procédé selon la revendication 5, selon lequel chaque granulé (10) ne contient qu'une particule de diamant (7). 6. The method of claim 5, wherein each granule (10) contains only one diamond particle (7).
7. Procédé selon les revendications 5 ou 6, selon lequel le frittage de la couche d'imprégnation diamantée (11) est réalisé par un procédé isostatique à chaud. 7. The method of claim 5 or 6, wherein the sintering of the diamond impregnation layer (11) is performed by a hot isostatic process.
8. Procédé selon l'une des revendications 5 à7, selon lequel la conversion de la couche de poudre de diamant (13) en une couche PDC (5) est catalysée par du cobalt. 8. Method according to one of claims 5 to 7, wherein the conversion of the diamond powder layer (13) to a PDC layer (5) is catalyzed by cobalt.
9. Procédé selon l'une des revendications 5 à 8, selon lequel la couche d'imprégnation diamantée (11) est usinée sur plusieurs faces jusqu'à obtention de surfaces planes (8) avec des diamants affleurants (12). 9. A method according to one of claims 5 to 8, wherein the diamond impregnation layer (11) is machined on several sides to obtain flat surfaces (8) with flush diamonds (12).
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