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Home >> Polycrystalline diamond compact, PDC cutters

A pdc cutter will be used in a pdc drill, which helps to drill through surfaces for the longest time possible. A reliable cutter can help you drill through the surfaces without the need of digging to get better results. In most cases, the pdc cutters will be manufactured through different stages, but at one place. The manufacturing prerequisites must meet the ISO standards of quality, and fixed pdc cutters mounted on bit matrix is kind of pdc drill bit.

The pdc cutters are made with a blend of high pressure and high temperatures, it is a combination of a diamond grit, usually a Polycrystalline diamond layer, together with a carbide substrate. The compact is formed under a maximum temperature of 2800°C and a maximum temperature of about 1 million psi. During the compact formation, a cobalt alloy is present, acting as a catalyst in the process of sintering. Also, this cobalt alloy helps to bind the diamond and the carbide. That implies that the alloy cobalt is very vital in the cutter. When the cutter is being cooled, the tungsten carbide will shrink at a faster rate compared to the diamond, which is about 2.5 faster. This process needs controlling, which is called the Intellectual Property and tends to be a confidential process of the manufacturers.

pdc cutter pdc cutters polycrystalline diamond compact polycrystalline diamond compact
pdc cutters pdc cutters polycrystalline diamond compact polycrystalline diamond compact
pdc cutters pdc cutters polycrystalline diamond compact polycrystalline diamond compact
pdc cutters pdc cutters polycrystalline diamond compact polycrystalline diamond compact
polycrystalline diamond compact polycrystalline diamond compact polycrystalline diamond compact polycrystalline diamond compact
polycrystalline diamond compact polycrystalline diamond compact polycrystalline diamond compact polycrystalline diamond compact
pdc cutters pdc cutters    
pdc cutters pdc cutters    

The PDC Cutters
Technically, this is a cutter that has been made by combining a layer of polycrystalline diamond along with a tungsten carbide substrate. They also come in various categories, here are the common pdc cutter categories:
• High abrasion resistance, HABP. These are cutters that have perfect abrasion resistance, along with a higher impact resistance, for the sake of achieving better results. The HABP cutters are designed for drilling areas with cutter rounding and high wear chances.
• The High Impact Toughness, HITP. This is also a high grade cutter that has amazing abrasion resistance, along with a greater impact resistance. They are mostly meant for the drilling conditions that have tough and uneven surfaces.
• The General Purpose cutters. These cutters have a higher value, they offer a medium performance and they are used for general purposes. They also have a higher impact resistance.
They are designed with varied specifications and features, which allow them to offer different results in the drilling industry. The variation in the features and the specifications also help to drill through different surfaces.

size diameter height diamond thickness diamond chamfer carbide chamfer
0804 8.20 mm 4.50 mm 1.0±0.1 mm    
0808 8.20 mm 8.00 mm 1.0±0.1 mm    
1004 10.00 mm 4.50 mm 1.0±0.1 mm    
1304 13.30 mm 4.50 mm 1.0±0.1 mm    
1308 13.44 mm 8.00 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1313 13.44 mm 13.20 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1608 16.00 mm 8.00 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1613 16.00 mm 13.20 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1908 19.05 mm 8.00 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1913 19.05 mm 13.20 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°
1916 19.05 mm 16.00 mm 2.0 ± 0.2 mm 0.25 mm×45° 0.50 mm ×45°

Applications
The pdc cutter is used in many situations in drilling, which will vary, according to the design of the cutter itself. The cutter is capable of drilling between depths of 100 to 20,000 feet. They can be used to dig extra long depths in general. Some of the applications of the pdc cutter include water well drilling, geothermal drilling, natural gas and oil drilling, bearing elements, among others.

Variations
There are various designs and variations of the PDC cutters and they include the small cutters and the large cutters. The larger cutters will measure between 19 to 25mm and they are more aggressive. Nevertheless, they can intensify the fluctuations of the torque. Also, in case the Bottom Hole Assembly has not been designed to contain the enhanced aggressiveness, there might be some wavering. On the other hand, the smaller cutters will come in sizes between 8 and 16mm. Also, the smaller cutters can drill at a higher Rate of penetration, in comparison to the larger cutters. Though this is in specific applications like when drilling through limestone.

The majority of the bits that have a smaller cutter can survive a higher impact loading. One obvious difference is that the small cutters will give out tinier cuttings, compared to the larger cutters. The large cuttings can also be defective with the hole cleaning. This is mostly if the drilling fluid is not able to carry the cuttings to the annulus.

Restrictions
The performance of the pdc drill bit will be inhibited by the abrasive wear, the heat damage as well as the impact damage. The interference with the performance can be affected even on the softest surface. Nevertheless, the most common challenges of the pdc cutters are the abrasive wears. For that matter, they tend to be super vulnerable to specific surfaces as well as excess heat.

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