AP23484450 – Development of innovative composite diamond-containing materials with high mechanical and operational characteristics for the equipment of drilling tools

Objective of the project – Improving the design of drilling tools for drilling wells for various purposes, consisting in the rational placement and configuration of working elements obtained by plasma spark sintering of composite diamond-containing materials Cdiamond ‒ (WC‒Co) ‒CrB2 ‒ ZrO2.

Relevance: The relevance of the project is determined by the need to develop highly efficient drilling tools for operation in hard rock conditions. Modern requirements for such tools include a combination of high wear resistance, strength, and cost-effectiveness, which cannot be achieved without the development of new composite materials. The use of WC–Co matrices with dispersion-strengthening additives such as CrB₂ and ZrO₂ makes it possible to combine high adhesion between diamond grains and the matrix with improved mechanical properties of the composite. Optimization of composition and sintering regimes to achieve maximum performance characteristics of the tool is of particular importance. The application of modified plasma spark sintering technology allows increasing wear resistance while simultaneously reducing energy consumption and production costs. Thus, the development of new composite materials and their production technologies is a relevant task aimed at improving the efficiency of drilling operations and enhancing product competitiveness.

Scientific supervisor: Doctor of technical sciences, Professor, Boranbay Tovbasarovich Ratov

Expected and achieved results: During the implementation of the project, a methodology for preparing multicomponent diamond-containing mixtures with uniform distribution of components, including diamond, WC, Co, CrB₂, and ZrO₂, was developed. Samples of hard alloy matrices and composite diamond-containing materials of various compositions were fabricated and sintered for experimental studies. An analysis of existing drilling tool designs and directions for their improvement was carried out, along with a patent review. A technology for mixture preparation based on stepwise introduction of components in an alcohol medium and controlled drying was developed, ensuring structural homogeneity of the composites. The dependence of rock destruction efficiency by diamond-containing matrices on rock hardness and abrasiveness was established. The samples were sintered using plasma spark sintering at temperatures up to 1450 °C, a pressure of 30 MPa, and under vacuum conditions, which prevented recrystallization and ensured an equilibrium structure of the materials. The shape, size, and morphology of WC, Co, CrB₂, ZrO₂, and diamond powders were determined both in their initial state and in mixtures. The formation of agglomerates and distribution features of particles in the composites were identified. Based on the research results, working drawings of diamond drill bits were developed in accordance with modern requirements. It was found that adding 6% ZrO₂ and 2% CrB₂ to the 94WC–6Co composite significantly increases compressive and flexural strength. It was determined that exceeding the additive content leads to deterioration of properties due to the formation of micropores and microcracks. Data on mechanical properties, including stiffness, creep, and elastic and plastic deformation work, were obtained. It was demonstrated that the developed composites exhibit improved performance characteristics compared to the base material. Author supervision was carried out during the production of a pilot batch of drilling tools in accordance with patents of the Republic of Kazakhstan. Patent applications were submitted for the developed solutions. As a result of the project, new composite materials and technological solutions were created, ensuring increased durability and efficiency of drilling tools operating under challenging conditions.

List of publications with links to them

1. Сейдалиев А.А., Калжанова А.Б., Гусманова А.Г., Ратов Б.Т., Куттыбаев А.Е., Сарбопеева М.Д., Утепов З.Г. Оптимизация эксплуатационных свойств бурового инструмента с алмазосодержащими элементами // Нефть и газ. – 2025. – Т. 2. – № 146. – С. 42–52. – DOI: https://doi.org/10.37878/2708-0080/2025-2.03
2. Ratov B., Kuttybayev A., Tileuberdi N., Utepov Z., Aliakbar M., Zhanggirkhanova A., Pashchenko O., Kamyshatskyi O., Khomenko V., Zaichuk O., Seidaliyev A. Application of Plasticizers Octadecane to Pentatriacontane and Ethylene Glycol in the Manufacture of Metaloceramic Alloys // ES Materials and Manufacturing. – 2025. – Vol. 28. – No. 1563. – P. 1–14. – DOI: https://dx.doi.org/10.30919/mm1563
3. Ratov B., Mechnik V., Hevorkian E., Rucki M., Pieniak D., Bondarenko N., Kolodnitskyi V., Starik S., Bilorusets V., Chishkala V., Sundetova P., Bektilevov A., Shukmanova A., Seidaliyev A. Wear Resistance of the Refractory WC–Co Diamond-Reinforced Composite with Zirconia Additive // Materials. – 2025. – Vol. 18. – No. 1965. – P. 1–17. – DOI: https://doi.org/10.3390/ma18091965