Thermally stable polycrystalline diamond and methods of making the same

A polycrystalline diamond, diamond technology, applied in the direction of manufacturing tools, metal processing, earth-moving drilling and mining, etc., can solve problems such as failure of PCD cutting elements

Active Publication Date: 2016-04-27
SMITH INT INC
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  • Abstract
  • Description
  • Claims
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Problems solved by technology

Although PCD is extremely hard and wear-resistant, PCD cutting elements can still fail during normal operation

Method used

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  • Thermally stable polycrystalline diamond and methods of making the same
  • Thermally stable polycrystalline diamond and methods of making the same
  • Thermally stable polycrystalline diamond and methods of making the same

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Embodiment Construction

[0017] As used herein, the term "carbonate-based polycrystalline diamond" refers to a process obtained by exposing individual diamond grains in the presence of carbonate material to conditions of high pressure and high temperature (HPHT) sufficient so that adjacent Intergranular bonding occurs between the diamond crystals to form a diamond-to-diamond bond and a network or matrix phase of interstitial regions dispersed between the bonded diamond grains resulting in the final material. The carbonate-based polycrystalline diamond of the present invention may be referred to as polycrystalline diamond or PCD, but is distinct from conventionally formed polycrystalline diamond formed by transition metal solvent catalysts (described in the background section). Additionally, one or more embodiments relate to oxide-based polycrystalline diamond formed by decomposing a carbonate-based polycrystalline diamond body.

[0018] The carbonate-based polycrystalline diamond body may have a micro...

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Abstract

A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high- temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material.

Description

[0001] Cross References to Related Applications [0002] This patent application claims priority and benefit to U.S. Patent Application No. 14 / 481,570, filed September 9, 2014, and U.S. Provisional Patent Application No. 61 / 876,696, filed September 11, 2013, the entire contents of which It is hereby incorporated herein by reference. Background technique [0003] Polycrystalline diamond ("PCD") materials and PCD elements formed therefrom are well known in the art. Conventional PCD can be formed by exposing diamond particles to high pressure / high temperature (HPHT) process conditions in the presence of a suitable solvent metal catalyst material that promotes the desired intercrystalline diamond and The diamond bonds, thereby forming a PCD structure. The resulting PCD structures yield enhanced wear resistance and hardness properties, making such PCD materials very useful in aggressive wear and cutting applications requiring high levels of wear resistance and hardness. Figure 1...

Claims

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Application Information

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IPC IPC(8): E21B10/46B24D3/06B24D3/10
CPCE21B10/5735B24D3/04B24D99/005B24D18/0009B01J3/062E21B10/567B24D3/10
Inventor Y·鲍L·赵J·D·贝尔纳普Z·林
Owner SMITH INT INC
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