Abstract:
Provided is polycrystalline diamond having a diamond single phase as basic composition, in which the polycrystalline diamond includes a plurality of crystal grains and contains boron, hydrogen, oxygen, and the remainder including carbon and trace impurities; the boron is dispersed in the crystal grains at an atomic level, and greater than or equal to 90 atomic % of the boron is present in an isolated substitutional type; hydrogen and oxygen are present in an isolated substitutional type or an interstitial type in the crystal grains; each of the crystal grains has a grain size of less than or equal to 500 nm; and the polycrystalline diamond has a surface covered with a protective film.
Abstract:
A method of forming a polycrystalline diamond body includes mixing a sintering agent with diamond powder to form a premixed layer, the sintering agent including at least one alkaline earth metal carbonate; forming an infiltration layer adjacent to the premixed layer, the infiltration layer including an infiltrant material including at least one alkaline earth metal carbonate; and subjecting the premixed layer and the infiltration layer to high pressure high temperature conditions.
Abstract:
A method of making a body of polycrystalline superhard material comprising placing an aggregated mass of grains of superhard material into a canister, placing a ceramic layer either in direct contact with the aggregated mass of grains of superhard material or in indirect contact therewith, the ceramic layer being spaced from the grains by an interlayer of material when present, the ceramic layer having a surface with surface topology, the surface topology imprinting a pattern in the aggregated mass of grains of superhard material complementary to the surface topology, the ceramic material and the material of the interlayer being such that they do not react chemically with the superhard material and/or a sinter catalyst material for the grains of superhard material. The aggregated mass of grains of superhard material and ceramic layer are subjected to a pressure of greater than 5.5 GPa and sintered to form a body of polycrystalline superhard material having a surface topology complementary to the surface topology of the ceramic layer. The ceramic layer and interlayer if present are then removed from the body of polycrystalline material. There is also disclosed a body of polycrystalline superhard material having a surface topology on a first surface, the first surface being substantially free of material from a canister used in formation of the body of polycrystalline superhard material.
Abstract:
A method of producing a component of a composite of diamond and a binder, wherein a Hot Isostatic gas Pressure process (HIP) is used, includes the step of enclosing a de-bound green body having compacted diamond particles in an infiltrant. The method includes the further steps of enclosing the de-bound green body and the infiltrant in a Zr-capsule that has Zirconium as a main constituent and sealing the Zr-capsule, and applying a predetermined pressure-temperature cycle on the unit formed by the de-bound green body, infiltrant and capsule in which the infiltrant infiltrates the de-bound green body and the de-bound green body is further densified in the sense that the volume thereof is decreased.
Abstract:
Methods for forming cutting elements, methods for forming polycrystalline compacts, and related polycrystalline compacts are disclosed. Grains of a hard material are subjected to a high-pressure, high-temperature process to form a polycrystalline compact. Inclusion of at least one relatively quick spike in system pressure or temperature during an otherwise plateaued temperature or pressure stage accommodates formation of inter-granular bonds between the grains. The brevity of the peak stage may avoid undesirable grain growth. Embodiments of the methods may also include at least one of oscillating at least one system condition (e.g., pressure, temperature) and subjecting the grains to ultrasonic or mechanical vibrations. A resulting polycrystalline compact may include a high density of inter-granularly bonded hard material with a minimized amount of catalyst material, and may provide improved thermal stability, wear resistance, toughness, and behavior during use of a cutting element incorporating the polycrystalline compact.
Abstract:
Embodiments of the invention relate to methods of modeling leaching behavior of a polycrystalline diamond (“PCD”) material used in leached polycrystalline diamond compacts (“PDCs”) and methods of monitoring leaching of a PCD material. In an embodiment, a method of modeling leaching behavior is disclosed. A PCD table is provided, which includes a plurality of bonded diamond grains defining a plurality of interstitial regions in which a metallic material is disposed. The PCD table is leached with a leaching agent to at least partially remove the metallic material from the PCD table. A leach depth of the PCD table is determined. A concentration of at least one constituent of the leaching agent is also determined. The leach depth is correlated with the concentration of the at least one metal to generate the model of leaching behavior.