3D打印金刚石复合片及其钻头的研究进展

吴晶晶; 张绍和; 曲飞龙; 苏舟; 孔祥旺; 何焘

doi:10.13394/j.cnki.jgszz.2022.3003

3D打印金刚石复合片及其钻头的研究进展

doi: 10.13394/j.cnki.jgszz.2022.3003

吴晶晶^1,,
张绍和^{2, 3, ,},
曲飞龙⁴,
苏舟^{2, 3},
孔祥旺^{2, 3},
何焘^{2, 3}

1.
湖南工业大学土木工程学院, 湖南株洲 412007
2.
有色金属成矿预测与地质环境监测教育部重点实验室, 长沙 410083
3.
中南大学地球科学与信息物理学院, 长沙 410083
4.
中冶长天国际工程有限责任公司, 长沙 410205

基金项目: 国家重点研发计划（2021YFB3701800）；湖南省自然科学基金面上项目（2022JJ30709）。

详细信息

作者简介:
吴晶晶，女，1989年生，博士研究生。主要研究方向：碎岩材料与工具。E-mail：wujingjing0408@163.com

通讯作者:
张绍和，男，1967年生，教授。主要研究方向：地质工程智能化技术、岩土钻掘工程理论与技术。E-mail：zhangshaohe@163.com

中图分类号: TG74; TQ164
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- 被引次数: 0
出版历程
- 收稿日期: 2022-07-03
- 修回日期: 2022-08-13
- 录用日期: 2022-08-20
- 刊出日期: 2023-02-20

Research progress of 3D printing PDC and PDC bit

WU Jingjing^1
,,
ZHANG Shaohe^{2, 3
, ,},
QU Feilong⁴,
SU Zhou^{2, 3},
KONG Xiangwang^{2, 3},
HE Tao^{2, 3}

1.
College of Civil Engineering, Hunan University of Technology, Zhuzhou 412007, Hunan, China
2.
Key Laboratory of Metallogenic Prediction of Nonferrous Metals and Geological Environment Monitoring, Ministry of Education, Changsha 410083, China
3.
School of Geosciences and Info-Physics, Central South University, Changsha 410083, China
4.
Zhongye Changtian International Engineering Co., Ltd., Changsha 410205, China

摘要

摘要: PDC钻头已成为油气勘探领域的首选钻头类型，日益提升的PDC钻头性能要求特别是钻进效率要求给钻头制造带来较大挑战。钻头工作面结构改进是PDC钻头实现高效破岩的关键，但这给PDC钻头制造带来难题。3D打印技术是一种新型的快速成形技术，具有制造任意复杂形状结构、个性化定制和创意设计的优点，将3D打印工艺应用于PDC及其钻头的生产是未来发展的必然趋势。本文中介绍了目前用于制备PDC及其钻头的3D打印技术的基本原理，包括光固化成形技术（SLA）、熔融沉积技术（FDM）、激光选区烧结（SLS）、激光选区熔化技术（SLM）和喷墨粘粉式（3DP）等；总结了现有3D打印技术在PDC及其钻头制造方面的研究进展，并对未来3D打印PDC钻头的发展进行了展望。
- 3D打印 /
- 金刚石复合片 /
- 金刚石复合片钻头 /
- 模具成形 /
- 复杂结构
Abstract: PDC bit has become the preferred type of drill bits in the field of oil and gas exploration. The ever-increasing performance requirements of PDC bits, especially the drilling efficiency, have brought great challenges to the drill bits. The improvement of the drill bit working face structure is crucial to the efficient rock breaking of PDC bits. However, this brings great difficulties to the manufacture of drill bits. 3D printing technology is a new type of rapid prototyping technology which has the advantages of manufacturing any complex shape structures, personalized customization and creative design. It is an inevitable trend to apply 3D printing technology to the production of PDC bits. This paper focuses on the basic principles of 3D printing technologies currently used to prepare PDC bits, including photolithography (SLA), fused deposition (FDM), selective laser sintering (SLS), selective laser melting (SLM) and three dimensional printing (3DP), etc. And then it summarizes the research progress of the existing 3D printing technology in the manufacture of PDC and PDC bits, and gives an outlook on the development of 3D printing PDC and PDC bits in the future.
- 3D printing /
- polycrystalline diamond compacts /
- PDC bit /
- mould forming /
- complex structure

HTML全文

图 1 三维骨架硬质合金基体的聚晶金刚石复合片

1-硬质合金基体；2-金刚石聚晶；3-三维骨架结构层；4-圆柱状硬质合金

Figure 1. Polycrystalline diamond composite with 3D bone structure on cemented carbide matrix

1-Cemented carbide matrix; 2-Polycrystalline diamond; 3-Structure of 3D bone; 4-Cylindrical cemented carbide

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图 2 无钴渐变层金刚石复合片

Figure 2. PDC without Co gradient layer

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图 3 冷热交替3D打印法制备金刚石复合片流程

Figure 3. Process of preparing PDC by alternating hot and cold 3D printings

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图 4 PDC钻头模具成形示意图

Figure 4. Schematic diagram of PDC drill die forming

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图 5 SLA 3D打印PDC钻头基础模具与PDC钻头模型

Figure 5. Mold and model of PDC bit 3D printed by SLA

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图 6 FDM 3D打印工艺成形的PDC钻头基础模具及其硅胶模

Figure 6. Basic mold and silica gel mold of PDC bit 3D printed by FDM

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图 7 熔模铸造工艺流程

(a) 蜡型; (b) 组装; (c) 涂敷浆料; (d) 敷砂; (e) 脱蜡; (f) 型壳焙烧;(g) 浇筑; (h) 脱模

Figure 7. Investment casting process flow

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图 8 SLS技术成形的砂型直接用于PDC钻头烧结

Figure 8. Sand mold formed by SLS technology directly for sintering PCD bits

(a) Sand mold; (b) Directly applied for sintering bits

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表 1 用于制造PDC及其钻头的3D打印技术及其特点^[15-21]

Table 1. 3D printing technologies and their characteristics for manufacturing PDC and PDC bits^[15-21]

工艺	材料类型	物理形态	几何单元	作用形式		坐标运动
光固化成型(SLA)	光敏树脂	液态（层厚可小至16 μm）	光斑点（100～200 μm）	紫外激光辐射，光斑范围内树脂发生光子聚合物而固化，激光功率3～5 W		激光束X、Y向，工作台Z向
熔融沉积技术(FDM)	低熔点线材	固态	熔融丝线	喷头电阻加热模块使线材熔化并在挤出喷头后迅速固化		激光束X、Y向，工作台Z向（常见）
激光选区烧结(SLS)	粉末材料	固态（粒径为 50～100 μm）	粉末点	红外激光照射，光斑范围内低熔点粉末发生熔化并在激光束离开后迅速固化，激光功率≥400 W		激光束X、Y向，工作台Z向
激光选区熔化(SLM)	粉末材料	固态（粒径为 50～100 μm）	粉末点	红外激光照射，光斑范围内粉末完全熔化并在激光束离开后迅速固化，激光功率< 1000 W		激光束X、Y向，工作台Z向
喷墨粘粉式(3DP)	粉末材料	（粒径为 50～100 μm）	粉末点	利用喷头按指定路径将粘结剂喷在预先铺好的粉层特定区域，完成一个层面的建造		激光束X、Y向，工作台Z向

工艺	获得累积			后处理	优点	缺点
光固化成型(SLA)	液态树脂浸没一层，刮板保证平整，层间内树脂同样发生光子聚合物而固化，并使层间粘结在一起			滤干、烘干、去支撑、再固化等	精度高，表面质量好，原材料利用率高	成形材料少，成本高，且固化过程易收缩形变
熔融沉积技术(FDM)	熔融丝线继续被喷头挤出而沉积，发生固化的同时与上层粘结在一起			去支撑、表面磨抛	技术成熟，成本低，多色彩打印	精度较低，产品具有台阶效应
激光选区烧结(SLS)	粉末材料铺展一层，展辊保证平整，层间内低熔点粉末同样被激光熔化、激光束离开后迅速固化并使层间粘结在一起			吹掉余粉、孔隙致密	成形速度快，成形结构复杂	力学性能差，表面精度差
激光选区熔化(SLM)	粉末材料铺展一层，展辊保证平整，层间内粉末同样被激光完全熔化、激光束离开后迅速固化并使层间粘结在一起			致密提升	表面质量、性能俱佳，成形结构复杂	尺寸有限，力学性能差，表面精度差
喷墨粘粉式(3DP)	粘结剂继续被喷头喷射出而沉积，发生固化的同时与上层粘结在一起			补强处理	成形快，无需支撑材料，可全彩打印	实体强度低，精细度差等

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表 2 不同材料质量比和工艺参数条件下的复合材料性能对比

Table 2. Comparisons of performance of composite materials with different raw material ratios at different parameters

序号	硬质合金				金刚石				复合材料
序号	质量 m₁ g	扫描速率 v₁ mm·s⁻¹	扫描电流 I₁ mA	融化温度 t₁ ℃	质量 m₂ g	扫描速率 v₂ mm·s⁻¹	扫描电流 I₂ mA	融化温度 t₂ ℃	导热系数 α W·m⁻¹K⁻¹	摩擦系数 f	热膨胀系数 λ ℃⁻¹	硬度值 HV	冲击韧性 T J
1	858	1.0×10⁴	10	1380	7.0	1.0×10⁴	6	1450	550	0.5	1.18×10⁻⁶	5000	300
2	854	6.0×10⁴	10	1400	6.4	6.0×10⁴	2	1460	530	0.4	1.00×10⁻⁶	4800	320
3	850	1.0×10⁴	10	1380	6.0	1.0×10⁴	6	1450	500	0.3	0.90×10⁻⁶	4900	310

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表 3 不同骨架材料和成形工艺条件下的复合片的平均落球冲击次数

Table 3. Average numbers of falling ball impacts on composites with different bones under different parameters

案例	骨架材料	三维骨架基体成形工艺	金刚石微粉填充方法	平均落球冲击次数
案例1	Co-Cr-Mo	SLM	过凝胶挤入法	20.6
案例2	Ti6Al4V	SLM	过凝胶挤入法	24.8
案例3	Mo	SLM	过凝胶挤入法	35.4
案例4	W	SLM	过凝胶挤入法	38.2
案例5	WC-Co + Ti6Al4V	SLM	过凝胶挤入法	50.4
案例6	WC-Co	SLM	过凝胶挤入法	57.6
案例7	WC-Co	SLM	振动法	56.8
案例8	WC-Co	SLM	溶剂沉积法	57.4
案例9	WC-Co	3DP	溶剂沉积法	55.8
对比例	无骨价	粉末冶金液相	粉末冶金液相烧结 + 高温高压烧结	6.8

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