Abstract:
A method of producing polycrystalline diamond aggregates, wherein a carbon-containing material is given a required shape, after which, in the presence of a catalyst taken in the form of a powder whose envelope surrounds the carbon-containing material, said material is subjected to the action of pressure and simultaneous heating by an electric current pulse with a duration of 0.1 to 10.0 sec.
Abstract:
A compact comprising substantially graphite-free diamond particles having a continuous coating of titanium or molybdenum held in a matrix into which the titanium or molybdenum can diffuse. The matrix may for example, be an alloy selected from the group of Fe/Ni, Ni/Co/Cr/Fe, Fe/Si and Ti/Si alloys. The invention also provides a method of making such a compact by mixing the desired metal powders in suitable proportions with the coated diamond particles and compacting the mixture under pressure and temperature conditions in the diamond stable zone.
Abstract:
A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1,400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm3 and a modulus of at least about 1,000 GPa. An earth-boring tool may include such a cutting element secured to a body.
Abstract:
Grains of superabrasive material may be infiltrated with a molten metal alloy at a relatively low temperature, and the molten metal alloy may be solidified within interstitial spaces between the grains of superabrasive material to form a solid metal alloy having the grains of superabrasive material embedded therein. The solid metal alloy with the grains of superabrasive material embedded therein may be subjected to a high pressure and high temperature process to form a polycrystalline superabrasive material. A polycrystalline superabrasive material also may be formed by depositing material on surfaces of grains of superabrasive material in a chemical vapor infiltration process to form a porous body, which then may be subjected to a high pressure and high temperature process. Polycrystalline compacts and cutting elements including such compacts may be formed using such methods.
Abstract:
A polycrystalline compact comprises a plurality of grains of hard material and a plurality of nanoparticles disposed in interstitial spaces between the plurality of grains of hard material. The nanoparticles have cores of a first material and at least one oxide material on the cores. An earth-boring tool comprises such a polycrystalline compact. A method of forming a polycrystalline compact comprises combining a plurality of hard particles with a plurality of nanoparticles to form a mixture and sintering the mixture to form a polycrystalline hard material comprising a plurality of interbonded grains of hard material. A method of forming a cutting element comprises infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of nanoparticles.
Abstract:
A polycrystalline superhard construction comprises a body of polycrystalline superhard material, and a substrate of hard material bonded thereto along an interface. The body of polycrystalline superhard material comprises a first region abutting the substrate along the interface and a second region bonded to the first region. The second region defines a rake face, a cutting edge, a chamfer and at least a part of a flank face, the cutting edge being defined by an edge of the flank face joined to the chamfer, the chamfer extending between the cutting edge and the rake face. The height of the chamfer in a plane parallel to the plane through which the longitudinal axis of the polycrystalline superhard construction extends is less than the thickness of the second region. The first region comprises a material having coarser grains than the second region. There is also disclosed a method of making the same.
Abstract:
A polycrystalline super hard construction comprises a body of polycrystalline diamond (PCD) material and a plurality of interstitial regions between inter-bonded diamond grains forming the polycrystalline diamond material. The body of PCD material comprises a working surface positioned along an outside portion of the body, and a first region adjacent the working surface, the first region being a thermally stable region. The first region and/or a further region and/or the body of PCD material has/have an average oxygen content of less than around 300 ppm. A method of forming such a construction is also disclosed.
Abstract:
Methods of forming polycrystalline diamond include encapsulating diamond particles and a hydrocarbon substance in a canister, and subjecting the encapsulated diamond particles and hydrocarbon substance to a pressure and a temperature sufficient to form inter-granular bonds between the diamond particles. 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.
Abstract:
Polycrystalline diamond compacts (“PDCs”) and methods of manufacturing such PDCs. In an embodiment, the PDC includes a polycrystalline diamond (“PCD”) table having at least a portion of a metal-solvent catalyst removed therefrom. Removing at least a portion of a metal-solvent catalyst from the PCD table may increase the porosity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst. Likewise, removing at least a portion of a metal-solvent catalyst from the PCD table may decrease the specific magnetic saturation and increase the coercivity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst.