US20140318027A1 - Methods of making polycrystalline diamond compacts - Google Patents
Methods of making polycrystalline diamond compacts Download PDFInfo
- Publication number
- US20140318027A1 US20140318027A1 US14/330,851 US201414330851A US2014318027A1 US 20140318027 A1 US20140318027 A1 US 20140318027A1 US 201414330851 A US201414330851 A US 201414330851A US 2014318027 A1 US2014318027 A1 US 2014318027A1
- Authority
- US
- United States
- Prior art keywords
- polycrystalline diamond
- silicon
- region
- substrate
- partially porous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 344
- 239000010432 diamond Substances 0.000 title claims abstract description 344
- 238000000034 method Methods 0.000 title claims description 75
- 239000000758 substrate Substances 0.000 claims abstract description 102
- 230000002093 peripheral effect Effects 0.000 claims abstract description 21
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 123
- 239000000463 material Substances 0.000 claims description 123
- 229910052710 silicon Inorganic materials 0.000 claims description 123
- 239000010703 silicon Substances 0.000 claims description 123
- 239000003054 catalyst Substances 0.000 claims description 112
- 239000002904 solvent Substances 0.000 claims description 88
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 43
- 229910017052 cobalt Inorganic materials 0.000 claims description 31
- 239000010941 cobalt Substances 0.000 claims description 31
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 31
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 16
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 14
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 229910052759 nickel Inorganic materials 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 6
- 230000000873 masking effect Effects 0.000 claims 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 abstract description 34
- 229910010271 silicon carbide Inorganic materials 0.000 abstract description 34
- 239000002245 particle Substances 0.000 description 63
- 238000005520 cutting process Methods 0.000 description 29
- 238000005245 sintering Methods 0.000 description 23
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 19
- 229910052721 tungsten Inorganic materials 0.000 description 19
- 239000010937 tungsten Substances 0.000 description 19
- 238000012545 processing Methods 0.000 description 12
- 229910000676 Si alloy Inorganic materials 0.000 description 11
- 229910045601 alloy Inorganic materials 0.000 description 10
- 239000000956 alloy Substances 0.000 description 10
- 238000005553 drilling Methods 0.000 description 10
- 229910001092 metal group alloy Inorganic materials 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- AIOWANYIHSOXQY-UHFFFAOYSA-N cobalt silicon Chemical compound [Si].[Co] AIOWANYIHSOXQY-UHFFFAOYSA-N 0.000 description 6
- 238000001764 infiltration Methods 0.000 description 6
- 230000008595 infiltration Effects 0.000 description 6
- 229910000765 intermetallic Inorganic materials 0.000 description 6
- 238000002386 leaching Methods 0.000 description 6
- 239000006104 solid solution Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 239000011856 silicon-based particle Substances 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000002826 coolant Substances 0.000 description 4
- 239000010438 granite Substances 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 238000003754 machining Methods 0.000 description 4
- 229910017604 nitric acid Inorganic materials 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000002253 acid Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- 239000008367 deionised water Substances 0.000 description 3
- 238000009760 electrical discharge machining Methods 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 150000001247 metal acetylides Chemical class 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- 229910021417 amorphous silicon Inorganic materials 0.000 description 2
- QZPSXPBJTPJTSZ-UHFFFAOYSA-N aqua regia Chemical compound Cl.O[N+]([O-])=O QZPSXPBJTPJTSZ-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 239000010955 niobium Substances 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 238000005491 wire drawing Methods 0.000 description 2
- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 description 1
- XMWRBQBLMFGWIX-UHFFFAOYSA-N C60 fullerene Chemical class C12=C3C(C4=C56)=C7C8=C5C5=C9C%10=C6C6=C4C1=C1C4=C6C6=C%10C%10=C9C9=C%11C5=C8C5=C8C7=C3C3=C7C2=C1C1=C2C4=C6C4=C%10C6=C9C9=C%11C5=C5C8=C3C3=C7C1=C1C2=C4C6=C2C9=C5C3=C12 XMWRBQBLMFGWIX-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 229910021419 crystalline silicon Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229910003472 fullerene Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-N hydrofluoric acid Substances F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QPJSUIGXIBEQAC-UHFFFAOYSA-N n-(2,4-dichloro-5-propan-2-yloxyphenyl)acetamide Chemical compound CC(C)OC1=CC(NC(C)=O)=C(Cl)C=C1Cl QPJSUIGXIBEQAC-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052903 pyrophyllite Inorganic materials 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000013112 stability test Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- -1 tungsten carbide Chemical class 0.000 description 1
- 238000005019 vapor deposition process Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009763 wire-cut EDM Methods 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
- B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
- B24D3/10—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
- C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1068—Making hard metals based on borides, carbides, nitrides, oxides or silicides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
- C04B2237/16—Silicon interlayers
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
- C04B2237/36—Non-oxidic
- C04B2237/363—Carbon
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/40—Metallic
- C04B2237/401—Cermets
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/61—Joining two substrates of which at least one is porous by infiltrating the porous substrate with a liquid, such as a molten metal, causing bonding of the two substrates, e.g. joining two porous carbon substrates by infiltrating with molten silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
- C22C2026/006—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes with additional metal compounds being carbides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2204/00—End product comprising different layers, coatings or parts of cermet
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2220/00—Shaping
- F16C2220/60—Shaping by removing material, e.g. machining
- F16C2220/62—Shaping by removing material, e.g. machining by turning, boring, drilling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/043—Sliding surface consisting mainly of ceramics, cermets or hard carbon, e.g. diamond like carbon [DLC]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/26—Brasses; Bushes; Linings made from wire coils; made from a number of discs, rings, rods, or other members
Definitions
- PDCs polycrystalline diamond compacts
- drilling tools e.g., cutting elements, gage trimmers, etc.
- machining equipment e.g., machining equipment, bearing apparatuses, wire-drawing machinery, and in other mechanical systems.
- a PDC cutting element or cutter typically includes a superabrasive diamond layer or table.
- the diamond table is formed and bonded to a substrate using an ultra-high pressure, ultra-high temperature (“HPHT”) process.
- HPHT ultra-high pressure, ultra-high temperature
- the substrate is often brazed or otherwise joined to an attachment member such as a stud or a cylindrical backing.
- a stud carrying the PDC may be used as a PDC cutting element when mounted to a bit body of a rotary drill bit by press-fitting, brazing, or otherwise securing the stud into a receptacle formed in the bit body.
- the PDC cutting element may also be brazed directly into a preformed pocket, socket, or other receptacle formed in the bit body.
- a rotary drill bit may include a number of PDC cutting elements affixed to the drill bit body.
- PDCs are normally fabricated by placing a cemented carbide substrate into a container or cartridge with a volume of diamond particles positioned on a surface of the cemented carbide substrate.
- a number of such cartridges may be typically loaded into an HPHT press.
- the substrates and volume of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains defining a diamond table.
- the catalyst material is often a solvent catalyst, such as cobalt, nickel, or iron that is used for facilitating the intergrowth of the diamond particles.
- a constituent of the cemented carbide substrate such as cobalt from a cobalt-cemented tungsten carbide substrate, liquefies and sweeps from a region adjacent to the volume of diamond particles into interstitial regions between the diamond particles during the HPHT process.
- the cobalt acts as a catalyst to facilitate intergrowth between the diamond particles, which results in formation of bonded diamond grains.
- a solvent catalyst may be mixed with the diamond particles prior to subjecting the diamond particles and substrate to the HPHT process.
- the solvent catalyst dissolves carbon from the diamond particles or portions of the diamond particles that graphitize due to the high temperature being used in the HPHT process.
- the solubility of the stable diamond phase in the solvent catalyst is lower than that of the metastable graphite under HPHT conditions.
- the undersaturated graphite tends to dissolve into solvent catalyst and the supersaturated diamond tends to deposit onto existing diamond particles to form diamond-to-diamond bonds. Accordingly, diamond grains become mutually bonded to form a matrix of polycrystalline diamond with interstitial regions between the bonded diamond grains being occupied by the solvent catalyst.
- the presence of the solvent catalyst in the diamond table is believed to reduce the thermal stability of the diamond table at elevated temperatures.
- the difference in thermal expansion coefficient between the diamond grains and the solvent catalyst is believed to lead to chipping or cracking in the PDC during drilling or cutting operations, which consequently can degrade the mechanical properties of the PDC or cause failure.
- some of the diamond grains can undergo a chemical breakdown or back-conversion with the solvent catalyst.
- portions of diamond grains may transform to carbon monoxide, carbon dioxide, graphite, or combinations thereof, thus, degrading the mechanical properties of the PDC.
- Embodiments of the present invention relate to methods of fabricating superabrasive articles, such as PDCs, and intermediate articles formed during fabrication of such PDCs.
- PDCs superabrasive articles
- Many different PDC embodiments disclosed herein include a thermally-stable polycrystalline diamond table in which silicon carbide occupies a portion of the interstitial regions thereof formed between bonded diamond grains.
- a method of fabricating a superabrasive article is disclosed.
- a mass of unsintered diamond particles may be infiltrated with metal-solvent catalyst from a metal-solvent-catalyst-containing material to promote formation of a sintered body of diamond grains including interstitial regions. At least a portion of the interstitial regions may also be infiltrated with silicon from a silicon-containing material. The silicon reacts with the sintered body to form silicon carbide within a portion of the interstitial regions.
- another method of fabricating a superabrasive article is disclosed. At least a portion of interstitial regions of a pre-sintered-polycrystalline diamond body may be infiltrated with silicon from a silicon-containing material. At least a portion of metal-solvent catalyst located within the at least a portion of interstitial regions of the pre-sintered-polycrystalline diamond body may be displaced into a porous mass. The silicon and the pre-sintered-polycrystalline diamond body are reacted to form silicon carbide within the at least a portion of the interstitial regions. A section of the polycrystalline diamond table so-formed may be removed by a suitable material-removal process so that an upper region of the polycrystalline diamond table includes substantially only silicon carbide within the interstitial regions thereof.
- a polycrystalline diamond compact in another embodiment, includes a substrate and a polycrystalline diamond table attached to the substrate.
- the polycrystalline diamond table including an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the peripheral surface.
- Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions.
- the polycrystalline diamond table includes a first region extending inwardly from the upper surface and the chamfer, with the first region substantially contouring the upper surface and the chamfer.
- the first region includes silicon carbide positioned within at least some of the interstitial regions thereof.
- the polycrystalline diamond table includes a bonding region bonded to the substrate, with the bonding region including metal-solvent catalyst positioned within a second portion of the interstitial regions.
- a method of fabricating a polycrystalline diamond compact includes positioning an at least partially porous polycrystalline body between a silicon-containing material and a substrate that is adjacent to a metal-solvent catalyst.
- the at least partially porous polycrystalline body exhibits an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the at least one peripheral surface.
- the method further includes subjecting the at least partially porous polycrystalline body, the silicon-containing material, and the substrate to an HPHT process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with silicon from the silicon-containing material.
- a polycrystalline diamond compact in yet another embodiment, includes a substrate and a polycrystalline diamond table attached to the substrate.
- the polycrystalline diamond table including an upper surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions.
- the polycrystalline diamond table includes a first region including silicon carbide positioned within a first portion of the interstitial regions, the first region extending over only a selected portion of the upper surface.
- the polycrystalline diamond table further includes a bonding region bonded to the substrate, with the bonding region including metal-solvent catalyst positioned within a second portion of the interstitial regions.
- a method of fabricating a polycrystalline diamond compact includes positioning an at least partially porous polycrystalline body between a silicon-containing material and a substrate adjacent to a metal-solvent catalyst.
- the at least partially porous polycrystalline body includes an upper surface and at least one peripheral surface, with the silicon-containing material extending over only a portion of the upper surface and/or at least a portion of the at least one peripheral surface.
- the method further includes subjecting the at least partially porous polycrystalline body, the silicon-containing material, and the substrate to an HPHT process to infiltrate a first region of the at least partially porous polycrystalline body that extends along only a portion of the upper surface thereof
- FIG. 1A is a schematic side cross-sectional view of an assembly including a substrate, a porous polycrystalline diamond body, and a silicon-containing material used to fabricate a PDC according to one embodiment of the present invention.
- FIG. 1B is a schematic side cross-sectional view of an assembly including a substrate, a porous polycrystalline diamond body in which a region remote from the substrate contains tungsten carbide, and a silicon-containing material used to fabricate a PDC according to one embodiment of the present invention.
- FIG. 2A is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown in FIG. 1A .
- FIG. 2B is a schematic perspective view of the PDC shown in FIG. 2A .
- FIG. 2C is a schematic cross-sectional view of the PDC so-formed when the polycrystalline diamond body shown in FIG. 1A includes a preformed chamfer according to another embodiment.
- FIG. 3A is a schematic side cross-sectional view of another assembly that may be used to form a PDC with a selectively-shaped cutting region according to another embodiment of the present invention.
- FIG. 3B is a schematic side cross-sectional view of another assembly that may be used to form a PDC in which silicon infiltrates into a polycrystalline diamond body through sides thereof according to another embodiment of the present invention.
- FIG. 4A is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown in FIG. 3A .
- FIG. 4B is a schematic top plan view of the PDC resulting from HPHT processing of the assembly shown in FIG. 3A when the silicon-containing material included multiple wedge-shaped portions.
- FIG. 5 is a schematic side cross-sectional view of another assembly that may be used to form the PDC shown in FIGS. 2A and 2B according to another embodiment of the present invention.
- FIG. 6 is a schematic side cross-sectional view of another assembly that may be used to form the PDC shown in FIGS. 2A and 2B according to yet another embodiment of the present invention.
- FIG. 7 is a schematic side cross-sectional view of an assembly including a substrate, unsintered diamond particles, a metal-solvent-catalyst material, and a silicon-containing material used to fabricate a PDC according to another embodiment of the present invention.
- FIG. 8 is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown in FIG. 7 .
- FIG. 9 is a schematic side cross-sectional view of an assembly including a substrate, a silicon-containing material, a diamond table, and porous mass used to fabricate a PDC according to another embodiment of the present invention.
- FIG. 10 is a schematic side cross-sectional view of the resulting structure formed from HPHT processing of the assembly shown in FIG. 9 .
- FIG. 11 is a PDC formed by removing a portion of the multi-region structure shown in FIG. 10 .
- FIG. 12 is a schematic cross-sectional view of an assembly including a substrate, a mass of unsintered diamond particles, and layers of metal-solvent-catalyst-containing material and silicon-containing material disposed between the substrate and the mass of unsintered diamond particles used to fabricate a PDC according to another embodiment of the present invention.
- FIG. 13 is a schematic side cross-sectional view of the resulting structure from HPHT processing of the assembly shown in FIG. 12 .
- FIG. 14 is an isometric view of one embodiment of a rotary drill bit including at least one superabrasive cutting element including a PDC configured according to any of the various PDC embodiments of the present invention.
- FIG. 15 is a top elevation view of the rotary drill bit of FIG. 14 .
- FIG. 16 is a graph showing the measured temperature versus linear distance during a vertical turret lathe test on a conventional, leached PDC and a PDC according to working example 2 of the present invention.
- FIG. 17 is a graph showing the measured normal force versus linear distance during a vertical turret lathe test on a conventional, leached PDC and a PDC according to working example 2 of the present invention.
- FIG. 18 is a graph illustrating the wear flat volume characteristics of a conventional, leached PDC and a PDC according to working example 2 of the present invention.
- Embodiments of the present invention relate to methods of fabricating superabrasive articles, such as PDCs, and intermediate articles formed during fabrication of such PDCs.
- many different PDC embodiments disclosed herein include a thermally-stable polycrystalline diamond table in which silicon carbide occupies a portion of the interstitial regions formed between bonded diamond grains.
- the superabrasive articles disclosed herein may be used in a variety of applications, such as drilling tools (e.g., compacts, cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and other apparatuses.
- the term “superabrasive” means a material that exhibits a hardness exceeding a hardness of tungsten carbide.
- a superabrasive article is an article of manufacture, at least a portion of which exhibits a hardness exceeding the hardness of tungsten carbide.
- FIGS. 1A-2B show an embodiment of a method according to the present invention for fabricating a PDC and the resulting structure of the PDC.
- an assembly 10 includes an at least partially porous polycrystalline diamond body 14 (i.e., a pre-sintered-polycrystalline diamond body) positioned adjacent to a substrate 12 .
- the assembly 10 further includes a silicon-containing material 16 positioned adjacent to the polycrystalline diamond body 14 on a side of the polycrystalline diamond body 14 opposite the substrate 12 .
- the silicon-containing material 16 may comprise a green body of elemental silicon particles (e.g., crystalline or amorphous silicon particles) in the form of a tape-casted tape that is placed adjacent to the polycrystalline diamond body 14 .
- the silicon-containing material 16 may comprise a disc of silicon.
- the polycrystalline diamond body 14 includes a plurality of interstitial regions that were previously occupied by metal-solvent catalyst.
- the polycrystalline diamond body 14 may be fabricated by subjecting a plurality of diamond particles (e.g., diamond particles having an average particle size between 0.5 ⁇ m to about 150 ⁇ m) to an HPHT sintering process in the presence of a metal-solvent catalyst, such as cobalt, or other catalyst to facilitate intergrowth between the diamond particles to form a polycrystalline diamond table of bonded diamond grains.
- a metal-solvent catalyst such as cobalt, or other catalyst to facilitate intergrowth between the diamond particles to form a polycrystalline diamond table of bonded diamond grains.
- the sintered diamond grains of the polycrystalline diamond body 14 may exhibit an average grain size of about 20 ⁇ m or less.
- the polycrystalline diamond table so-formed may be immersed in an acid, such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or subjected to another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table.
- an acid such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or subjected to another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table.
- the polycrystalline diamond table is not formed by sintering the diamond particles on a cemented-tungsten-carbide substrate or otherwise in the presence of tungsten carbide.
- the interstitial regions of the polycrystalline diamond body 14 may contain no tungsten and/or tungsten carbide or insignificant amounts of tungsten and/or tungsten carbide, which can inhibit removal of the metal-solvent catalyst.
- a polycrystalline diamond table may be formed by HPHT sintering diamond particles in the presence of tungsten carbide.
- diamond particles may be placed adjacent to a cemented tungsten carbide substrate and/or tungsten carbide particles may be mixed with the diamond particles prior to HPHT sintering.
- the polycrystalline diamond table so-formed may include tungsten and/or tungsten carbide that is swept in with metal-solvent catalyst from the substrate or intentionally mixed with the diamond particles during HPHT sintering process.
- some tungsten and/or tungsten carbide from the substrate may be dissolved or otherwise transferred by the liquefied metal-solvent catalyst (e.g., cobalt from a cobalt-cemented tungsten carbide substrate) of the substrate that sweeps into the diamond particles.
- the polycrystalline diamond table so-formed may be separated from the substrate using a lapping process, a grinding process, wire-electrical-discharge machining (“wire EDM”), or another suitable material-removal process.
- the separated polycrystalline diamond table may be immersed in a suitable acid (e.g., a hydrochloric acid/hydrogen peroxide solution) to remove substantially all of the metal-solvent catalyst from the interstitial regions and form the polycrystalline diamond body 14 .
- a suitable acid e.g., a hydrochloric acid/hydrogen peroxide solution
- tungsten and/or tungsten carbide may remain distributed throughout the polycrystalline diamond body 14 even after leaching.
- the presence of the tungsten and/or tungsten carbide within the polycrystalline diamond body 14 is currently believed to significantly improve the abrasion resistance thereof even after infiltration with silicon and HPHT bonding to the substrate 12 , as will discussed in more detail below.
- the polycrystalline diamond body 14 may comprise a first portion including tungsten and/or tungsten carbide and a second portion that is substantially free of tungsten and/or tungsten carbide.
- a layer of metal-solvent catalyst e.g., cobalt
- a cemented carbide substrate e.g., cobalt-cemented tungsten carbide substrate
- metal-solvent catalyst from the substrate also sweeps in, which may carry or transfer tungsten and/or tungsten carbide.
- a first region of the polycrystalline diamond table so-formed adjacent to the substrate includes tungsten and/or tungsten carbide and a second region remote from the substrate is substantially free of tungsten and/or tungsten carbide.
- the volume of the layer of metal-solvent catalyst may be selected so that the second region exhibits a thickness substantially greater than the second region.
- the metal-solvent catalyst within the interstitial regions between bonded diamond grains of the polycrystalline diamond table may be removed from the second region more easily.
- the metal-solvent catalyst may be leached from the first region using a hydrochloric acid/hydrogen peroxide solution and the metal-solvent catalyst in the second region may be leached using a less aggressive nitric acid/hydrofluoric acid solution.
- the polycrystalline diamond body 14 so-formed after leaching may be oriented with the second region (shown as 14 A) that is substantially free of tungsten and/or tungsten carbide positioned adjacent to the substrate 12 in the assembly 10 and the first region (shown as 14 B) that includes tungsten and/or tungsten carbide positioned remote from the substrate 12 to form at least part of a working or cutting region of a PDC that is ultimately formed after processing.
- the polycrystalline diamond body 14 may be formed by sintering diamond particles or other particles capable of forming diamond in response to an HPHT sintering process without a catalyst.
- sintering diamond particles or other particles capable of forming diamond in response to an HPHT sintering process without a catalyst.
- the substrate 12 may comprise a cemented-carbide material, such as a cobalt-cemented tungsten carbide material or another suitable material.
- a cemented-carbide material such as a cobalt-cemented tungsten carbide material or another suitable material.
- nickel, iron, and alloys thereof are other metal-solvent catalysts that may comprise the substrate 12 .
- Other materials that may comprise the substrate 12 include, without limitation, cemented carbides including titanium carbide, niobium carbide, tantalum carbide, vanadium carbide, and combinations of any of the preceding carbides cemented with iron, nickel, cobalt, or alloys thereof.
- a representative thickness for the substrate 12 is a thickness of about 0.100 inches to at least about 0.350 inches, more particularly about 0.150 inches to at least about 0.300 inches, and even more particularly about 0.170 inches to at least about 0.290 inches.
- the assembly 10 may be placed in a pressure transmitting medium, such as a refractory metal can, graphite structure, pyrophyllite or other pressure transmitting structure, or another suitable container or supporting element.
- a pressure transmitting medium such as a refractory metal can, graphite structure, pyrophyllite or other pressure transmitting structure, or another suitable container or supporting element.
- the pressure transmitting medium including the assembly 10 , is subjected to an HPHT process using an ultra-high pressure press at a temperature of at least about 1000° Celsius (e.g., about 1300° Celsius to about 1600° Celsius) and a pressure of at least 40 kilobar (e.g., about 50 kilobar to about 70 kilobar) for a time sufficient to sinter the assembly 10 and form a PDC 18 as shown in FIGS. 2A and 2B .
- the HPHT bonds the polycrystalline diamond body 14 to the substrate 12 and causes at least partial infiltration of the silicon into the polycrystalline diamond body 14 .
- the HPHT temperature may be sufficient to melt at least one constituent of the substrate 12 (e.g., cobalt, nickel, iron, or another constituent) and the silicon of the silicon-containing material 16 .
- the PDC 18 may exhibit other geometries than the geometry illustrated in FIGS. 2A and 2B .
- the PDC 18 may exhibit a non-cylindrical geometry.
- the HPHT sintered PDC 18 comprises a polycrystalline diamond table 15 that may include three regions: a first region 20 , a second-intermediate region 22 , and a third region 24 (i.e., a bonding region).
- the first region 20 includes polycrystalline diamond with substantially only silicon carbide formed within at least some of the interstitial regions between the bonded diamond grains of the first region 20 . It is noted that the interstitial regions of at least the first region 20 may also include tungsten carbide when tungsten carbide is present in the polycrystalline diamond body 14 , such as in the embodiment shown in FIG. 1B .
- silicon from the silicon-containing material 16 liquefies and at least partially infiltrates the interstitial regions of the polycrystalline diamond body 14 .
- the silicon reacts with the diamond grains of the polycrystalline diamond body 14 to form silicon carbide, which occupies at least some of the interstitial regions between the diamond grains and bonds to the diamond grains.
- the amount of the silicon-containing material 16 may be selected so that the silicon of the silicon-containing material 16 fills a selected portion of the interstitial regions of the polycrystalline diamond body 14 .
- the second-intermediate region 22 of the polycrystalline diamond table 15 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of the second-intermediate region 22 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of the second-intermediate region 22 .
- metal-solvent catalyst e.g., cobalt
- substantially all of or only a portion of the interstitial regions of the second-intermediate region 22 may include an alloy of silicon and the metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- at least some of the interstitial regions of the second-intermediate region 22 of the polycrystalline diamond table 15 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst.
- the third region 24 includes polycrystalline diamond with substantially only metal-solvent catalyst (e.g., cobalt) occupying at least some of the interstitial regions between the bonded diamond grains.
- the metal-solvent catalyst occupying the interstitial regions of the third region 24 is liquefied and swept into the polycrystalline diamond body 14 from the substrate 12 or another source (e.g., a metal disk, particles, etc.) during the HPHT process.
- the third region 24 provides a strong, metallurgical bond between the substrate 12 and the polycrystalline diamond table 15 to thereby function as a bonding region.
- at least the first region 20 of the polycrystalline diamond table 15 may be substantially free of non-silicon carbide type carbides, such as tungsten carbide, when the polycrystalline diamond body 14 is not formed in the presence of tungsten carbide.
- the PDC 18 shown in FIGS. 2A and 2B exhibits an improved thermal stability relative to a conventional PDC in which the interstitial regions of the diamond table are occupied with only cobalt or another metal-solvent catalyst. Additionally, the wear resistance of the PDC 18 may be improved relative to a conventional PDC because the silicon carbide phase occupying the interstitial regions of the first region 20 exhibits a hardness greater than a hardness of cobalt or other metal-solvent catalysts.
- the PDC 18 may also include a chamfer along a peripheral region thereof, which may be preformed in the polycrystalline diamond body 14 (e.g., by machining or grinding) or may be machined in the polycrystalline diamond table 15 after formation of the PDC 18 .
- FIG. 2C is a cross-sectional view of the PDC 18 so-formed when the polycrystalline diamond body 14 exhibits a preformed chamfer according to another embodiment.
- at least the first region 20 and, in some cases, the second-intermediate region 22 substantially contours a preformed chamfer 25 and an upper surface 27 of the polycrystalline diamond table 15 , with the chamfer 25 extending between the upper surface 27 and at least one peripheral surface 29 .
- the silicon infiltrates into the polycrystalline diamond table 15 so that a depth “d” of the first region 20 is substantially the same when measured from the upper surface 27 and the chamfer 25 .
- the depth “d” may be about 50 ⁇ m to about 1000 ⁇ m, about 150 ⁇ m to about 500 ⁇ m, or about 100 ⁇ m to about 200 ⁇ m.
- the substrate 12 may be omitted.
- an assembly of the polycrystalline diamond body 14 and the silicon-containing material 16 may be subjected to an HPHT process to form a polycrystalline diamond table.
- a carbide layer e.g., a tungsten carbide layer
- U.S. Patent Application Publication No. 20080085407 is incorporated herein, in its entirety, by this reference.
- the polycrystalline diamond table may be brazed or otherwise secured to a bit body of a rotary drill bit.
- a PDC may be formed with a polycrystalline diamond table including a cutting region exhibiting a selected configuration.
- the cutting region may comprise bonded diamond grains with silicon carbide within at least some of the interstitial regions between the bonded diamond grains.
- a silicon-containing material 16 ′ in the form of body of silicon or amorphous silicon, green body of silicon particles in the form of a tape-casted tape in the form of a tape-casted tape may be placed adjacent to the polycrystalline diamond body 14 .
- the silicon-containing material 16 ′ may exhibit an annular geometry, a wedge-shaped geometry, or another suitable geometry.
- a mask 21 e.g., a mica disk or other ceramic mask
- a PDC 18 ′ is formed with a polycrystalline diamond table 15 ′ including cutting region 20 ′ formed peripherally about intermediate region 22 ′ and a third region 24 ′.
- the cutting region 20 ′ comprises bonded diamond grains with substantially only silicon carbide within the interstitial regions between the bonded diamond grains.
- the intermediate region 22 ′ comprises bonded diamond grains with silicon carbide within a portion of the interstitial regions and metal-solvent catalyst from the substrate 12 or another source within another portion of the interstitial regions.
- substantially all of or only a portion of the interstitial regions of the second-intermediate region 22 ′ includes an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- at least some of the interstitial regions of the second-intermediate region 22 ′ of the polycrystalline diamond table 15 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst.
- the third region 24 ′ is formed adjacent to the substrate 12 and provides a strong, metallurgical bond between the polycrystalline diamond table 15 ′ and the substrate 12 .
- the third region 24 ′ comprises bonded diamond grains with substantially only the metal-solvent catalyst from the substrate 12 or another source within the interstitial regions between the bonded diamond grains.
- the third region 24 ′ provides a tough core that compliments the more thermally-stable first region 20 ′.
- the geometry of the cutting region 20 ′ of the polycrystalline diamond table 15 ′ may also be formed to exhibit other selected geometries.
- FIG. 4B is a top plan view of the PCD table 15 ′ when the silicon-containing material 16 ′ exhibited a wedge-shaped geometry, with multiple wedge-shaped portions forming the cutting region 20 ′.
- the cutting region 20 ′ and the intermediate region 22 ′ may exhibit an annular geometry, as described hereinabove, or another selected geometry.
- the polycrystalline diamond body 14 may also be chamfered.
- the polycrystalline diamond table 15 ′ may also be chamfered after being formed.
- the polycrystalline diamond table 15 ′ may be subjected to a leaching process to deplete the third region 24 ′ shown in FIGS. 4A and 4B of metal-solvent catalyst (e.g., cobalt). Leaching the third region 24 ′ may improve the overall thermal-stability of the polycrystalline diamond table 15 ′.
- the metal-solvent catalyst may be depleted from the third region 24 ′ to a selected depth from the upper surface and the peripheral surface.
- the leach depth may be about 50 ⁇ m to about 1000 ⁇ m, about 150 ⁇ m to about 500 ⁇ m, or about 100 ⁇ m to about 200 ⁇ m.
- the leaching may be performed to remove substantially all of the metal-solvent catalyst from the third region 24 ′.
- FIG. 3B shows another embodiment of the present invention in which a silicon-containing material 16 ′′ may be positioned adjacent to at least one peripheral surface 17 of the polycrystalline diamond body 14 .
- HPHT processing causes silicon from the silicon-containing material 16 ′′ to at least partially or substantially infiltrate the polycrystalline diamond body 14 .
- the silicon from the silicon-containing material 16 ′′ may partially infiltrate the polycrystalline diamond body 14 to form a PDC including a multi-region polycrystalline diamond table.
- the PDC 18 may be formed by subjecting an assembly 21 to HPHT conditions similar to that employed on the assembly 10 .
- the assembly 21 includes a silicon-containing material 16 positioned adjacent to a substrate 12 , and between the substrate 12 and a polycrystalline diamond body 14 .
- the assembly 21 is heated at a sufficient rate so that the metal-solvent catalyst (e.g., cobalt) and the silicon in the silicon-containing material 16 are in a liquid state at substantially the same time.
- the metal-solvent catalyst e.g., cobalt
- Such heating may cause the molten, metal-solvent catalyst (e.g., from the substrate 12 , metal-solvent catalyst mixed with the silicon-containing material 16 , or another source) to occupy a portion of the interstitial regions of the polycrystalline diamond body 14 and may cause the molten silicon to occupy other portions of the interstitial regions of the polycrystalline diamond body 14 .
- the resultant, as-sintered PDC may exhibit a similar multi-region diamond table as the polycrystalline diamond table 15 shown in FIGS. 2A and 2B .
- FIG. 6 shows another embodiment of the present invention in which a PDC 13 including a leached polycrystalline diamond table 19 and a silicon-containing material 16 are assembled and HPHT processed using HPHT conditions as described generally hereinabove with respect to the assembly 10 .
- the PDC 13 may be formed from a conventional PDC with a polycrystalline diamond table that comprises bonded diamond grains with cobalt or another metal-solvent catalyst occupying the interstitial regions between the bonded diamond grains.
- the metal-solvent catalyst may be substantially removed from the polycrystalline diamond table by leaching using an acid, such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table.
- an acid such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table.
- a silicon-containing material 16 may be positioned adjacent to the leached polycrystalline diamond table 19 on a side thereof opposite the substrate 12 .
- the leached polycrystalline diamond table 19 and the silicon-containing material 16 are subjected to an HPHT process to infiltrate the leached polycrystalline diamond table 19 with silicon from the silicon-containing material 16 to form a PDC having a polycrystalline diamond table with the same or similar construction as the polycrystalline diamond table 15 shown in FIGS. 2A and 2B .
- FIGS. 7 and 8 show another embodiment of a method according to the present invention for forming a PDC.
- an assembly 24 includes a mass of unsintered diamond particles 28 positioned adjacent to the substrate 12 .
- the mass of unsintered diamond particles 28 may be a green body of diamond particles 28 in the form of a tape-casted tape.
- the diamond particles 28 may exhibit an average particle size of about 20 ⁇ m or less.
- the diamond particles 28 may exhibit an average particle size of about 5 ⁇ m to about 50 ⁇ m.
- the mass of unsintered diamond particles 28 may exhibit a thickness, for example, of about 0.150 inches to about 0.200 inches.
- the assembly 24 further includes a metal-solvent-catalyst-containing material 26 positioned adjacent to the mass of diamond particles 28 , and a silicon-containing material 16 positioned adjacent to the metal-solvent-catalyst-containing material 26 .
- the metal-solvent-catalyst-containing material 26 may include or may be formed from a material, such as cobalt, nickel, iron, or alloys thereof.
- the metal-solvent-catalyst-containing material 26 may also be a green body of metal-solvent-catalyst particles in the form of a tape-casted tape, a thin disc of metal-solvent-catalyst material, or any other suitable metal-solvent-catalyst material or structure, without limitation.
- the assembly 24 may be subjected to an HPHT sintering process using HPHT process conditions similar to those previously discussed to form a PDC 42 shown in FIG. 8 .
- the metal-solvent catalyst of the metal-solvent-catalyst-containing material 26 melts and infiltrates the diamond particles 28 to effect intergrowth between the diamond particles 28 .
- Molten silicon from the silicon-containing material 16 also infiltrates the diamond particles 28 and the infiltration by the molten silicon follows the infiltration of the metal-solvent catalyst.
- the metal-solvent catalyst from the metal-solvent-catalyst-containing material 26 promotes bonding of the diamond particles 28 to form polycrystalline diamond and the silicon infiltrates the polycrystalline diamond so-formed.
- the silicon reacts with the diamond grains of the polycrystalline diamond to form silicon carbide within some of the interstitial regions between the bonded diamond grains.
- the amount of the silicon-containing material 16 metal-solvent-catalyst-containing material 26 may be selected so that the silicon of the silicon-containing material 16 and the metal-solvent catalyst from the metal-solvent-catalyst-containing material 26 , respectively, only fill a portion of the interstitial regions of the polycrystalline diamond formed during the HPHT process.
- the PDC 42 formed by HPHT sintering the assembly 24 includes a multi-region polycrystalline diamond table 35 similar in configuration to the polycrystalline diamond table 15 shown in FIGS. 2A and 2B .
- the polycrystalline diamond table 35 includes: a first region 36 , a second-intermediate region 38 , and a third region 40 .
- the first region 36 includes substantially only silicon carbide within at least some of the interstitial regions between the bonded diamond grains.
- the second-intermediate region 38 may include silicon carbide within a portion of the interstitial regions between the bonded diamond grains, along with metal-solvent catalyst from the metal-solvent-catalyst-containing material 26 and/or the substrate 12 within other portions of the interstitial regions of the second-intermediate region 38 .
- substantially all of or only a portion of the interstitial regions of the second-intermediate region 38 may include an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- the interstitial regions of the second-intermediate region 38 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst.
- the third region 40 adjacent to the substrate 12 , includes substantially only metal-solvent catalyst from the substrate 12 or another source within the interstitial regions thereof for forming a strong, metallurgical bond between the polycrystalline diamond table 35 and the substrate 12 .
- FIGS. 9-11 show yet another embodiment of a method according to the present invention for forming a PDC.
- an assembly 44 is formed by positioning a silicon-containing material 16 between a substrate 12 and a pre-sintered-polycrystalline diamond table 46 .
- the polycrystalline diamond table 46 may exhibit a thickness of, for example, about 0.090 inches and an average grain size of about 20 ⁇ m or less.
- the polycrystalline diamond table 46 comprises bonded diamond grains sintered using a metal-solvent catalyst, such as cobalt, nickel, iron, or alloys thereof. Accordingly, the polycrystalline diamond table 46 includes bonded diamond grains with the metal-solvent catalyst occupying interstitial regions between the bonded diamond grains.
- the polycrystalline diamond table 46 may not be formed by sintering diamond particles in the presence of tungsten carbide so that the interstitial regions of the polycrystalline diamond table 46 contain no tungsten and/or tungsten carbide or insignificant amounts of tungsten and/or tungsten carbide. In other embodiments of the present invention, a portion or substantially the entire polycrystalline diamond table 46 may be formed to include tungsten and/or tungsten carbide distributed therethrough, as previously described with respect to the polycrystalline diamond body 14 shown in FIGS. 1A and 1B .
- a first region of the polycrystalline diamond table 46 that is substantially free of tungsten and/or tungsten carbide may be positioned adjacent to the silicon-containing material 16
- a second region of the polycrystalline diamond table 46 that includes tungsten and/or tungsten carbide may be positioned remote from the silicon-containing material 16
- the assembly 44 further includes a porous mass 48 positioned adjacent to the polycrystalline diamond table 46 on a side of the polycrystalline diamond table 46 opposite the silicon-containing material 16 .
- the porous mass 48 may be unsintered diamond particles, unsintered aluminum oxide particles, unsintered silicon carbide particles, or another suitable porous mass.
- the porous mass 48 may also be a green body of diamond particles in the form of a tape-casted tape, or any other form, without limitation.
- the assembly 44 may be subjected to an HPHT sintering process using sintering conditions similar to the sintering conditions employed on the assembly 10 to bond the various components of the assembly 44 together and to form a polycrystalline diamond structure 50 shown in FIG. 10 .
- silicon from the silicon-containing material 16 melts and displaces all or a portion of the metal-solvent catalyst of the polycrystalline diamond table 46 into the porous mass 48 .
- the metal-solvent catalyst of the polycrystalline diamond table 46 may also be partially or completed molten at the same time as the silicon from the silicon-containing material 16 .
- the amount of silicon-containing material 16 is selected so that substantially all of the metal-solvent catalyst of the polycrystalline diamond table 46 is displaced into the porous mass 48 . In another embodiment of the present invention, the amount of the silicon-containing material 16 may be selected so that the silicon from the silicon-containing material 16 displaces only a portion of the metal-solvent catalyst of the polycrystalline diamond table 46 .
- the silicon reacts with the diamond grains of the polycrystalline diamond table 46 or another carbon source to form silicon carbide within interstitial regions between the bonded diamond grains of the polycrystalline diamond table 46 . Additionally, metal-solvent catalyst from the substrate 12 or another source also melts and infiltrates into a region of the polycrystalline diamond table 46 adjacent the substrate 12 .
- the polycrystalline diamond structure 50 formed by HPHT processing of the assembly 44 comprises a multi-region polycrystalline diamond table 55 that may include: a first region 52 , a second region 54 , a third region 56 , a fourth region 58 , and a fifth region 60 .
- the first region 52 includes the particles from the porous mass 48 with at least some of the interstitial regions thereof occupied by substantially only the metal-solvent catalyst displaced from the polycrystalline diamond table 46 .
- the second region 54 includes the particles from the porous mass 48 with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- the second region 54 may also extend into the HPHT processed polycrystalline diamond table 46 .
- the third region 56 , fourth region 58 , and fifth region 60 may be formed from the HPHT processed polycrystalline diamond table 46 , which exhibits a reduced thickness due to the HPHT processing.
- the third region 56 includes polycrystalline diamond with substantially only silicon carbide within at least some of the interstitial regions between the bonded diamond grains.
- the fourth region 58 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- the fourth region 58 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of the fourth region 58 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of the fourth region 58 .
- metal-solvent catalyst e.g., cobalt
- at least some of the interstitial regions of the fourth region 58 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst.
- the fifth region 60 adjacent to the substrate 12 , includes substantially only metal-solvent catalyst from the substrate 12 within at least some of the interstitial regions between bonded diamond grains for forming a strong, metallurgical bond between the multi-region polycrystalline diamond table 55 and the substrate 12 .
- a PDC 63 including a multi-region structure 65 similar in configuration to the polycrystalline diamond table 15 shown in FIGS. 2A and 2B may be formed by removing the first region 52 and the second region 54 of the multi-region structure 65 using a lapping process, a grinding process, wire EDM, or another suitable material-removal process.
- FIGS. 12 and 13 show yet another embodiment of a method according to the present invention for forming a PDC.
- an assembly 59 includes a mass of unsintered diamond particles 62 with a silicon-containing material 16 and a metal-solvent catalyst-containing material 26 positioned between the mass of unsintered diamond particles 62 and a substrate 12 .
- the metal-solvent-catalyst-containing material 26 is positioned adjacent to the mass of unsintered diamond particles 62 and the silicon-containing material 16 is positioned adjacent to the substrate 12 .
- the assembly 59 may be subjected to an HPHT sintering process using sintering conditions similar to the sintering conditions employed on the assembly 10 to form a polycrystalline diamond structure 61 shown in FIG. 13 .
- the silicon-containing material 16 and the metal-solvent catalyst-containing material 26 are melted, and metal-solvent catalyst from the metal-solvent-catalyst-containing material 26 infiltrates the mass of unsintered diamond particles 62 to promote bonding between the diamond particles, thus, forming polycrystalline diamond that comprises bonded diamond grains with interstitial regions between the bonded diamond grains.
- the silicon from the silicon-containing material 16 follows the infiltration of the mass 62 by the metal-solvent-catalyst-containing material 26 and infiltrates the polycrystalline diamond so-formed. The silicon reacts with the diamond grains to form silicon carbide within some of the interstitial regions.
- the polycrystalline diamond structure 61 formed by HPHT sintering of the assembly 59 comprises a multi-region polycrystalline diamond table 69 that may include: a first region 64 , a second region 65 , a third region 66 , a fourth region 67 , and a fifth region 68 .
- the first region 64 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by substantially only the metal-solvent catalyst from the metal-solvent-catalyst-containing material 26 .
- the second region 65 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon.
- the second region 65 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of the second region 65 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of the second region 65 .
- the interstitial regions of the second region 65 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst.
- the third region 66 includes polycrystalline diamond with substantially only silicon carbide within at least some of the interstitial regions thereof.
- the fourth region 67 may include a composition and microstructure that is the same or similar to the second region 65 .
- the fifth region 68 adjacent to the substrate 12 includes substantially only metal-solvent catalyst from the substrate 12 or another source within the interstitial regions thereof for forming a strong, metallurgical bond between the multi-region polycrystalline diamond table 69 and the substrate 12 .
- a PDC including a polycrystalline diamond table similar in configuration to the polycrystalline diamond table 15 shown in FIGS. 2A and 2B may be formed by removing the first region 64 and the second region 65 using a lapping process, a grinding process, wire EDM, or another suitable material-removal process.
- silicon is introduced into a polycrystalline diamond table by infiltrating molten silicon.
- silicon may be introduced in vapor form such as via chemical vapor deposition or another suitable vapor deposition process.
- a polycrystalline diamond table that has been integrally formed with a cemented carbide substrate and leached to a selected depth from an upper surface thereof may also benefit from being infiltrated with silicon in molten or vapor form to form a more thermally-stable polycrystalline diamond table.
- FIGS. 14 and 15 show an isometric view and a top elevation view, respectively, of a rotary drill bit 70 according to one embodiment of the present invention.
- the rotary drill bit 70 includes at least one PDC configured according to any of the previously described PDC embodiments.
- the rotary drill bit 70 comprises a bit body 72 that includes radially and longitudinally extending blades 74 with leading faces 76 , and a threaded pin connection 78 for connecting the bit body 72 to a drilling string.
- the bit body 72 defines a leading end structure for drilling into a subterranean formation by rotation about a longitudinal axis 80 and application of weight-on-bit.
- At least one PDC, fabricated according to any of the previously described PDC embodiments, may be affixed to rotary drill bit 70 .
- each PDC 86 may include a polycrystalline diamond table 88 bonded to a substrate 90 .
- the PDCs 86 may comprise any PDC disclosed herein, without limitation.
- a number of the PDCs 86 may be conventional in construction.
- circumferentially adjacent blades 74 define so-called junk slots 82 therebetween, as known in the art.
- the rotary drill bit 70 includes a plurality of nozzle cavities 84 for communicating drilling fluid from the interior of the rotary drill bit 70 to the PDCs 86 .
- FIGS. 14 and 15 merely depict one embodiment of a rotary drill bit that employs at least one cutting element that comprises a PDC fabricated and structured in accordance with the disclosed embodiments, without limitation.
- the rotary drill bit 70 is used to represent any number of earth-boring tools or drilling tools, including, for example, core bits, roller-cone bits, fixed-cutter bits, eccentric bits, bicenter bits, reamers, reamer wings, or any other downhole tool including PDCs, without limitation.
- the PDCs disclosed herein may also be utilized in applications other than cutting technology.
- the disclosed PDC embodiments may be used in wire dies, bearings, artificial joints, inserts, cutting elements, and heat sinks.
- any of the PDCs disclosed herein may be employed in an article of manufacture including at least one superabrasive element or compact.
- a rotor and a stator may each include a PDC according to any of the embodiments disclosed herein and may be operably assembled to a downhole drilling assembly.
- U.S. Pat. Nos. 4,410,054; 4,560,014; 5,364,192; 5,368,398; and 5,480,233 disclose subterranean drilling systems within which bearing apparatuses utilizing PDCs disclosed herein may be incorporated.
- PDCs disclosed herein may also form all or part of heat sinks, wire dies, bearing elements, cutting elements, cutting inserts (e.g., on a roller cone type drill bit), machining inserts, or any other article of manufacture as known in the art.
- Other examples of articles of manufacture that may use any of the PDCs disclosed herein are disclosed in U.S. Pat. Nos. 4,811,801; 4,268,276; 4,468,138; 4,738,322; 4,913,247; 5,016,718; 5,092,687; 5,120,327; 5,135,061; 5,154,245; 5,460,233; 5,544,713; and 6,793,681, the disclosure of each of which is incorporated herein, in its entirety, by this reference.
- a conventional PDC was formed from a mixture of diamond particles having an average grain size of about 18 ⁇ m.
- the mixture was placed adjacent to a cobalt-cemented tungsten carbide substrate.
- the mixture and substrate were placed in a niobium can and HPHT sintered at a temperature of about 1400° Celsius and a pressure of about 5 GPa to about 8 GPa for about 90 seconds to form the conventional PDC.
- the conventional PDC was acid-leached to a depth of about 70 ⁇ m to remove substantially all of the cobalt from a region of the polycrystalline diamond table.
- the thickness of the polycrystalline diamond table of the PDC was 0.090 inches and a 0.012 inch chamfer was machined in the polycrystalline diamond table.
- the thermal stability of the conventional PDC so-formed was evaluated by measuring the distance cut in a Sierra White granite workpiece prior to failure without using coolant in a vertical turret lathe test.
- the distance cut is considered representative of the thermal stability of the PDC.
- the conventional PDC was able to cut a distance of about only 2000 linear feet in the workpiece prior to failure.
- Evidence of failure of the conventional PDC is best shown in FIG. 16 where the measured temperature of the conventional PDC during cutting increased dramatically at around about 2000 linear feet and in FIG. 17 where the normal force required to continue cutting also increased dramatically at around about 2000 linear feet.
- a PDC was formed by first fabricating a leached polycrystalline diamond body.
- the leached polycrystalline diamond body was formed by HPHT sintering diamond particles having an average grain size of about 18 ⁇ m in the presence of cobalt.
- the sintered-polycrystalline-diamond body included cobalt within the interstitial regions between bonded diamond grains.
- the sintered-polycrystalline-diamond body was leached using a solution of 90% nitric acid/10% de-ionized water for a time sufficient to remove substantially all of the cobalt from the interstitial regions to form the leached polycrystalline diamond body.
- the leached polycrystalline diamond body was placed adjacent to a cobalt-cemented tungsten carbide substrate.
- a green layer of silicon particles was placed adjacent to the leached polycrystalline diamond body on a side thereof opposite the cobalt-cemented tungsten carbide substrate.
- the leached polycrystalline diamond body, cobalt-cemented tungsten carbide substrate, and green layer of silicon particles were placed within a niobium can, and HPHT sintered at a temperature of about 1400° Celsius and a pressure of about 5 GPa to about 7 GPa for about 60 seconds to form a PDC that exhibited a similar multi-region diamond table as the polycrystalline diamond table 15 shown in FIGS. 2A and 2B , with silicon carbide formed in a portion of the interstitial regions between the bonded diamond grains.
- the thickness of the polycrystalline diamond table was about 0.090 inches and a chamfer of about 0.01065 inch was machined in the polycrystalline diamond table.
- the thermal stability of the PDC of example 2 was evaluated by measuring the distance cut in a Sierra White granite workpiece without using coolant in a vertical turret lathe test.
- the PDC of example 2 was able to cut a distance of over 14000 linear feet in a granite workpiece without failing and without using coolant. This is best shown in FIGS. 16 and 17 where the measured temperature ( FIG. 16 ) of the PDC of example 2 during cutting of the workpiece and the normal force required to continue cutting the workpiece ( FIG. 17 ) does not increase dramatically as occurred with the conventional PDC of comparative example 1 during cutting. Therefore, thermal stability tests indicate that the PDC of example 2 exhibited a significantly improved thermal stability compared to the conventional PDC of comparative example 1.
- the wear resistance of the PDCs of comparative example 1 and example 2 were evaluated by measuring the volume of the PDC removed versus the volume of a Sierra White granite workpiece removed in a vertical turret lathe with water used as a coolant. As shown in FIG. 18 , the wearflat volume tests indicated that the PDC of example 2 exhibited a slightly decreased wear resistance compared to the wear resistance of the PDC of comparative example 1. However, the wear resistance of the PDC of example 2 is still more than sufficient to function as a PDC for subterranean drilling applications. Drop-weight tests also indicated that a PDC fabricated according to example 2 exhibits an impact resistance similar to a conventionally fabricated PDC, such as the comparative example 1. Therefore, the PDC of example 2 exhibited a significantly superior thermal stability compared to the conventional PDC of comparative example 1 without significantly compromising wear resistance and impact resistance.
Abstract
A polycrystalline diamond compact includes a substrate and a polycrystalline diamond table attached to the substrate. The polycrystalline diamond table includes an upper surface and at least one peripheral surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions. The polycrystalline diamond table includes a region having silicon carbide positioned within at least some of the interstitial regions thereof. In an embodiment, the first region extends over only a selected portion of the upper surface and/or at least a portion of the at least one peripheral surface. In another embodiment, the first region substantially contours the upper surface and a chamfer.
Description
- This application is a divisional of U.S. application Ser. No. 13/032,350 filed on 22 Feb. 2011, which is a continuation-in-part of U.S. application Ser. No. 11/983,619 filed on 9 Nov. 2007, now U.S. Pat. No. 8,034,136, issued 11 Oct. 2011, which claims the benefit of U.S. Provisional Application No. 60/860,098 filed on 20 Nov. 2006 and U.S. Provisional Application No. 60/876,701 filed on 21 Dec. 2006, the contents of each of the foregoing applications are incorporated herein, in their entirety, by this reference.
- Wear-resistant, superabrasive compacts are utilized for a variety of mechanical applications. For example, polycrystalline diamond compacts (“PDCs”) are used in drilling tools (e.g., cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and in other mechanical systems.
- PDCs have found particular utility as superabrasive cutting elements in rotary drill bits, such as roller cone drill bits and fixed cutter drill bits. A PDC cutting element or cutter typically includes a superabrasive diamond layer or table. The diamond table is formed and bonded to a substrate using an ultra-high pressure, ultra-high temperature (“HPHT”) process. The substrate is often brazed or otherwise joined to an attachment member such as a stud or a cylindrical backing. A stud carrying the PDC may be used as a PDC cutting element when mounted to a bit body of a rotary drill bit by press-fitting, brazing, or otherwise securing the stud into a receptacle formed in the bit body. The PDC cutting element may also be brazed directly into a preformed pocket, socket, or other receptacle formed in the bit body. Generally, a rotary drill bit may include a number of PDC cutting elements affixed to the drill bit body.
- Conventional PDCs are normally fabricated by placing a cemented carbide substrate into a container or cartridge with a volume of diamond particles positioned on a surface of the cemented carbide substrate. A number of such cartridges may be typically loaded into an HPHT press. The substrates and volume of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains defining a diamond table. The catalyst material is often a solvent catalyst, such as cobalt, nickel, or iron that is used for facilitating the intergrowth of the diamond particles.
- In one conventional approach, a constituent of the cemented carbide substrate, such as cobalt from a cobalt-cemented tungsten carbide substrate, liquefies and sweeps from a region adjacent to the volume of diamond particles into interstitial regions between the diamond particles during the HPHT process. The cobalt acts as a catalyst to facilitate intergrowth between the diamond particles, which results in formation of bonded diamond grains. Often, a solvent catalyst may be mixed with the diamond particles prior to subjecting the diamond particles and substrate to the HPHT process.
- The solvent catalyst dissolves carbon from the diamond particles or portions of the diamond particles that graphitize due to the high temperature being used in the HPHT process. The solubility of the stable diamond phase in the solvent catalyst is lower than that of the metastable graphite under HPHT conditions. As a result of this solubility difference, the undersaturated graphite tends to dissolve into solvent catalyst and the supersaturated diamond tends to deposit onto existing diamond particles to form diamond-to-diamond bonds. Accordingly, diamond grains become mutually bonded to form a matrix of polycrystalline diamond with interstitial regions between the bonded diamond grains being occupied by the solvent catalyst.
- The presence of the solvent catalyst in the diamond table is believed to reduce the thermal stability of the diamond table at elevated temperatures. For example, the difference in thermal expansion coefficient between the diamond grains and the solvent catalyst is believed to lead to chipping or cracking in the PDC during drilling or cutting operations, which consequently can degrade the mechanical properties of the PDC or cause failure. Additionally, some of the diamond grains can undergo a chemical breakdown or back-conversion with the solvent catalyst. At extremely high temperatures, portions of diamond grains may transform to carbon monoxide, carbon dioxide, graphite, or combinations thereof, thus, degrading the mechanical properties of the PDC.
- Therefore, manufacturers and users of superabrasive materials continue to seek improved thermally stable, superabrasive materials and processing techniques.
- Embodiments of the present invention relate to methods of fabricating superabrasive articles, such as PDCs, and intermediate articles formed during fabrication of such PDCs. Many different PDC embodiments disclosed herein include a thermally-stable polycrystalline diamond table in which silicon carbide occupies a portion of the interstitial regions thereof formed between bonded diamond grains.
- In one embodiment of the present invention, a method of fabricating a superabrasive article is disclosed. A mass of unsintered diamond particles may be infiltrated with metal-solvent catalyst from a metal-solvent-catalyst-containing material to promote formation of a sintered body of diamond grains including interstitial regions. At least a portion of the interstitial regions may also be infiltrated with silicon from a silicon-containing material. The silicon reacts with the sintered body to form silicon carbide within a portion of the interstitial regions.
- In another embodiment of the present invention, another method of fabricating a superabrasive article is disclosed. At least a portion of interstitial regions of a pre-sintered-polycrystalline diamond body may be infiltrated with silicon from a silicon-containing material. At least a portion of metal-solvent catalyst located within the at least a portion of interstitial regions of the pre-sintered-polycrystalline diamond body may be displaced into a porous mass. The silicon and the pre-sintered-polycrystalline diamond body are reacted to form silicon carbide within the at least a portion of the interstitial regions. A section of the polycrystalline diamond table so-formed may be removed by a suitable material-removal process so that an upper region of the polycrystalline diamond table includes substantially only silicon carbide within the interstitial regions thereof.
- In another embodiment of the present invention, a polycrystalline diamond compact includes a substrate and a polycrystalline diamond table attached to the substrate. The polycrystalline diamond table including an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the peripheral surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions. The polycrystalline diamond table includes a first region extending inwardly from the upper surface and the chamfer, with the first region substantially contouring the upper surface and the chamfer. The first region includes silicon carbide positioned within at least some of the interstitial regions thereof. The polycrystalline diamond table includes a bonding region bonded to the substrate, with the bonding region including metal-solvent catalyst positioned within a second portion of the interstitial regions.
- In a further embodiment of the present invention, a method of fabricating a polycrystalline diamond compact includes positioning an at least partially porous polycrystalline body between a silicon-containing material and a substrate that is adjacent to a metal-solvent catalyst. The at least partially porous polycrystalline body exhibits an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the at least one peripheral surface. The method further includes subjecting the at least partially porous polycrystalline body, the silicon-containing material, and the substrate to an HPHT process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with silicon from the silicon-containing material.
- In yet another embodiment of the present invention, a polycrystalline diamond compact includes a substrate and a polycrystalline diamond table attached to the substrate. The polycrystalline diamond table including an upper surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions. The polycrystalline diamond table includes a first region including silicon carbide positioned within a first portion of the interstitial regions, the first region extending over only a selected portion of the upper surface. The polycrystalline diamond table further includes a bonding region bonded to the substrate, with the bonding region including metal-solvent catalyst positioned within a second portion of the interstitial regions.
- In still a further embodiment of the present invention, a method of fabricating a polycrystalline diamond compact includes positioning an at least partially porous polycrystalline body between a silicon-containing material and a substrate adjacent to a metal-solvent catalyst. The at least partially porous polycrystalline body includes an upper surface and at least one peripheral surface, with the silicon-containing material extending over only a portion of the upper surface and/or at least a portion of the at least one peripheral surface. The method further includes subjecting the at least partially porous polycrystalline body, the silicon-containing material, and the substrate to an HPHT process to infiltrate a first region of the at least partially porous polycrystalline body that extends along only a portion of the upper surface thereof
- Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.
- The drawings illustrate several embodiments of the present invention, wherein like reference numerals refer to like or similar elements in different views or embodiments shown in the drawings.
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FIG. 1A is a schematic side cross-sectional view of an assembly including a substrate, a porous polycrystalline diamond body, and a silicon-containing material used to fabricate a PDC according to one embodiment of the present invention. -
FIG. 1B is a schematic side cross-sectional view of an assembly including a substrate, a porous polycrystalline diamond body in which a region remote from the substrate contains tungsten carbide, and a silicon-containing material used to fabricate a PDC according to one embodiment of the present invention. -
FIG. 2A is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown inFIG. 1A . -
FIG. 2B is a schematic perspective view of the PDC shown inFIG. 2A . -
FIG. 2C is a schematic cross-sectional view of the PDC so-formed when the polycrystalline diamond body shown inFIG. 1A includes a preformed chamfer according to another embodiment. -
FIG. 3A is a schematic side cross-sectional view of another assembly that may be used to form a PDC with a selectively-shaped cutting region according to another embodiment of the present invention. -
FIG. 3B is a schematic side cross-sectional view of another assembly that may be used to form a PDC in which silicon infiltrates into a polycrystalline diamond body through sides thereof according to another embodiment of the present invention. -
FIG. 4A is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown inFIG. 3A . -
FIG. 4B is a schematic top plan view of the PDC resulting from HPHT processing of the assembly shown inFIG. 3A when the silicon-containing material included multiple wedge-shaped portions. -
FIG. 5 is a schematic side cross-sectional view of another assembly that may be used to form the PDC shown inFIGS. 2A and 2B according to another embodiment of the present invention. -
FIG. 6 is a schematic side cross-sectional view of another assembly that may be used to form the PDC shown inFIGS. 2A and 2B according to yet another embodiment of the present invention. -
FIG. 7 is a schematic side cross-sectional view of an assembly including a substrate, unsintered diamond particles, a metal-solvent-catalyst material, and a silicon-containing material used to fabricate a PDC according to another embodiment of the present invention. -
FIG. 8 is a schematic side cross-sectional view of the PDC resulting from HPHT processing of the assembly shown inFIG. 7 . -
FIG. 9 is a schematic side cross-sectional view of an assembly including a substrate, a silicon-containing material, a diamond table, and porous mass used to fabricate a PDC according to another embodiment of the present invention. -
FIG. 10 is a schematic side cross-sectional view of the resulting structure formed from HPHT processing of the assembly shown inFIG. 9 . -
FIG. 11 is a PDC formed by removing a portion of the multi-region structure shown inFIG. 10 . -
FIG. 12 is a schematic cross-sectional view of an assembly including a substrate, a mass of unsintered diamond particles, and layers of metal-solvent-catalyst-containing material and silicon-containing material disposed between the substrate and the mass of unsintered diamond particles used to fabricate a PDC according to another embodiment of the present invention. -
FIG. 13 is a schematic side cross-sectional view of the resulting structure from HPHT processing of the assembly shown inFIG. 12 . -
FIG. 14 is an isometric view of one embodiment of a rotary drill bit including at least one superabrasive cutting element including a PDC configured according to any of the various PDC embodiments of the present invention. -
FIG. 15 is a top elevation view of the rotary drill bit ofFIG. 14 . -
FIG. 16 is a graph showing the measured temperature versus linear distance during a vertical turret lathe test on a conventional, leached PDC and a PDC according to working example 2 of the present invention. -
FIG. 17 is a graph showing the measured normal force versus linear distance during a vertical turret lathe test on a conventional, leached PDC and a PDC according to working example 2 of the present invention. -
FIG. 18 is a graph illustrating the wear flat volume characteristics of a conventional, leached PDC and a PDC according to working example 2 of the present invention. - Embodiments of the present invention relate to methods of fabricating superabrasive articles, such as PDCs, and intermediate articles formed during fabrication of such PDCs. For example, many different PDC embodiments disclosed herein include a thermally-stable polycrystalline diamond table in which silicon carbide occupies a portion of the interstitial regions formed between bonded diamond grains. The superabrasive articles disclosed herein may be used in a variety of applications, such as drilling tools (e.g., compacts, cutting elements, gage trimmers, etc.), machining equipment, bearing apparatuses, wire-drawing machinery, and other apparatuses. As used herein, the term “superabrasive” means a material that exhibits a hardness exceeding a hardness of tungsten carbide. For example, a superabrasive article is an article of manufacture, at least a portion of which exhibits a hardness exceeding the hardness of tungsten carbide.
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FIGS. 1A-2B show an embodiment of a method according to the present invention for fabricating a PDC and the resulting structure of the PDC. As shown inFIG. 1A , anassembly 10 includes an at least partially porous polycrystalline diamond body 14 (i.e., a pre-sintered-polycrystalline diamond body) positioned adjacent to asubstrate 12. Theassembly 10 further includes a silicon-containingmaterial 16 positioned adjacent to thepolycrystalline diamond body 14 on a side of thepolycrystalline diamond body 14 opposite thesubstrate 12. In one embodiment of the present invention, the silicon-containingmaterial 16 may comprise a green body of elemental silicon particles (e.g., crystalline or amorphous silicon particles) in the form of a tape-casted tape that is placed adjacent to thepolycrystalline diamond body 14. In another embodiment of the present invention, the silicon-containingmaterial 16 may comprise a disc of silicon. - Still referring to
FIG. 1A , thepolycrystalline diamond body 14 includes a plurality of interstitial regions that were previously occupied by metal-solvent catalyst. Thepolycrystalline diamond body 14 may be fabricated by subjecting a plurality of diamond particles (e.g., diamond particles having an average particle size between 0.5 μm to about 150 μm) to an HPHT sintering process in the presence of a metal-solvent catalyst, such as cobalt, or other catalyst to facilitate intergrowth between the diamond particles to form a polycrystalline diamond table of bonded diamond grains. In one embodiment of the present invention, the sintered diamond grains of thepolycrystalline diamond body 14 may exhibit an average grain size of about 20 μm or less. The polycrystalline diamond table so-formed may be immersed in an acid, such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or subjected to another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table. - In one embodiment of the present invention, the polycrystalline diamond table is not formed by sintering the diamond particles on a cemented-tungsten-carbide substrate or otherwise in the presence of tungsten carbide. In such an embodiment, the interstitial regions of the
polycrystalline diamond body 14 may contain no tungsten and/or tungsten carbide or insignificant amounts of tungsten and/or tungsten carbide, which can inhibit removal of the metal-solvent catalyst. - In other embodiments of the present invention, a polycrystalline diamond table may be formed by HPHT sintering diamond particles in the presence of tungsten carbide. For example, diamond particles may be placed adjacent to a cemented tungsten carbide substrate and/or tungsten carbide particles may be mixed with the diamond particles prior to HPHT sintering. In such an embodiment, the polycrystalline diamond table so-formed may include tungsten and/or tungsten carbide that is swept in with metal-solvent catalyst from the substrate or intentionally mixed with the diamond particles during HPHT sintering process. For example, some tungsten and/or tungsten carbide from the substrate may be dissolved or otherwise transferred by the liquefied metal-solvent catalyst (e.g., cobalt from a cobalt-cemented tungsten carbide substrate) of the substrate that sweeps into the diamond particles. The polycrystalline diamond table so-formed may be separated from the substrate using a lapping process, a grinding process, wire-electrical-discharge machining (“wire EDM”), or another suitable material-removal process. The separated polycrystalline diamond table may be immersed in a suitable acid (e.g., a hydrochloric acid/hydrogen peroxide solution) to remove substantially all of the metal-solvent catalyst from the interstitial regions and form the
polycrystalline diamond body 14. However, an indeterminate amount of tungsten and/or tungsten carbide may remain distributed throughout thepolycrystalline diamond body 14 even after leaching. The presence of the tungsten and/or tungsten carbide within thepolycrystalline diamond body 14 is currently believed to significantly improve the abrasion resistance thereof even after infiltration with silicon and HPHT bonding to thesubstrate 12, as will discussed in more detail below. - In a variation of the above-described embodiment in which the
polycrystalline diamond body 14 has tungsten and/or tungsten carbide distributed therein, thepolycrystalline diamond body 14 may comprise a first portion including tungsten and/or tungsten carbide and a second portion that is substantially free of tungsten and/or tungsten carbide. For example, a layer of metal-solvent catalyst (e.g., cobalt) may be positioned between diamond particles and a cemented carbide substrate (e.g., cobalt-cemented tungsten carbide substrate) and subjected to HPHT conditions. During the HPHT sintering process, metal-solvent catalyst from the layer sweeps through the diamond particles to effect intergrowth and bonding. Because the volume of the layer of metal-solvent catalyst is selected so that it is not sufficient to fill the volume of all of the interstitial regions between the diamond particles, metal-solvent catalyst from the substrate also sweeps in, which may carry or transfer tungsten and/or tungsten carbide. Thus, a first region of the polycrystalline diamond table so-formed adjacent to the substrate includes tungsten and/or tungsten carbide and a second region remote from the substrate is substantially free of tungsten and/or tungsten carbide. The volume of the layer of metal-solvent catalyst may be selected so that the second region exhibits a thickness substantially greater than the second region. In this embodiment, the metal-solvent catalyst within the interstitial regions between bonded diamond grains of the polycrystalline diamond table may be removed from the second region more easily. For example, the metal-solvent catalyst may be leached from the first region using a hydrochloric acid/hydrogen peroxide solution and the metal-solvent catalyst in the second region may be leached using a less aggressive nitric acid/hydrofluoric acid solution. As shown inFIG. 1B , thepolycrystalline diamond body 14 so-formed after leaching may be oriented with the second region (shown as 14A) that is substantially free of tungsten and/or tungsten carbide positioned adjacent to thesubstrate 12 in theassembly 10 and the first region (shown as 14B) that includes tungsten and/or tungsten carbide positioned remote from thesubstrate 12 to form at least part of a working or cutting region of a PDC that is ultimately formed after processing. - Referring again to
FIG. 1A , in another embodiment of the present invention, thepolycrystalline diamond body 14 may be formed by sintering diamond particles or other particles capable of forming diamond in response to an HPHT sintering process without a catalyst. For example, U.S. Pat. Nos. 7,516,804 and 7,841,428, each of which is incorporated herein, in its entirety, by this reference, disclose that ultra-dispersed diamond particles and fullerenes may be mixed with diamond particles and HPHT sintered to form a polycrystalline diamond body. - The
substrate 12 may comprise a cemented-carbide material, such as a cobalt-cemented tungsten carbide material or another suitable material. For example, nickel, iron, and alloys thereof are other metal-solvent catalysts that may comprise thesubstrate 12. Other materials that may comprise thesubstrate 12 include, without limitation, cemented carbides including titanium carbide, niobium carbide, tantalum carbide, vanadium carbide, and combinations of any of the preceding carbides cemented with iron, nickel, cobalt, or alloys thereof. A representative thickness for thesubstrate 12 is a thickness of about 0.100 inches to at least about 0.350 inches, more particularly about 0.150 inches to at least about 0.300 inches, and even more particularly about 0.170 inches to at least about 0.290 inches. - The
assembly 10 may be placed in a pressure transmitting medium, such as a refractory metal can, graphite structure, pyrophyllite or other pressure transmitting structure, or another suitable container or supporting element. Methods and apparatuses for sealing enclosures suitable for holding theassembly 10 are disclosed in U.S. patent application Ser. No. 11/545,929, which is incorporated herein, in its entirety, by this reference. The pressure transmitting medium, including theassembly 10, is subjected to an HPHT process using an ultra-high pressure press at a temperature of at least about 1000° Celsius (e.g., about 1300° Celsius to about 1600° Celsius) and a pressure of at least 40 kilobar (e.g., about 50 kilobar to about 70 kilobar) for a time sufficient to sinter theassembly 10 and form aPDC 18 as shown inFIGS. 2A and 2B . Stated another way, the HPHT bonds thepolycrystalline diamond body 14 to thesubstrate 12 and causes at least partial infiltration of the silicon into thepolycrystalline diamond body 14. The HPHT temperature may be sufficient to melt at least one constituent of the substrate 12 (e.g., cobalt, nickel, iron, or another constituent) and the silicon of the silicon-containingmaterial 16. ThePDC 18 may exhibit other geometries than the geometry illustrated inFIGS. 2A and 2B . For example, thePDC 18 may exhibit a non-cylindrical geometry. - As shown in
FIGS. 2A and 2B , the HPHT sinteredPDC 18 comprises a polycrystalline diamond table 15 that may include three regions: afirst region 20, a second-intermediate region 22, and a third region 24 (i.e., a bonding region). Thefirst region 20 includes polycrystalline diamond with substantially only silicon carbide formed within at least some of the interstitial regions between the bonded diamond grains of thefirst region 20. It is noted that the interstitial regions of at least thefirst region 20 may also include tungsten carbide when tungsten carbide is present in thepolycrystalline diamond body 14, such as in the embodiment shown inFIG. 1B . During the HPHT process, silicon from the silicon-containingmaterial 16 liquefies and at least partially infiltrates the interstitial regions of thepolycrystalline diamond body 14. The silicon reacts with the diamond grains of thepolycrystalline diamond body 14 to form silicon carbide, which occupies at least some of the interstitial regions between the diamond grains and bonds to the diamond grains. Further, the amount of the silicon-containingmaterial 16 may be selected so that the silicon of the silicon-containingmaterial 16 fills a selected portion of the interstitial regions of thepolycrystalline diamond body 14. - During the HPHT process, metal-solvent catalyst from the
substrate 12 or another source also sweeps into the interstitial regions of thepolycrystalline diamond body 14 and fills some of the interstitial regions thereof, in addition to silicon carbide filling other interstitial regions as previously described with respect to thefirst region 20. In one embodiment of the present invention, the second-intermediate region 22 of the polycrystalline diamond table 15 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of the second-intermediate region 22 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of the second-intermediate region 22. In another embodiment of the present invention, substantially all of or only a portion of the interstitial regions of the second-intermediate region 22 may include an alloy of silicon and the metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. In yet another embodiment of the present invention, at least some of the interstitial regions of the second-intermediate region 22 of the polycrystalline diamond table 15 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst. Thethird region 24 includes polycrystalline diamond with substantially only metal-solvent catalyst (e.g., cobalt) occupying at least some of the interstitial regions between the bonded diamond grains. The metal-solvent catalyst occupying the interstitial regions of thethird region 24 is liquefied and swept into thepolycrystalline diamond body 14 from thesubstrate 12 or another source (e.g., a metal disk, particles, etc.) during the HPHT process. Thethird region 24 provides a strong, metallurgical bond between thesubstrate 12 and the polycrystalline diamond table 15 to thereby function as a bonding region. It is noted that at least thefirst region 20 of the polycrystalline diamond table 15 may be substantially free of non-silicon carbide type carbides, such as tungsten carbide, when thepolycrystalline diamond body 14 is not formed in the presence of tungsten carbide. - The
PDC 18 shown inFIGS. 2A and 2B exhibits an improved thermal stability relative to a conventional PDC in which the interstitial regions of the diamond table are occupied with only cobalt or another metal-solvent catalyst. Additionally, the wear resistance of thePDC 18 may be improved relative to a conventional PDC because the silicon carbide phase occupying the interstitial regions of thefirst region 20 exhibits a hardness greater than a hardness of cobalt or other metal-solvent catalysts. - The
PDC 18 may also include a chamfer along a peripheral region thereof, which may be preformed in the polycrystalline diamond body 14 (e.g., by machining or grinding) or may be machined in the polycrystalline diamond table 15 after formation of thePDC 18. For example,FIG. 2C is a cross-sectional view of thePDC 18 so-formed when thepolycrystalline diamond body 14 exhibits a preformed chamfer according to another embodiment. In such an embodiment, at least thefirst region 20 and, in some cases, the second-intermediate region 22 substantially contours a preformedchamfer 25 and anupper surface 27 of the polycrystalline diamond table 15, with thechamfer 25 extending between theupper surface 27 and at least oneperipheral surface 29. As the polycrystalline diamond table 15 had a preformed chamfer, the silicon infiltrates into the polycrystalline diamond table 15 so that a depth “d” of thefirst region 20 is substantially the same when measured from theupper surface 27 and thechamfer 25. The depth “d” may be about 50 μm to about 1000 μm, about 150 μm to about 500 μm, or about 100 μm to about 200 μm. - Although the
assembly 10 shown inFIGS. 1A and 1B includes thesubstrate 12, in another embodiment of the present invention, thesubstrate 12 may be omitted. In such an embodiment of the present invention, an assembly of thepolycrystalline diamond body 14 and the silicon-containingmaterial 16 may be subjected to an HPHT process to form a polycrystalline diamond table. After the HPHT process, a carbide layer (e.g., a tungsten carbide layer) may be deposited on the polycrystalline diamond table, as disclosed in U.S. Patent Application Publication No. 20080085407, to form a PDC and enable attaching the PDC to a bit body of a rotary drill bit. U.S. Patent Application Publication No. 20080085407 is incorporated herein, in its entirety, by this reference. In another embodiment of the present invention, the polycrystalline diamond table may be brazed or otherwise secured to a bit body of a rotary drill bit. - One of ordinary skill in the art will recognize that many variations for selectively forming silicon carbide regions within a pre-sintered-polycrystalline-diamond body may be employed. For example, in another embodiment of the present invention, a PDC may be formed with a polycrystalline diamond table including a cutting region exhibiting a selected configuration. The cutting region may comprise bonded diamond grains with silicon carbide within at least some of the interstitial regions between the bonded diamond grains. By only infiltrating a selected region of an at least partially porous polycrystalline diamond body with silicon, the toughness may be improved. As shown in
FIG. 3A , a silicon-containingmaterial 16′ in the form of body of silicon or amorphous silicon, green body of silicon particles in the form of a tape-casted tape in the form of a tape-casted tape may be placed adjacent to thepolycrystalline diamond body 14. For example, the silicon-containingmaterial 16′ may exhibit an annular geometry, a wedge-shaped geometry, or another suitable geometry. A mask 21 (e.g., a mica disk or other ceramic mask) may be disposed adjacent to the silicon-containingmaterial 16′ to cover regions of thepolycrystalline diamond body 14 that are not covered by silicon-containingmaterial 16′ help prevent silicon infiltration into the masked region of thepolycrystalline diamond body 14. - As shown in
FIG. 4A , upon subjectingassembly 10′ to HPHT conditions as described generally hereinabove with respect to theassembly 10, aPDC 18′ is formed with a polycrystalline diamond table 15′ including cuttingregion 20′ formed peripherally aboutintermediate region 22′ and athird region 24′. The cuttingregion 20′ comprises bonded diamond grains with substantially only silicon carbide within the interstitial regions between the bonded diamond grains. In one embodiment of the present invention, theintermediate region 22′ comprises bonded diamond grains with silicon carbide within a portion of the interstitial regions and metal-solvent catalyst from thesubstrate 12 or another source within another portion of the interstitial regions. In another embodiment of the present invention, substantially all of or only a portion of the interstitial regions of the second-intermediate region 22′ includes an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. In yet another embodiment of the present invention, at least some of the interstitial regions of the second-intermediate region 22′ of the polycrystalline diamond table 15 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst. Thethird region 24′ is formed adjacent to thesubstrate 12 and provides a strong, metallurgical bond between the polycrystalline diamond table 15′ and thesubstrate 12. Thethird region 24′ comprises bonded diamond grains with substantially only the metal-solvent catalyst from thesubstrate 12 or another source within the interstitial regions between the bonded diamond grains. Thethird region 24′ provides a tough core that compliments the more thermally-stablefirst region 20′. Depending upon the geometry of the silicon-containingmaterial 16′, the geometry of the cuttingregion 20′ of the polycrystalline diamond table 15′ may also be formed to exhibit other selected geometries. -
FIG. 4B is a top plan view of the PCD table 15′ when the silicon-containingmaterial 16′ exhibited a wedge-shaped geometry, with multiple wedge-shaped portions forming the cuttingregion 20′. Of course, other geometries may be employed for the cuttingregion 20′ and theintermediate region 22′ that depart from the illustrated geometry shown inFIG. 4B . For example, the cuttingregion 20′ and theintermediate region 22′ may exhibit an annular geometry, as described hereinabove, or another selected geometry. - Of course, in any of the embodiments described herein that selectively infiltrate the
polycrystalline diamond body 14 with silicon, thepolycrystalline diamond body 14 may also be chamfered. However, the polycrystalline diamond table 15′ may also be chamfered after being formed. - In some embodiments, the polycrystalline diamond table 15′ may be subjected to a leaching process to deplete the
third region 24′ shown inFIGS. 4A and 4B of metal-solvent catalyst (e.g., cobalt). Leaching thethird region 24′ may improve the overall thermal-stability of the polycrystalline diamond table 15′. The metal-solvent catalyst may be depleted from thethird region 24′ to a selected depth from the upper surface and the peripheral surface. For example, the leach depth may be about 50 μm to about 1000 μm, about 150 μm to about 500 μm, or about 100 μm to about 200 μm. The leaching may be performed to remove substantially all of the metal-solvent catalyst from thethird region 24′. -
FIG. 3B shows another embodiment of the present invention in which a silicon-containingmaterial 16″ may be positioned adjacent to at least oneperipheral surface 17 of thepolycrystalline diamond body 14. HPHT processing causes silicon from the silicon-containingmaterial 16″ to at least partially or substantially infiltrate thepolycrystalline diamond body 14. For example, the silicon from the silicon-containingmaterial 16″ may partially infiltrate thepolycrystalline diamond body 14 to form a PDC including a multi-region polycrystalline diamond table. - As shown in
FIG. 5 , in another embodiment of the present invention, thePDC 18 may be formed by subjecting anassembly 21 to HPHT conditions similar to that employed on theassembly 10. Theassembly 21 includes a silicon-containingmaterial 16 positioned adjacent to asubstrate 12, and between thesubstrate 12 and apolycrystalline diamond body 14. During HPHT processing, theassembly 21 is heated at a sufficient rate so that the metal-solvent catalyst (e.g., cobalt) and the silicon in the silicon-containingmaterial 16 are in a liquid state at substantially the same time. Such heating may cause the molten, metal-solvent catalyst (e.g., from thesubstrate 12, metal-solvent catalyst mixed with the silicon-containingmaterial 16, or another source) to occupy a portion of the interstitial regions of thepolycrystalline diamond body 14 and may cause the molten silicon to occupy other portions of the interstitial regions of thepolycrystalline diamond body 14. Upon cooling, the resultant, as-sintered PDC may exhibit a similar multi-region diamond table as the polycrystalline diamond table 15 shown inFIGS. 2A and 2B . -
FIG. 6 shows another embodiment of the present invention in which aPDC 13 including a leached polycrystalline diamond table 19 and a silicon-containingmaterial 16 are assembled and HPHT processed using HPHT conditions as described generally hereinabove with respect to theassembly 10. In this embodiment, thePDC 13 may be formed from a conventional PDC with a polycrystalline diamond table that comprises bonded diamond grains with cobalt or another metal-solvent catalyst occupying the interstitial regions between the bonded diamond grains. The metal-solvent catalyst may be substantially removed from the polycrystalline diamond table by leaching using an acid, such as aqua-regia, a solution of 90% nitric acid/10% de-ionized water, or another suitable process to remove at least a portion of the metal-solvent catalyst from the interstitial regions of the polycrystalline diamond table. After removal of the metal-solvent catalyst from thePDC 13, a silicon-containingmaterial 16 may be positioned adjacent to the leached polycrystalline diamond table 19 on a side thereof opposite thesubstrate 12. The leached polycrystalline diamond table 19 and the silicon-containingmaterial 16 are subjected to an HPHT process to infiltrate the leached polycrystalline diamond table 19 with silicon from the silicon-containingmaterial 16 to form a PDC having a polycrystalline diamond table with the same or similar construction as the polycrystalline diamond table 15 shown inFIGS. 2A and 2B . -
FIGS. 7 and 8 show another embodiment of a method according to the present invention for forming a PDC. As shown inFIG. 7 , anassembly 24 includes a mass ofunsintered diamond particles 28 positioned adjacent to thesubstrate 12. The mass ofunsintered diamond particles 28 may be a green body ofdiamond particles 28 in the form of a tape-casted tape. In one embodiment of the present invention, thediamond particles 28 may exhibit an average particle size of about 20 μm or less. In another embodiment of the present invention, thediamond particles 28 may exhibit an average particle size of about 5 μm to about 50 μm. The mass ofunsintered diamond particles 28 may exhibit a thickness, for example, of about 0.150 inches to about 0.200 inches. Theassembly 24 further includes a metal-solvent-catalyst-containingmaterial 26 positioned adjacent to the mass ofdiamond particles 28, and a silicon-containingmaterial 16 positioned adjacent to the metal-solvent-catalyst-containingmaterial 26. The metal-solvent-catalyst-containingmaterial 26 may include or may be formed from a material, such as cobalt, nickel, iron, or alloys thereof. The metal-solvent-catalyst-containingmaterial 26 may also be a green body of metal-solvent-catalyst particles in the form of a tape-casted tape, a thin disc of metal-solvent-catalyst material, or any other suitable metal-solvent-catalyst material or structure, without limitation. - The
assembly 24 may be subjected to an HPHT sintering process using HPHT process conditions similar to those previously discussed to form aPDC 42 shown inFIG. 8 . During HPHT sintering, the metal-solvent catalyst of the metal-solvent-catalyst-containingmaterial 26 melts and infiltrates thediamond particles 28 to effect intergrowth between thediamond particles 28. Molten silicon from the silicon-containingmaterial 16 also infiltrates thediamond particles 28 and the infiltration by the molten silicon follows the infiltration of the metal-solvent catalyst. Thus, the metal-solvent catalyst from the metal-solvent-catalyst-containingmaterial 26 promotes bonding of thediamond particles 28 to form polycrystalline diamond and the silicon infiltrates the polycrystalline diamond so-formed. The silicon reacts with the diamond grains of the polycrystalline diamond to form silicon carbide within some of the interstitial regions between the bonded diamond grains. The amount of the silicon-containingmaterial 16 metal-solvent-catalyst-containingmaterial 26 may be selected so that the silicon of the silicon-containingmaterial 16 and the metal-solvent catalyst from the metal-solvent-catalyst-containingmaterial 26, respectively, only fill a portion of the interstitial regions of the polycrystalline diamond formed during the HPHT process. - As shown in
FIG. 8 , thePDC 42 formed by HPHT sintering theassembly 24 includes a multi-region polycrystalline diamond table 35 similar in configuration to the polycrystalline diamond table 15 shown inFIGS. 2A and 2B . The polycrystalline diamond table 35 includes: afirst region 36, a second-intermediate region 38, and athird region 40. Thefirst region 36 includes substantially only silicon carbide within at least some of the interstitial regions between the bonded diamond grains. In one embodiment of the present invention, the second-intermediate region 38 may include silicon carbide within a portion of the interstitial regions between the bonded diamond grains, along with metal-solvent catalyst from the metal-solvent-catalyst-containingmaterial 26 and/or thesubstrate 12 within other portions of the interstitial regions of the second-intermediate region 38. In another embodiment of the present invention, substantially all of or only a portion of the interstitial regions of the second-intermediate region 38 may include an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. In yet another embodiment of the present invention, at least some of the interstitial regions of the second-intermediate region 38 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst. Thethird region 40, adjacent to thesubstrate 12, includes substantially only metal-solvent catalyst from thesubstrate 12 or another source within the interstitial regions thereof for forming a strong, metallurgical bond between the polycrystalline diamond table 35 and thesubstrate 12. -
FIGS. 9-11 show yet another embodiment of a method according to the present invention for forming a PDC. As shown inFIG. 9 , anassembly 44 is formed by positioning a silicon-containingmaterial 16 between asubstrate 12 and a pre-sintered-polycrystalline diamond table 46. The polycrystalline diamond table 46 may exhibit a thickness of, for example, about 0.090 inches and an average grain size of about 20 μm or less. The polycrystalline diamond table 46 comprises bonded diamond grains sintered using a metal-solvent catalyst, such as cobalt, nickel, iron, or alloys thereof. Accordingly, the polycrystalline diamond table 46 includes bonded diamond grains with the metal-solvent catalyst occupying interstitial regions between the bonded diamond grains. In one embodiment of the present invention, the polycrystalline diamond table 46 may not be formed by sintering diamond particles in the presence of tungsten carbide so that the interstitial regions of the polycrystalline diamond table 46 contain no tungsten and/or tungsten carbide or insignificant amounts of tungsten and/or tungsten carbide. In other embodiments of the present invention, a portion or substantially the entire polycrystalline diamond table 46 may be formed to include tungsten and/or tungsten carbide distributed therethrough, as previously described with respect to thepolycrystalline diamond body 14 shown inFIGS. 1A and 1B . For example, a first region of the polycrystalline diamond table 46 that is substantially free of tungsten and/or tungsten carbide may be positioned adjacent to the silicon-containingmaterial 16, while a second region of the polycrystalline diamond table 46 that includes tungsten and/or tungsten carbide may be positioned remote from the silicon-containingmaterial 16. Theassembly 44 further includes aporous mass 48 positioned adjacent to the polycrystalline diamond table 46 on a side of the polycrystalline diamond table 46 opposite the silicon-containingmaterial 16. Theporous mass 48 may be unsintered diamond particles, unsintered aluminum oxide particles, unsintered silicon carbide particles, or another suitable porous mass. Theporous mass 48 may also be a green body of diamond particles in the form of a tape-casted tape, or any other form, without limitation. - The
assembly 44 may be subjected to an HPHT sintering process using sintering conditions similar to the sintering conditions employed on theassembly 10 to bond the various components of theassembly 44 together and to form apolycrystalline diamond structure 50 shown inFIG. 10 . During sintering, silicon from the silicon-containingmaterial 16 melts and displaces all or a portion of the metal-solvent catalyst of the polycrystalline diamond table 46 into theporous mass 48. Depending on the sintering temperature, the metal-solvent catalyst of the polycrystalline diamond table 46 may also be partially or completed molten at the same time as the silicon from the silicon-containingmaterial 16. In one embodiment of the present invention, the amount of silicon-containingmaterial 16 is selected so that substantially all of the metal-solvent catalyst of the polycrystalline diamond table 46 is displaced into theporous mass 48. In another embodiment of the present invention, the amount of the silicon-containingmaterial 16 may be selected so that the silicon from the silicon-containingmaterial 16 displaces only a portion of the metal-solvent catalyst of the polycrystalline diamond table 46. The silicon reacts with the diamond grains of the polycrystalline diamond table 46 or another carbon source to form silicon carbide within interstitial regions between the bonded diamond grains of the polycrystalline diamond table 46. Additionally, metal-solvent catalyst from thesubstrate 12 or another source also melts and infiltrates into a region of the polycrystalline diamond table 46 adjacent thesubstrate 12. - As shown in
FIG. 10 , thepolycrystalline diamond structure 50 formed by HPHT processing of theassembly 44 comprises a multi-region polycrystalline diamond table 55 that may include: afirst region 52, asecond region 54, athird region 56, afourth region 58, and afifth region 60. Thefirst region 52 includes the particles from theporous mass 48 with at least some of the interstitial regions thereof occupied by substantially only the metal-solvent catalyst displaced from the polycrystalline diamond table 46. Thesecond region 54 includes the particles from theporous mass 48 with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. Depending upon the amount of the silicon-containingmaterial 16 employed, thesecond region 54 may also extend into the HPHT processed polycrystalline diamond table 46. Thethird region 56,fourth region 58, andfifth region 60 may be formed from the HPHT processed polycrystalline diamond table 46, which exhibits a reduced thickness due to the HPHT processing. Thethird region 56 includes polycrystalline diamond with substantially only silicon carbide within at least some of the interstitial regions between the bonded diamond grains. In one embodiment of the present invention, thefourth region 58 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. In another embodiment of the present invention, thefourth region 58 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of thefourth region 58 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of thefourth region 58. In yet another embodiment of the present invention, at least some of the interstitial regions of thefourth region 58 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst. Thefifth region 60, adjacent to thesubstrate 12, includes substantially only metal-solvent catalyst from thesubstrate 12 within at least some of the interstitial regions between bonded diamond grains for forming a strong, metallurgical bond between the multi-region polycrystalline diamond table 55 and thesubstrate 12. - As shown in
FIG. 11 , after forming thepolycrystalline diamond structure 50, aPDC 63 including amulti-region structure 65 similar in configuration to the polycrystalline diamond table 15 shown inFIGS. 2A and 2B may be formed by removing thefirst region 52 and thesecond region 54 of themulti-region structure 65 using a lapping process, a grinding process, wire EDM, or another suitable material-removal process. -
FIGS. 12 and 13 show yet another embodiment of a method according to the present invention for forming a PDC. As shown inFIG. 12 , anassembly 59 includes a mass ofunsintered diamond particles 62 with a silicon-containingmaterial 16 and a metal-solvent catalyst-containingmaterial 26 positioned between the mass ofunsintered diamond particles 62 and asubstrate 12. The metal-solvent-catalyst-containingmaterial 26 is positioned adjacent to the mass ofunsintered diamond particles 62 and the silicon-containingmaterial 16 is positioned adjacent to thesubstrate 12. Theassembly 59 may be subjected to an HPHT sintering process using sintering conditions similar to the sintering conditions employed on theassembly 10 to form apolycrystalline diamond structure 61 shown inFIG. 13 . During HPHT sintering, the silicon-containingmaterial 16 and the metal-solvent catalyst-containingmaterial 26 are melted, and metal-solvent catalyst from the metal-solvent-catalyst-containingmaterial 26 infiltrates the mass ofunsintered diamond particles 62 to promote bonding between the diamond particles, thus, forming polycrystalline diamond that comprises bonded diamond grains with interstitial regions between the bonded diamond grains. The silicon from the silicon-containingmaterial 16 follows the infiltration of themass 62 by the metal-solvent-catalyst-containingmaterial 26 and infiltrates the polycrystalline diamond so-formed. The silicon reacts with the diamond grains to form silicon carbide within some of the interstitial regions. - As shown in
FIG. 13 , thepolycrystalline diamond structure 61 formed by HPHT sintering of theassembly 59 comprises a multi-region polycrystalline diamond table 69 that may include: afirst region 64, asecond region 65, athird region 66, afourth region 67, and afifth region 68. Thefirst region 64 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by substantially only the metal-solvent catalyst from the metal-solvent-catalyst-containingmaterial 26. In one embodiment of the present invention, thesecond region 65 includes polycrystalline diamond with at least some of the interstitial regions thereof occupied by an alloy of silicon and metal-solvent catalyst, such as a silicon-cobalt solid solution alloy or an intermetallic compound of cobalt and silicon. In another embodiment of the present invention, thesecond region 65 may include polycrystalline diamond with silicon carbide formed within a portion of the interstitial regions between the bonded diamond grains of thesecond region 65 and metal-solvent catalyst (e.g., cobalt) occupying another portion of the interstitial regions between the bonded diamond grains of thesecond region 65. In yet another embodiment of the present invention, at least some of the interstitial regions of thesecond region 65 may include one or more of the following materials: silicon carbide, metal-solvent catalyst, silicon, and an alloy of silicon and metal-solvent catalyst. Thethird region 66 includes polycrystalline diamond with substantially only silicon carbide within at least some of the interstitial regions thereof. Thefourth region 67 may include a composition and microstructure that is the same or similar to thesecond region 65. Thefifth region 68 adjacent to thesubstrate 12 includes substantially only metal-solvent catalyst from thesubstrate 12 or another source within the interstitial regions thereof for forming a strong, metallurgical bond between the multi-region polycrystalline diamond table 69 and thesubstrate 12. After forming the multi-region polycrystalline diamond table 69, a PDC including a polycrystalline diamond table similar in configuration to the polycrystalline diamond table 15 shown inFIGS. 2A and 2B may be formed by removing thefirst region 64 and thesecond region 65 using a lapping process, a grinding process, wire EDM, or another suitable material-removal process. - In the embodiments described above, silicon is introduced into a polycrystalline diamond table by infiltrating molten silicon. However, it is contemplated that silicon may be introduced in vapor form such as via chemical vapor deposition or another suitable vapor deposition process. Additionally, a polycrystalline diamond table that has been integrally formed with a cemented carbide substrate and leached to a selected depth from an upper surface thereof may also benefit from being infiltrated with silicon in molten or vapor form to form a more thermally-stable polycrystalline diamond table.
-
FIGS. 14 and 15 show an isometric view and a top elevation view, respectively, of arotary drill bit 70 according to one embodiment of the present invention. Therotary drill bit 70 includes at least one PDC configured according to any of the previously described PDC embodiments. Therotary drill bit 70 comprises abit body 72 that includes radially and longitudinally extendingblades 74 with leadingfaces 76, and a threadedpin connection 78 for connecting thebit body 72 to a drilling string. Thebit body 72 defines a leading end structure for drilling into a subterranean formation by rotation about alongitudinal axis 80 and application of weight-on-bit. At least one PDC, fabricated according to any of the previously described PDC embodiments, may be affixed torotary drill bit 70. As best shown inFIG. 15 , a plurality ofPDCs 86 are secured to theblades 74. For example, eachPDC 86 may include a polycrystalline diamond table 88 bonded to asubstrate 90. More generally, thePDCs 86 may comprise any PDC disclosed herein, without limitation. In addition, if desired, in some embodiments of the present invention, a number of thePDCs 86 may be conventional in construction. Also, circumferentiallyadjacent blades 74 define so-calledjunk slots 82 therebetween, as known in the art. Additionally, therotary drill bit 70 includes a plurality ofnozzle cavities 84 for communicating drilling fluid from the interior of therotary drill bit 70 to thePDCs 86. -
FIGS. 14 and 15 merely depict one embodiment of a rotary drill bit that employs at least one cutting element that comprises a PDC fabricated and structured in accordance with the disclosed embodiments, without limitation. Therotary drill bit 70 is used to represent any number of earth-boring tools or drilling tools, including, for example, core bits, roller-cone bits, fixed-cutter bits, eccentric bits, bicenter bits, reamers, reamer wings, or any other downhole tool including PDCs, without limitation. - The PDCs disclosed herein may also be utilized in applications other than cutting technology. The disclosed PDC embodiments may be used in wire dies, bearings, artificial joints, inserts, cutting elements, and heat sinks. Thus, any of the PDCs disclosed herein may be employed in an article of manufacture including at least one superabrasive element or compact.
- Thus, the embodiments of PDCs disclosed herein may be used on any apparatus or structure in which at least one conventional PDC is typically used. For example, in one embodiment of the present invention, a rotor and a stator (i.e., a thrust bearing apparatus) may each include a PDC according to any of the embodiments disclosed herein and may be operably assembled to a downhole drilling assembly. U.S. Pat. Nos. 4,410,054; 4,560,014; 5,364,192; 5,368,398; and 5,480,233, the disclosure of each of which is incorporated herein, in its entirety, by this reference, disclose subterranean drilling systems within which bearing apparatuses utilizing PDCs disclosed herein may be incorporated. The embodiments of PDCs disclosed herein may also form all or part of heat sinks, wire dies, bearing elements, cutting elements, cutting inserts (e.g., on a roller cone type drill bit), machining inserts, or any other article of manufacture as known in the art. Other examples of articles of manufacture that may use any of the PDCs disclosed herein are disclosed in U.S. Pat. Nos. 4,811,801; 4,268,276; 4,468,138; 4,738,322; 4,913,247; 5,016,718; 5,092,687; 5,120,327; 5,135,061; 5,154,245; 5,460,233; 5,544,713; and 6,793,681, the disclosure of each of which is incorporated herein, in its entirety, by this reference.
- The following working examples of the present invention set forth various formulations for forming PDCs. The following working examples provide further detail in connection with the specific embodiments described above.
- A conventional PDC was formed from a mixture of diamond particles having an average grain size of about 18 μm. The mixture was placed adjacent to a cobalt-cemented tungsten carbide substrate. The mixture and substrate were placed in a niobium can and HPHT sintered at a temperature of about 1400° Celsius and a pressure of about 5 GPa to about 8 GPa for about 90 seconds to form the conventional PDC. The conventional PDC was acid-leached to a depth of about 70 μm to remove substantially all of the cobalt from a region of the polycrystalline diamond table. The thickness of the polycrystalline diamond table of the PDC was 0.090 inches and a 0.012 inch chamfer was machined in the polycrystalline diamond table. The thermal stability of the conventional PDC so-formed was evaluated by measuring the distance cut in a Sierra White granite workpiece prior to failure without using coolant in a vertical turret lathe test. The distance cut is considered representative of the thermal stability of the PDC. The conventional PDC was able to cut a distance of about only 2000 linear feet in the workpiece prior to failure. Evidence of failure of the conventional PDC is best shown in
FIG. 16 where the measured temperature of the conventional PDC during cutting increased dramatically at around about 2000 linear feet and inFIG. 17 where the normal force required to continue cutting also increased dramatically at around about 2000 linear feet. - A PDC was formed by first fabricating a leached polycrystalline diamond body. The leached polycrystalline diamond body was formed by HPHT sintering diamond particles having an average grain size of about 18 μm in the presence of cobalt. The sintered-polycrystalline-diamond body included cobalt within the interstitial regions between bonded diamond grains. The sintered-polycrystalline-diamond body was leached using a solution of 90% nitric acid/10% de-ionized water for a time sufficient to remove substantially all of the cobalt from the interstitial regions to form the leached polycrystalline diamond body. The leached polycrystalline diamond body was placed adjacent to a cobalt-cemented tungsten carbide substrate. A green layer of silicon particles was placed adjacent to the leached polycrystalline diamond body on a side thereof opposite the cobalt-cemented tungsten carbide substrate. The leached polycrystalline diamond body, cobalt-cemented tungsten carbide substrate, and green layer of silicon particles were placed within a niobium can, and HPHT sintered at a temperature of about 1400° Celsius and a pressure of about 5 GPa to about 7 GPa for about 60 seconds to form a PDC that exhibited a similar multi-region diamond table as the polycrystalline diamond table 15 shown in
FIGS. 2A and 2B , with silicon carbide formed in a portion of the interstitial regions between the bonded diamond grains. The thickness of the polycrystalline diamond table was about 0.090 inches and a chamfer of about 0.01065 inch was machined in the polycrystalline diamond table. - The thermal stability of the PDC of example 2 was evaluated by measuring the distance cut in a Sierra White granite workpiece without using coolant in a vertical turret lathe test. The PDC of example 2 was able to cut a distance of over 14000 linear feet in a granite workpiece without failing and without using coolant. This is best shown in
FIGS. 16 and 17 where the measured temperature (FIG. 16 ) of the PDC of example 2 during cutting of the workpiece and the normal force required to continue cutting the workpiece (FIG. 17 ) does not increase dramatically as occurred with the conventional PDC of comparative example 1 during cutting. Therefore, thermal stability tests indicate that the PDC of example 2 exhibited a significantly improved thermal stability compared to the conventional PDC of comparative example 1. - The wear resistance of the PDCs of comparative example 1 and example 2 were evaluated by measuring the volume of the PDC removed versus the volume of a Sierra White granite workpiece removed in a vertical turret lathe with water used as a coolant. As shown in
FIG. 18 , the wearflat volume tests indicated that the PDC of example 2 exhibited a slightly decreased wear resistance compared to the wear resistance of the PDC of comparative example 1. However, the wear resistance of the PDC of example 2 is still more than sufficient to function as a PDC for subterranean drilling applications. Drop-weight tests also indicated that a PDC fabricated according to example 2 exhibits an impact resistance similar to a conventionally fabricated PDC, such as the comparative example 1. Therefore, the PDC of example 2 exhibited a significantly superior thermal stability compared to the conventional PDC of comparative example 1 without significantly compromising wear resistance and impact resistance. - Although the present invention has been disclosed and described by way of some embodiments, it is apparent to those skilled in the art that several modifications to the described embodiments, as well as other embodiments of the present invention are possible without departing from the spirit and scope of the present invention. Additionally, the words “including” and “having,” as used herein, including the claims, shall be open ended and have the same meaning as the word “comprising.”
Claims (26)
1. A method of fabricating a polycrystalline diamond compact, comprising:
positioning an at least partially porous polycrystalline diamond body between a silicon-containing material and a substrate, wherein the at least partially porous polycrystalline diamond body exhibits an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the at least one peripheral surface;
subjecting the at least partially porous polycrystalline diamond body, the silicon-containing material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with silicon from the silicon-containing material.
2. The method of claim 1 wherein the substrate includes a metallic infiltrant, and wherein subjecting the at least partially porous polycrystalline diamond body, the silicon-containing material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with silicon from the silicon-containing material includes infiltrating a bonding region of the at least partially porous polycrystalline diamond body adjacent to the substrate with the metallic infiltrant.
3. The method of claim 1 wherein the first region extends inwardly to about the same depth from the upper surface as from the chamfer.
4. The method of claim 1 wherein the first region of the at least partially porous polycrystalline diamond body extends along only a selected portion of the upper surface.
5. The method of claim 1 wherein the silicon-containing material only covers a selected portion of the upper surface of the at least partially porous polycrystalline diamond body.
6. The method of claim 1 , further comprising masking a selected portion of the upper surface of the at least partially porous polycrystalline diamond body from the silicon-containing material.
7. The method of claim 1 wherein the at least partially porous polycrystalline diamond body exhibits an average grain diamond size of 20 μm or less.
8. The method of claim 1 wherein the at least partially porous polycrystalline diamond body includes tungsten carbide.
9. The method of claim 1 wherein the at least partially porous polycrystalline diamond body exhibits an average grain diamond size of 20 μm or less and includes tungsten carbide.
10. A method of fabricating a polycrystalline diamond compact, comprising:
positioning an at least partially porous polycrystalline diamond body between a first infiltrant material and a substrate including a metallic second infiltrant that is different than the first infiltrant material, wherein the at least partially porous polycrystalline diamond body exhibits an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the at least one peripheral surface;
subjecting the at least partially porous polycrystalline diamond body, the first infiltrant material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with material from the first infiltrant material.
11. The method of claim 10 wherein subjecting the at least partially porous polycrystalline diamond body, the first infiltrant material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with the material from the first infiltrant material includes infiltrating a bonding region of the at least partially porous polycrystalline diamond body adjacent to the substrate with the metallic second infiltrant.
12. The method of claim 10 wherein the first region extends inwardly to about the same depth from the upper surface as from the chamfer.
13. The method of claim 10 wherein the first region of the at least partially porous polycrystalline diamond body extends along only a selected portion of the upper surface.
14. The method of claim 10 wherein the first infiltrant material only covers a selected portion of the upper surface of the at least partially porous polycrystalline diamond body.
15. The method of claim 10 wherein the at least partially porous polycrystalline diamond body exhibits an average grain diamond size of 20 μm or less.
16. The method of claim 10 wherein the at least partially porous polycrystalline diamond body exhibits an average grain diamond size of 20 μm or less and includes tungsten carbide.
17. The method of claim 10 wherein the first infiltrant material includes a silicon-containing material.
18. The method of claim 10 wherein the metallic second infiltrant includes at least one of cobalt, iron, or nickel.
19. A method of fabricating a polycrystalline diamond compact, comprising:
positioning an at least partially porous polycrystalline diamond body between a first infiltrant material and a metallic second infiltrant having a composition different than the first infiltrant material, wherein the at least partially porous polycrystalline diamond body exhibits an upper surface, at least one peripheral surface, and a chamfer extending between the upper surface and the at least one peripheral surface;
subjecting the at least partially porous polycrystalline diamond body, the first infiltrant material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region that extends inwardly from the upper surface and the chamfer with material from the first infiltrant material.
20. The method of claim 19 wherein the first infiltrant material includes a silicon-containing material, wherein the metallic second infiltrant is included in a substrate, and wherein the metallic second infiltrant includes at least one of cobalt, iron, or nickel.
21. A method of fabricating a polycrystalline diamond compact, comprising:
positioning an at least partially porous polycrystalline diamond body between a silicon-containing material and a substrate that is adjacent to a metal-solvent catalyst, wherein the at least partially porous polycrystalline diamond body exhibits an upper surface and at least one peripheral surface, wherein the silicon-containing material extends over only a portion of the upper surface and/or at least a portion of the at least one peripheral surface;
subjecting the at least partially porous polycrystalline diamond body, the silicon-containing material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region of the at least partially porous polycrystalline body that extends along only a portion of the upper surface thereof.
22. The method of claim 21 wherein the substrate includes a metallic infiltrant; and wherein subjecting the at least partially porous polycrystalline diamond body, the silicon-containing material, and the substrate to a high-pressure, high-temperature process to infiltrate a first region of the at least partially porous polycrystalline body that extends along only a portion of the upper surface thereof includes infiltrating a bonding region of the at least partially porous polycrystalline diamond body adjacent to the substrate with the metallic infiltrant.
23. The method of claim 21 wherein the first region is configured as an annular region.
24. The method of claim 21 , further comprising masking a selected portion of the upper surface of the at least partially porous polycrystalline body from the silicon-containing material.
25. The method of claim 21 wherein the silicon-containing material includes a plurality of discrete portions that cover only the portion of the upper surface of the at least partially porous polycrystalline diamond body.
26. The method of claim 21 wherein the silicon-containing material extends about the at least a portion of the at least one peripheral surface of the at least partially porous polycrystalline diamond body.
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