PDC Cutters

HPHT Sintering & Non-Planar Interface Technology

The structural integrity of a PDC cutter relies on the bond between the Polycrystalline Diamond (PCD) layer and the Tungsten Carbide (WC-Co) substrate. During the drilling process, these two materials behave differently under load. The diamond layer is incredibly rigid but brittle, while the carbide substrate is tough but elastic. Under the extreme shear stress of drilling hard rock, this mismatch can lead to catastrophic delamination.

AIMRSE utilizes state-of-the-art High-Pressure High-Temperature (HPHT) presses operating at over 60 kbar and 1,500°C to sinter our cutters. Crucially, we employ advanced Non-Planar Interface (NPI) geometries. Instead of a flat interface, we engineer complex, 3D-mapped transition zones (such as concentric rings, spider-webs, or sinusoidal waves) that mechanically lock the diamond table to the substrate. This design distributes residual stresses more effectively and prevents the propagation of cracks along the interface boundary, increasing impact resistance by over 40% compared to standard flat-interface cutters.

Fig 1: Non-Planar Interface (NPI) Engineering: Distributing shear stress to prevent delamination in high-impact applications.

Thermal Stability & Deep Leaching Technology

Heat is the enemy of the diamond. Standard PDC cutters utilize Cobalt as a metal catalyst to facilitate the bonding of diamond crystals during sintering. However, Cobalt has a much higher coefficient of thermal expansion than diamond. When drilling friction raises the cutter temperature above 700°C, the trapped Cobalt expands, literally prying the diamond bonds apart from the inside—a phenomenon known as "Thermal Degradation." Furthermore, Cobalt catalyzes the reverse transformation of diamond back into graphite (Graphitization).

AIMRSE employs an advanced acid-leaching process to remove the Cobalt catalyst from the interstitial spaces of the diamond table to a precise depth (Deep Leaching). By creating a Thermally Stable Polycrystalline (TSP) layer, we effectively remove the cause of thermal failure. Our deep-leached cutters can operate at interface temperatures exceeding 1,100°C, making them essential for geothermal drilling and hard-rock formations where frictional heat generation is intense.

Fig 2: Microstructural Analysis: The left image shows cobalt inclusions (white spots); the right shows the leached, thermally stable lattice essential for high-temp drilling.

Chamfer Geometry & Edge Engineering

The geometry of the cutter's edge—the chamfer—determines how the cutter interacts with the formation. It is a calculated trade-off between aggressiveness (cutting efficiency) and durability (impact resistance). A sharp edge shears rock easily but is prone to chipping upon impact. A large chamfer protects the diamond table but requires significantly more Weight on Bit (WOB) to initiate rock failure. AIMRSE offers customizable edge preparations tailored to specific lithologies to optimize this balance.

Cutter Grade Specifications

We categorize our inventory based on the primary drilling challenge. Our engineering team can assist in selecting the correct grade based on your run records and IADC bit codes.

Fig 3: Grade Selection: From 8mm micro-cutters to massive 19mm cutters, we stock all standard API sizes for immediate bit repair or manufacturing.