Polycrystalline diamond compacts, method of fabricating same, and various applications

A polycrystalline diamond, composite sheet technology, applied in the manufacture of tools, shafts and bearings, earth-moving drilling, etc., can solve problems such as PDC failure

Active Publication Date: 2012-10-03
US SYNTHETIC CORP
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  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

Residual stress at the interface between the PCD table and cemented carbide substrate can lead to p...

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  • Polycrystalline diamond compacts, method of fabricating same, and various applications
  • Polycrystalline diamond compacts, method of fabricating same, and various applications
  • Polycrystalline diamond compacts, method of fabricating same, and various applications

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Embodiment Construction

[0032] Embodiments of the invention relate to PCDs exhibiting enhanced diamond-to-diamond bonding. The inventors currently believe that the rate of diamond nucleation and growth increases as the sintering pressure used during the HPHT process used to make such PCD moves further away from the graphite-diamond equilibrium line into the diamond stable region. This increased diamond nucleation and growth between diamond particles (for a given diamond particle formulation) can lead to the formation of PCD exhibiting one or more of the following properties: relatively low metal solvent catalyst content, high coercive force, lower specific magnetic saturation, or lower specific magnetic permeability (ie, the ratio of specific magnetic saturation to coercive force), compared to PCD formed at lower sintering pressures. Embodiments also relate to PDCs having PCD tables containing such PCDs, methods of making such PCDs and PDCs, and such PCDs and PDCs in rotary drill bits, bearing device...

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Abstract

Embodiments of the invention relate to polycrystalline diamond ("PCD") exhibiting enhanced diamond- to-diamond bonding. In an embodiment, polycrystalline diamond compact ("PDC") includes a PCD table having a maximum thickness. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds ("Oe") or more and a specific magnetic saturation of about 15 Gauss -cm3/grams ("G-cm3/g") or less. The PDC includes a substrate having an interfacial surface that is bonded to the PCD table. The interfacial surface exhibits a substantially planar topography. Other embodiments are directed to methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Description

[0001] Cross References to Related Applications [0002] This application claims priority to US Patent Application No. 12 / 690,998, filed January 21, 2010, which is hereby incorporated by reference in its entirety. Background technique [0003] Wear-resistant superabrasive compacts are used in a variety of mechanical applications. For example, polycrystalline diamond compact ("PDC") (polycrystalline diamond compact) is used in drilling tools (eg, cutting elements, drillers, etc.), machining equipment, bearing devices, wire drawing machines, and other mechanical devices. [0004] PDC has found particular application as a superabrasive cutting element in rotary drill bits such as roller cone bits and fixed cutting edge bits. PDC cutting elements typically include a superabrasive diamond layer, often referred to as a diamond table. The diamond table may be formed and bonded to the substrate using a high pressure, high temperature ("HPHT") process. The PDC cutting elements may a...

Claims

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Application Information

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IPC IPC(8): C22C26/00
CPCF16C2352/00E21B10/36B22F2998/00E21B10/5735B24D18/00C22C26/00F16C33/043B22F7/08F16C17/02F16C17/04F16C33/26Y10T428/24612Y10T428/249967Y10T428/24996E21B10/567C22C29/08E21B10/46E21B10/55F16C17/102
Inventor K·E·贝尔塔尼奥利D·P·米斯钱江J·K·威金斯M·A·韦尔D·穆霍帕德海艾
Owner US SYNTHETIC CORP
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