Composite Disc For Pdc Drill Bit

PDC Cutter, fully known as Polycrystalline Diamond Compact, is the core cutting element of PDC bits used in oil, geology, mining and other fields, and also a key component that determines the cutting performance, service life and drilling efficiency of the bits. It is integrally synthesized by solid-phase sintering process under special environments of ultra-high temperature (above 1400℃) and ultra-high pressure (5-7GPa) with micron-sized diamond powder and Tungsten Carbide (WC) substrate, consisting of two core parts: Polycrystalline Diamond (PCD) layer and Tungsten Carbide substrate.

三、 Typical Structural Parameters

1. PCD Layer Thickness: 0.7–2.0 mm (Cutting Surface)

 The diamond layer is the working layer for directly cutting rocks, and its thickness can be customized according to application scenarios. Thin diamond layers feature high cutting precision and good self-sharpening property, suitable for soft to medium-hard formations; thick diamond layers have stronger wear resistance, adapting to hard rocks and highly abrasive formations, effectively extending the overall service life of the cutter.

2. Tungsten Carbide Substrate

 Sintered with ultra-fine grain tungsten carbide and cobalt-based binder, it serves as the support body of the cutter with extremely high bending strength and impact toughness. It can effectively resist vibration and impact loads during drilling, prevent the cutter from chipping and falling off, and provide stable support and bonding force for the diamond layer.

3. Thermal Stability: ＜700℃

 The thermal stability temperature of conventional PDC cutters is lower than 700℃, and problems such as diamond graphitization and interlayer delamination are prone to occur in high-temperature environments. Special high-temperature resistant models can be upgraded to above 850℃, adapting to high-temperature drilling conditions in deep and ultra-deep wells, avoiding high-temperature failure and ensuring stable cutting performance.

4. Shape Tolerance

 Diameter tolerance: ±0.05 mm, height tolerance: ±0.1 mm, ensuring the dimensional accuracy of the cutter, facilitating bit welding and assembly, and ensuring uniform cutting stress.

四、 Key Selection Points

1. Small Diameter Series (13mm Series)

 Suitable for special drilling projects such as directional wells, horizontal wells, slim holes and sidetracking wells, adapting to high-speed drilling conditions. It features flexible cutting and strong formation adaptability, especially suitable for drilling operations with narrow boreholes and complex trajectories, which can effectively reduce drilling resistance and improve drilling accuracy.

2. Medium Diameter Series (16mm Series)

 The most widely used general-purpose series in the industry, balancing cutting efficiency, wear resistance and impact resistance with extremely high cost performance. It adapts to most conventional geological formations and drilling projects, and can meet usage requirements whether in oil drilling, geological exploration or mining basic excavation, making it the first choice for various conventional projects. 

3. Large Diameter Series (19–25mm Series)

 Designed for large boreholes, deep wells, ultra-deep wells, hard rocks, compact rocks and highly abrasive formations. Single cutter has large cutting area, strong bearing capacity and high rock breaking efficiency, with service life far exceeding small-size models. It is suitable for large-scale drilling projects, deep resource exploitation and long-period operation under harsh geological conditions, which can greatly reduce bit replacement frequency and construction cost.

4. Thickness Selection Reference

 8.0mm thickness type: Lighter and thinner overall size, small cutting resistance, fast drilling speed, suitable for shallow wells, soft to medium-hard formations and high-efficiency fast drilling scenarios; 13.2mm thickness type: Larger substrate thickness, better impact resistance, suitable for deep wells, hard rocks and complex formations with stronger durability.

五、 Core Advantages of The Product

1. Excellent performance: Combining high hardness and wear resistance of diamond with high toughness of tungsten carbide, stable cutting performance;

2. Strong self-sharpening property: Automatically form sharp edges during cutting, continuously and efficiently break rocks;

3. Longer service life: Service life is increased by several times compared with traditional cutting tools, reducing replacement frequency;

4. Wide adaptability: Can adapt to different formations and drilling conditions, complete in sizes and specifications;

5. Lower cost: High comprehensive drilling efficiency and low loss, greatly reducing the total cost of engineering construction.