Abstract:
Polycrystalline compacts include non-catalytic, non-carbide-forming particles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include forming a polycrystalline material including a hard material and a plurality of particles comprising a non-catalytic, non-carbide-forming material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic, non-carbide-forming particles.
Abstract:
An insert for an earth-boring tool includes a body and a coating disposed over at least a portion of the body. The coating comprises a ceramic comprising boron, aluminum, and magnesium. Polycrystalline diamond compact cutting elements may include a hard polycrystalline material, a supporting substrate, and a coating disposed over at least a portion of the hard polycrystalline material. An earth-boring drill bit may include a bit body and at least one polycrystalline diamond compact cutting element secured to the bit body. The polycrystalline diamond compact cutting element may have a coating comprising a ceramic of boron, aluminum, and magnesium, and may be disposed over at least a portion of a hard polycrystalline material. A method of forming an insert for an earth-boring tool may include forming a protective coating including a ceramic of boron, aluminum, and magnesium over a cutting element.
Abstract:
Coated diamond particles have solid diamond cores and at least one graphene layer. Methods of forming coated diamond particles include coating diamond particles with a charged species and coating the diamond particles with a graphene layer. A composition includes a substance and a plurality of coated diamond particles dispersed within the substance. An intermediate structure includes a hard polycrystalline material comprising a first plurality of diamond particles and a second plurality of diamond particles. The first plurality of diamond particles and the second plurality of diamond particles are interspersed. A method of forming a polycrystalline compact includes catalyzing the fox of inter-granular bonds between adjacent particles of a plurality of diamond particles having at least one graphene layer.
Abstract:
Cutting elements, earth-boring drill bits having such cutting elements and related methods are described herein. In some embodiments, a cutting element for an earth-boring tool may include a diamond table having an indentation in a cutting face thereof and a shaped feature in a substrate at the interface between the diamond table and the substrate, the shaped feature corresponding to the indentation in the cutting face of the diamond table. In further embodiments, a cutting element for an earth-boring tool may include a sacrificial structure positioned within an indentation in a diamond table. In additional embodiments, a method of forming a cutting element may include positioning a sacrificial structure in a mold, positioning a powdered precursor material over the sacrificial structure, and pressing and sintering the powdered precursor material to form a diamond table having an indentation in a cutting face formed by the sacrificial structure.
Abstract:
Methods of forming a polycrystalline compact for use in an earth-boring tool include sintering a plurality of hard particles with catalyst material to faun a polycrystalline material that includes a plurality of inter-bonded particles of hard material integrally formed with the catalyst material and introducing at least a portion of the polycrystalline material to a reactive material to remove at least a portion of the catalyst material contained within the polycrystalline material. The reactive material may include at least one of a molten glass, an ionic compound, a leaching liquor, and a chemical plasma. The reactive material may be introduced to the polycrystalline material at a temperature of greater than or equal to a melting point thereof.
Abstract:
A cutting element comprising a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface. The cutting element further includes a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate. The cutting element is also formed to include a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer.
Abstract:
Apparatuses for forming chamfers on superabrasive tables of cutting elements for earth-boring tools include a chuck for temporarily holding and positioning a cutting element, and at least one emitter for emitting a beam of energy toward an edge of a superabrasive table of a cutting element held and positioned by the chuck. Methods of forming cutting elements for earth-boring tools and methods for forming earth-boring tools are also disclosed.
Abstract:
A method of growing carbonaceous particles comprises depositing carbon from a carbon source, onto a particle nucleus, the particle nucleus being a carbon-containing material, an inorganic material, or a combination comprising at least one of the foregoing, and the carbon source comprising a saturated or unsaturated compound of C20 or less, the carbonaceous particles having a uniform particle size and particle size distribution. The method is useful for preparing polycrystalline diamond compacts (PDCs) by a high-pressure, high-temperature (HPHT) process.
Abstract:
A method of forming a polycrystalline diamond comprises derivatizing a nanodiamond to form functional groups, and combining the derivatized nanodiamond with a microdiamond having an average particle size greater than that of the derivatized nanodiamond, and a metal solvent-catalyst. A polycrystalline diamond compact is prepared by adhering the polycrystalline diamond to a support, and an article such as a cutting tool may be prepared from the polycrystalline diamond compact.
Abstract:
Methods of fabricating polycrystalline diamond include functionalizing surfaces of carbon-free nanoparticles with one or more functional groups, combining the functionalized nanoparticles with diamond nanoparticles and diamond grit to form a particle mixture, and subjecting the particle mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles and the diamond grit. Cutting elements for use in an earth-boring tool includes a polycrystalline diamond material formed by such processes. Earth-boring tools include such cutting elements.