Abstract:
An apparatus using a shape memory alloy such as nickel-titanium as a reaction vessel for self-sustaining combustion (SSC) reaction synthesis of ceramics, intermetallics, metal or ceramic matrix composites and the like and as a die material for pseudo-isostatic hot pressing by providing a uniaxial mechanical press to density the reaction products with or without the use of pressure transmitting powder. The process can also be used to perform thermal mechanical work on any article synthesized by the self-sustaining combustion reaction to obtain near net shape. With controlled thermal mechanical processing and fabrication of the shape memory alloy into a die configuration, its shape can be changed from a low temperature configuration to a high temperature configuration after being heated. The shape transformation temperature for nickel-titanium alloy in particular, ranges from about -200 degrees Centigrade to +100 degrees Centigrade depending primarily upon alloy composition. For a hollowed cylindrical die made from nickel-titanium alloy which possesses shape memory effect, the inner diameter of the die can change as much as 8% and exert tens of thousands of pounds per square inch pressure in the radial direction. As a result, densified near net shape parts synthesized by SSC, can be produced and pressed pseudo-isostatically without using an expensive and sophisticated press apparatus of the prior art.
Abstract:
A rolling mill/matrix combination capable of bringing about high pressure, high temperature conversions in a substantially continuous sequence is described. The material being subjected to high pressure is disposed within a series of separate sample containment pockets in a sheet of matrix material and the composite is compressed between a rolling metal element and a flat metal plate forcefully urged toward each other. Means are also set forth for direct heating of the sample material, while high pressure is applied thereto. The synthesis of cubic diamond is exemplary of the high pressures, high temperatures simultaneously attained with this apparatus.
Abstract:
Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
Abstract:
A thermally stable ultra-hard material, a cutting element incorporating such thermally stable ultra-hard material, and methods for forming the same. A thermally stable ultra-hard diamond element is combined with a second ultra-hard material volume forming an assembly. One or more surfaces of the thermally stable diamond element that face the second diamond volume are coated with a coating prior to combining the thermally stable diamond element with the second diamond volume. The assembly is sintered at high pressure and high temperature to form PCD from the second diamond volume.
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.