Abstract:
A method of making a cutter structure (1) comprises placing a pre-formed body (4) of hard material having a surface topography in a canister, placing an aggregated mass of grains of superhard material (2) over said surface topography, placing a punch (10) in contact with the superhard material (2), the punch (10) having a surface with a surface topography inverse to that of the hard material body to imprint a pattern in the superhard material (2) complementary to the surface topography of the punch (10). The surface of the punch (10) contacting the superhard material (2) being formed of a ceramic material that does not react chemically with the superhard material (12) and/or a sinter catalyst for the superhard material (2). A pressure of greater than 3 GPa is then together with a temperature sufficiently high for the catalyst to melt to form the cutter structure (1) with a layer of polycrystalline superhard material bonded to the hard material and having a surface topography corresponding to the surface topography of the hard material.
Abstract:
A capsule assembly for an ultra-high pressure furnace, comprising a containment tube having an interior side surface and defining a central longitudinal axis; a chamber suitable for accommodating a reaction assembly, a proximate and a distal end heater assembly, and a side heater assembly. When assembled, the chamber is contained within the containment tube and arranged longitudinally between the proximate and distal end heater assemblies. The side heater assembly is disposed adjacent the interior side surface and electrically connects the end heater assemblies with each other. Each end heater assembly has a respective peripheral side disposed adjacent the interior side surface Heat is produced in the chamber in response to an electric current flowing through the end and side heater assemblies. At least a proximate side heater barrier spaces apart the side heater assembly from at least the proximate end heater assembly, adjacent its peripheral side, operative to prevent a portion of the side heater assembly from intruding between the peripheral side of the proximate end heater assembly and the containment tube and short-circuiting at least part of the proximate end heater assembly, when the end heater assemblies move towards each other in response to a force applied by the ultra-high pressure furnace onto the capsule assembly along the central longitudinal axis.
Abstract:
A capsule assembly for an ultra-high pressure furnace, comprising a containment tube defining a central longitudinal axis, a chamber suitable for accommodating a reaction assembly, a proximate and a distal end heater assembly, and a side heater assembly. When assembled, the chamber and the side heater assembly are contained within the containment tube and arranged longitudinally between the proximate and distal end heater assemblies. Each end heater assembly comprises a respective conduction volume forming a respective electrical path through the end heat assembly. The side heater assembly electrically connects the respective conducting volumes to each other, and heat is produced in the chamber in response to an electric current flowing through the side heater assembly and the conducting volumes. At least the proximate end heater assembly comprises a first insulation component including an outer insulation volume. The conducting volume of at least the proximate end heater assembly includes an inner conducting volume, and the inner conducting volume is laterally spaced apart from the containment tube by the outer insulation volume.
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.
Abstract:
A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a superabrasive volume and a substrate. The substrate may be attached to the superabrasive volume via an interface. The superabrasive volume may be formed by a plurality of polycrystalline superabrasive particles. The superabrasive particles may have nano or sub-micron scale surface texture.
Abstract:
A method of forming a polycrystalline diamond compact comprises providing metallized diamond particles including diamond particles including nanograins of a sweep catalyst secured thereto, the sweep catalyst comprising at least one of tungsten and tungsten carbide and constituting between about 0.01 weight percent and about 1.0 weight percent of the metallized diamond particles and placing the metallized diamond particles and a metal solvent catalyst in a container. The metallized diamond particles are subjected to a high-temperature, high-pressure process in the presence of the metal solvent catalyst to form a polycrystalline diamond material having inter-bonded diamond grains and nanograins of tungsten carbide, the nanograins of tungsten carbide covering less than about twenty percent of a surface area of the inter-bonded diamond grains. Polycrystalline diamond compacts and earth-boring tools including the polycrystalline diamond compacts are also disclosed.
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:
A polycrystalline diamond compact made from a high pressure, high temperature process is provided. The compact includes a metal carbide substrate including a binder and at least one inner layer of polycrystalline diamond disposed on the substrate. The polycrystalline diamond has a diamond phase and a metal phase forming an interconnected mutually exclusive network. The metal phase is a material different than that of the binder of the substrate to provide improved diamond sintering and final polycrystalline diamond compact properties. Prior to processing at least one coating is disposed on the substrate, and the layer of diamond particles is disposed on the at least one coating. During the high pressure, high temperature process the coating melts and fully sweeps into the diamond layer.
Abstract:
A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a superabrasive volume and a substrate. The substrate may be attached to the superabrasive volume via an interface. The superabrasive volume may be formed by a plurality of polycrystalline superabrasive particles. The superabrasive particles may have nano or sub-micron scale surface texture.
Abstract:
PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm