Impact fatigue fracture of polycrystalline diamond compact (PDC) cutters and the effect of microstructure

Kanyanta, Valentine; Dormer, Aaron; Murphy, Neal; Invankovic, Alojz

doi:10.1016/j.ijrmhm.2014.06.003

Cited by 52 publications

(19 citation statements)

References 18 publications

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“…Kanyanta et al [69] studied the impact fatigue of PDC, and showed that grain size could influence the fatigue behavior, with larger grain-size grades offering greater fatigue resistance. They developed an in-house cyclic impact test facility and compared the impact behavior of two grades of PDC of different grain sizes (mean grain sizes of 6 and 30 µm).…”

Section: Impactmentioning

confidence: 99%

“…The repeated impacts of the cutter on the rock can cause the initiation of microscopic fatigue cracks, the propagation of which can result in the chipping and spalling of fragments from the cutter. Kanyanta et al [69] studied the impact fatigue of PDC, and showed that grain size could influence the fatigue behavior, with larger grain-size grades offering greater fatigue resistance. They developed an in-house cyclic impact test facility and compared the impact behavior of two grades of PDC of different grain sizes (mean grain sizes of 6 and 30 µm).…”

Section: Impactmentioning

confidence: 99%

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Applications of Diamond to Improve Tribological Performance in the Oil and Gas Industry

Wheeler

2018

Lubricants

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The use of diamond in tribological applications in the oil and gas industry is reviewed. The high hardness, strength, and corrosion resistance of diamond make it an attractive option for components that are susceptible to degradation by abrasive, erosive, or adhesive wear; such components may also be prone to corrosion owing to the nature of the environments to which they are often exposed. Applications such as drill bits, bearings, and mechanical seals benefit from the use of diamond, while choke valves are the subject of research programs to assess the suitability of chemical vapor deposition (CVD) diamond for these components. Also discussed are some of the conditions experienced by the components and how the properties of diamond enhance their operating lives.

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Section: Impactmentioning

confidence: 99%

Section: Impactmentioning

confidence: 99%

Applications of Diamond to Improve Tribological Performance in the Oil and Gas Industry

Wheeler

2018

Lubricants

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“…Numerous studies have shown that cyclical loading substantially reduces the force required to fracture the diamond (Kanyanta, 2014). Monotonic loading is not completely representative of tangential forces acting on the face of a cutter in an actual drilling environment, but it is a quick and telling test.…”

Section: Face Loading Testmentioning

confidence: 99%

Unique Hybrid Drill Bit with Novel PDC Cutters Improves Performance in Ultra-Deepwater Brazil Pre-Salt Application

Oliveira

Freesz

Izbinski

et al. 2015

Day 1 Tue, October 27, 2015

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The Brazil ultra-deepwater, pre-salt application has been a very challenging drilling environment since exploration activity began in 2005. The initial pre-salt section contains limestone with random silicified nodules. Over the last few years, operators have collected large amounts of data for service companies to analyze to improve drilling performance through bit design. Using this information, a hybrid bit design with the most advanced cutter and bit technology was developed successfully increasing the distance drilled by 138% and the rate of penetration (ROP) by 171%.Prior to advanced hybrid bit technology, a variety of other drill bit technologies such as polycrystalline diamond compact (PDC) bits and impregnated designs were used in the pre-salt. Historically, impregnated bits had longer runs, but with high mechanical specific energy (MSE) and low ROP, drilling with these bits was not economical. Contrarily, PDC bits can deliver higher ROP but cannot drill as far as impregnated bits. Three hybrid designs, the last one using dual-chamfer technology, were brought into this application to reduce cost-per-meter through better drilling efficiency and ROP. Each successive design managed to exceed customer expectations.Extensive laboratory tests were conducted on the hybrid designs to address the demanding needs of pre-salt applications. These unique bits showed promising results on atmospheric surface rig tests and in pressurized bottomhole simulator testing. Hybrid bits produced much less torque, with smoother torque fluctuations and faster ROPs than roller-cone and PDC bits through the simulated interbedded formations in laboratory testing. Novel dual-chamfer cutters used in the bit have been lab tested on a vertical turret lathe (VTL), a visual pressurized single-point-cutter (VSPC) test machine and a monotonic loading test. Cutter testing showed positive VTL results and increased resistance to diamond fractures.Ultra-deepwater drilling is very demanding and expensive, so operators want to achieve total depth in just one run by avoiding trips to change out the bit or bottomhole assembly (BHA). The improved bit and cutter technology resulted in significant cost savings and confidence for the customer. The performance of the hybrid bit with dual-chamfer cutters was significantly better than offsets, saving the operator approximately USD 9769/m.

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“…Considering fracture toughness evaluation, research has been traditionally restricted to the static regime using Brazilian disk and double torsion testing methods [4,5]. More recent work however, has adopted high rate bending tests using a drop-weight tower [6], and the dynamic impact fatigue fracture of PCD compacts has also been investigated [7]. Despite these studies, there remains a limited body of knowledge in this area compared to traditional ceramic cutting tools, and thus, the investigation of the dynamic fracture toughness of PCD is vital for the evaluation and design of improved material grades.…”

Section: Introductionmentioning

confidence: 99%

Effect of loading rate on the fracture toughness and failure mechanisms of polycrystalline diamond (PCD)

McNamara

Carolan

Alveen

et al. 2016

International Journal of Refractory Metals and Hard Materials

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Impact fatigue fracture of polycrystalline diamond compact (PDC) cutters and the effect of microstructure

Abstract: Impact fatigue fracture of polycrystalline diamond compact (PDC) cutters and the effect of microstructure.

Cited by 52 publications

References 18 publications

Applications of Diamond to Improve Tribological Performance in the Oil and Gas Industry

Applications of Diamond to Improve Tribological Performance in the Oil and Gas Industry

Unique Hybrid Drill Bit with Novel PDC Cutters Improves Performance in Ultra-Deepwater Brazil Pre-Salt Application

Effect of loading rate on the fracture toughness and failure mechanisms of polycrystalline diamond (PCD)

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