dea presentation 2003-02-27dea-global.org/wp-content/uploads/2009/11/dennis-tool.pdf · dea...
TRANSCRIPT
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HEADQUARTERSHOUSTON, TEXAS
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PDC DIAMOND PRODUCTS FOR FIXED CUTTER BITS
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ROLLING CONE BIT COMPONENTSPDC, MICROWAVE SINTERED WC/TSD
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PDC AND CARBIDE WIRE DRAWING DIE BLANKS
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PDC DIAMOND RADIAL AND THRUST BEARINGS
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♦ Even at twice the load that produces galling and premature failure in ball bearings, diamond bearings continue to operate.
♦ Diamond bearings begin with a lower friction coefficient that does not increase with rotation time.
♦ Diamond bearings can withstand heat up to 1,600 degrees Fahrenheit.
♦ Diamond bearings perform well in mud, air, or air mist environments.
♦ Diamond bearings are not affected by contaminates in the lubricating system.
DIAMOND BEARINGS OUTPERFORM
BALL BEARINGS
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PDC DIAMOND RADIAL AND THRUST BEARINGS
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200 1400 1600 1800 2000
MOTOR DIFFERENTIAL PRESSURE - PS I
BALL BEARING
PDC DIAMOND BEARING
ERRATIC RESPONSE DUE TO BALL GALLING
TO
RQ
UE
F
OO
T -
LB
S
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SINTERED CARBIDE MICROGRAPHS at 1500X
MICROWAVESINTERED
CONVENTIONALLYSINTERED
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MW PROCESSES AND EQUIPMENT DEVELOPMENT
• Develop MW Applicators for Sintering Cemented Carbide and Other Materials
• Develop Basic Processing Parameters • Manufacture MW Sintering Systems• Service MW Equipment and Processes
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MW SINTERING SUPPORT
The V Group - Inventors, Designers, Builders
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SCHEMATIC OF AUTOMATED APPLICATOR
Crucibles Move from Top to Bottom and to Left
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AUTOMATED EJECTION SYSTEM
Crucibles move down and to the right through load lock.
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V14.2 PRODUCTION UNIT
Installed At Manufacturing Location
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MW SINTERING OF CARBIDE
• Volumetric Heating - Energy Transfer
• Sintering Time - Minutes
• Shrinkage - Uniform, Original Shape Maintained
• Uniform Melting - Co
• Grain Growth - Minimized
• Density - Theoretical
• Hardness - Equal or Better than Standards
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ADVANTAGES OF MW SINTERED WC
•FINER GRAIN STRUCTURE
•NO GRAIN GROWTH INHIBITORS REQUIRED•UNIFORM COBALT DISTRIBUTION•IMPROVED ABRASION RESISTANCE•IMPROVED EROSION RESISTANCE•IMPROVED CORROSION RESISTANCE•IMPROVED IMPACT STRENGTH•MORE ENERGY EFFICIENT PROCESS•LESS CAPITAL INTENSIVE
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MICROWAVESINTERED
IMPROVED EROSION RESISTANCE OF
MW SINTERED WC
CONVENTIONALLYSINTERED
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IMPACT TESTINGMW SINTERED VS. SINTER HIP
Impact Resistance vs Cobalt Content
0
5
10
15
20
25
30
0 10 20 30 40
%Co
Imp
act
En
erg
y at
F
ract
ure
, J
NOTE: Curves assumed to reach the same low point at 0wt% cobalt, and to converge at high cobalt. Data from 6 wt% to 25 wt% cobalt are from real production parts; in some cases, pressed by the powder supplier, with microwave sintering the ONLY difference in the production sequence for the parts
Microwave
HIP
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MICROWAVESINTERED
CONVENTIONALLYSINTERED
IMPROVED IMPACT STRENGTH OF MW SINTERED CARBIDE
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ABRASION TESTINGMW SINTERED VS. SINTER HIP
Granite Log Abrasion Tests(20 passes using our standard conditions)
0
5000
10000
15000
20000
0 5 10 15 20 25Pass No.
Rat
io a
fter
pas
s
MW SubmicronMahlonite - 15%Co -15 vol% diamond
HIP sintered-impreg -15 vol% diamond(25/35 grit)
MW sinteredsubmicron carbide -no impreg - 10% Co
Conv. sint. 6%Co -1 micron WC
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MICROWAVE SINTERED TSD INSERTS
DTC PART# 1215414.4mm DIAM x 12.7mm LONG
3 TSD ELEMENTS 4mmDIA
ABRASION RESISTANT TSDMICROWAVE SINTERED IN
TUNGSTEN CARBIDE
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Ductility test performed on a selected FC-0208 steel sample and
microstructure before etching
Conventional sinteringMicrowave sintering
Microwave 1260C -20 min.
Conventional 1260C -20 min.
Microwave and conventionally processed samples of hollow cylindrical shape (Fe-Cu-C steel) were tested for their ductility andtoughness. Figure A and B shows the parts after load at failure. It was found that conventional part failed at a load of 320 lbs andmicrowave part at 430 lbs, an increase of about 30% in the strength. Also conventional part broke into 4 pieces (B) and the microwave part into two flat pieces (A) indicating higher ductility.Pores in the microwave sintered samples have more rounded edges (C) in contrast to the sharp edges (D) in conventionallysintered sample. It is commonly known that sintered product exhibits an increasing ductility when the pore shape is more spherical.
Load at failure:
430 lbs 320 lbs
A B
C D
DUCTILITY AND STRENGTH OF MW SINTERED STEEL
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PDC DIAMOND GOLF CLUBS
Low friction polished diamond insert imparts minimal spin on ball for straighter shots
Ultra-hard diamond insert delivers efficient energy transfer for more controlled distance