Abstract:
Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing.
Abstract:
Thermally stable polycrystalline constructions comprise a diamond body joined with a substrate, and may have a nonplanar interface. The construction may include an interlayer interposed between the diamond body and substrate. The diamond body preferably has a thickness greater than about 1.5 mm, and comprises a matrix phase of bonded together diamond crystals and interstitial regions disposed therebetween that are substantially free of a catalyst material used to sinter the diamond body. A replacement material is disposed within the interstitial regions. A population of the interstitial regions may include non-solvent catalyst material and/or an inf?ltrant aid disposed therein. The diamond body comprises two regions; namely, a first region comprising diamond grains that may be sized smaller than diamond grains in a second region, and/or the first region may comprise a diamond volume that is greater than that in the second region.
Abstract:
A cutting element having a substrate, an abrasive layer mounted to the substrate at an interface, and a longitudinal axis extending through the abrasive layer and the substrate is disclosed, therein the substrate has a binder material, a plurality of metal carbide grains bonded together by an amount of the binder material, and at least one binder gradient, and wherein the amount of binder material decreases along at least one direction to form the at least one binder gradient.
Abstract:
Diamond-bonded constructions include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix phase of bonded-together diamond crystals, and interstitial regions comprising a reaction product. The reaction product is formed by reaction between the diamond crystals and a reactive material. The reactant is carbide former and the reaction product is a carbide. The diamond-bonded body includes a further diamond region extending from the thermally stable region that comprises the matrix phase and a Group VIII metal disposed within interstitial regions of the matrix phase. The thermally stable region is substantially free of a catalyst material used to initially form the diamond-bonded body. The diamond-bonded body may include a material layer formed the reaction product that is disposed on a surface of the diamond-bonded body thermally stable region.
Abstract:
An ultra-hard and metallic construction comprises an ultra-hard component that is attached to a metallic component via a braze joint. The braze joint is interposed between the ultra-hard component and the metallic component, and comprises a first braze material bonded to a surface of the ultra-hard component. The braze joint includes an intervening layer in direct contact with the first braze material, and that is formed from a rigid material. The braze joint further comprises a second braze material that is interposed between the intervening layer and the metallic component, and that is different from the first braze material.
Abstract:
An ultra-hard and metallic construction comprises an ultra-hard component that is attached to a metallic component via a braze joint. The braze joint is interposed between the ultra-hard component and the metallic component, and comprises a first braze material bonded to a surface of the ultra-hard component. The braze joint includes an intervening layer in direct contact with the first braze material, and that is formed from a rigid material. The braze joint further comprises a second braze material that is interposed between the intervening layer and the metallic component, and that is different from the first braze material.
Abstract:
Thermally stable polycrystalline constructions include a body having a polycrystalline ultra-hard phase and a plurality of empty voids. The construction includes a backside support member over at least a portion of the backside surface of the body and a sidewall support member over at least a portion of the sidewall surface of the body extending an axial distance along at least a portion of the body and at least partially covering a circumferential surface of the body. The construction has a compressive stress exerted on the body.