Polycrystalline Diamond Compacts with Crushed Nanoparticles

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Solution Overview

Problem

Incorporating diamond nanoparticles into polycrystalline diamond compacts for earth-boring tools is challenging due to their dissolution in the liquid binder during high-temperature/high-pressure processing, leading to loss of abrasion resistance, fracture toughness, and thermal stability, and compromising the sintering quality and mechanical integrity of the diamond table.

Innovation Solution

Encapsulating micron-sized diamond grains and crushed diamond nanoparticles in a canister and subjecting them to a pressure of at least 5.0 GPa and a temperature of at least 1000°C in the presence of a binder to form inter-granular bonds between the diamond grains and nanoparticles, ensuring they remain bonded and maintain their beneficial characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If diamond nanoparticles are incorporated into polycrystalline diamond compacts to improve abrasion resistance, fracture toughness, and thermal stability, then the mechanical properties are enhanced, but the nanoparticles dissolve in the liquid binder during HTHP processing, leading to loss of these beneficial characteristics

Engineering Contradiction:

Improvemechanical properties (abrasion resistance, fracture toughness, thermal stability)VSAvoiddiamond nanoparticle dissolution

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent introduces an organic binder as an intermediary substance between the diamond nanoparticles and the metal catalyst binder. The organic binder forms a protective barrier during HTHP processing that prevents the diamond nanoparticles from dissolving in the liquid metal binder, thereby preserving the mechanical properties while still allowing the metal catalyst to facilitate sintering.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite binder system consisting of both organic binder and metal catalyst binder. This composite approach allows the organic component to protect the nanoparticles from dissolution while the metal component provides catalytic activity for sintering, thus resolving the contradiction between nanoparticle stability and sintering effectiveness.

Inventive Principle:

Principle #40Composite materials

2Reliability

If high concentration of diamond nanoparticles is used to enhance PCD performance, then abrasion resistance and thermal stability improve, but sintering quality is compromised due to loss of binder volume and inhibition of liquid-state binder infiltration

Engineering Contradiction:

Improveabrasion resistance and thermal stabilityVSAvoidsintering quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The organic binder acts as a protective intermediary that allows high concentrations of diamond nanoparticles to be incorporated without compromising sintering quality. It prevents nanoparticle dissolution and maintains adequate binder volume for proper infiltration, enabling both high nanoparticle content and good sintering quality to coexist.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical and chemical parameters of the binder system by introducing an organic component with different properties than conventional metal-only binders. This allows the system to maintain adequate binder volume and infiltration capability even at high nanoparticle concentrations, thus improving both nanoparticle retention and sintering quality.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method results in a polycrystalline diamond compact with improved thermal stability and mechanical durability, including enhanced abrasion resistance and reduced catalyst material, leading to a more effective cutting element for earth-boring tools.

Implementation Method 1

subjecting them to a pressure of at least 5.0 GPa and a temperature of at least 1000°C in the presence of a binder to form inter-granular bonds between the diamond grains and nanoparticles

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

in the presence of a binder to form inter-granular bonds

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10030450B2Polycrystalline compacts including crushed diamond nanoparticles, cutting elements and earth boring tools including such compacts, and methods of forming same

Publication Date: 2018.07.24 BAKER HUGHES CO

AI summary

A polycrystalline compact comprises a plurality of diamond grains of micron size, submicron size, or both, and a plurality of crushed diamond nanoparticles disposed in interstitial spaces between the plurality of diamond grains. A method of forming a polycrystalline compact comprises combining a plurality of micron and/or submicron-sized diamond grains and a plurality of crushed diamond nanoparticles to form a mixture and sintering the mixture in a presence of a binder to form a polycrystalline hard material comprising a plurality of inter-bonded diamond grains and diamond nanoparticles. Cutting elements comprising a polycrystalline compact and earth-boring tools bearing such compacts are also disclosed.