Polycrystalline diamond compact including crack-resistant polycrystalline diamond table

Patent metadata

Field	Value
Publication number	US-10022840-B1
Application number	US-201414515768-A
Country	US
Kind code	B1
Filing date	Oct 16, 2014
Priority date	Oct 16, 2013
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a substrate and a polycrystalline diamond (“PCD”) table mounted to the substrate. The PCD table includes an upper surface and one or more recesses extending inwardly from the upper surface of the PCD table. The one or more recesses may help prevent, stop, or limit crack propagation and may redistribute, breakup, or relieve stresses in the PCD table. In some embodiments, the one or more recesses exhibit, in plain view, a generally rectangular geometry, a generally circular geometry, or a generally triangular geometry. In some embodiments, the PCD table includes one or more channels that extend from a vertex of the one or more recesses. In some embodiments, the one or more channels and the one or more recesses may be at least partially filled with a sacrificial material. Methods for forming such PDCs are also discussed.

First claim

What is claimed is:

1. A polycrystalline diamond compact, comprising:
a substrate; and
a polycrystalline diamond table bonded to the substrate, the polycrystalline diamond table including a plurality of diamond grains bonded together that define a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one catalyst disposed therein, the polycrystalline diamond table including an upper surface including one or more recesses extending inwardly therefrom to a selected depth, the one or more recesses at least partially filled with one or more sacrificial materials, wherein the one or more sacrificial materials are substantially free of the at least one catalyst;
wherein the one or more sacrificial materials include a plurality of stacked discs, at least some of the plurality of stacked discs exhibiting different lateral dimensions.

2. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table includes one or more channels extending from the one or more recesses.

3. The polycrystalline diamond compact of claim 2 , wherein the one or more channels extend from a vertex of the one or more recesses.

4. The polycrystalline diamond compact of claim 1 , wherein the selected depth that the one or more recesses extends is approximately a thickness of the polycrystalline diamond table.

5. The polycrystalline diamond compact of claim 1 , wherein the selected depth that the one or more recesses extend is less than a thickness of the polycrystalline diamond table.

6. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses is located off center on the polycrystalline diamond table.

7. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses exhibit, in plan view, a generally rectangular geometry, a generally circular geometry, a generally triangular geometry, or a generally star-shaped geometry.

8. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses include at least one sidewall, the at least one sidewall exhibiting a generally stepped-type geometry, a generally vertical geometry, a generally tapered geometry or a generally curved geometry.

9. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses includes an annular recess.

10. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses form a network of recesses that separate a plurality of protrusions.

11. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses exhibit a decreasing diameter with increasing distance from the substrate.

12. The polycrystalline diamond compact of claim 1 , wherein the substrate includes a non-planar interface and the polycrystalline diamond table exhibits a geometry that generally contours the non-planar interface of the substrate.

13. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses exhibit a geometry that functions to preferentially initiate crack propagation at selected regions of the polycrystalline diamond table.

14. The polycrystalline diamond compact of claim 1 , wherein the one or more sacrificial materials include at least one of one or more refractory metal materials, or one or more ceramics.

15. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table is leached to remove at least one infiltrant material from a portion thereof.

16. The polycrystalline diamond compact of claim 1 , wherein the one or more recesses comprise about 30% to about 45% by volume of the polycrystalline diamond table.

17. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table includes a plurality of diamond grains that are directly bonded to each other to define a plurality of interstitial regions therebetween, wherein at least some of the one or more sacrificial materials at least partially occupy at least some of the plurality of interstitial regions.

18. The polycrystalline diamond compact of claim 1 , wherein the upper surface forms a substantially planar surface.

19. The polycrystalline diamond compact of claim 16 , wherein the one or more sacrificial materials substantially completely fills the one or more recesses.

20. A polycrystalline diamond compact, comprising:
a substrate; and
a polycrystalline diamond table bonded to the substrate, the polycrystalline diamond table including a plurality of diamond grains bonded together that define a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one catalyst disposed therein, the polycrystalline diamond table including an upper surface and one or more sacrificial materials that are substantially free of the at least one catalyst, the one or more sacrificial materials defining one or more recesses and one or more channels extending from at least one of the one or more recesses, the one or more recesses and the one or more channels comprise about 30% to about 80% by volume of the polycrystalline diamond table;
wherein the one or more sacrificial materials include a plurality of stacked discs, at least some of the plurality of stacked discs exhibiting different lateral dimensions.

21. The polycrystalline diamond compact of claim 20 , wherein the one or more recesses and the one or more channels comprise about 30% to about 45% by volume of the polycrystalline diamond table.

22. The polycrystalline diamond compact of claim 1 , wherein the one or more sacrificial materials consist essentially of one or more refractory metal materials.

23. The polycrystalline diamond compact of claim 1 , wherein the one or more sacrificial materials consist essentially of one or more ceramics.

24. The polycrystalline diamond compact of claim 23 , wherein the one or more ceramics include hexagonal boron nitride, silicon carbide, aluminum oxide, or combinations thereof.

25. The polycrystalline diamond compact of claim 1 , wherein at least one of the one or more recesses includes at least one surface exhibiting a stepped geometry.

26. The polycrystalline diamond compact of claim 1 , wherein the plurality of stacked discs form a solid body.

27. The polycrystalline diamond compact of claim 1 , wherein the different lateral dimensions are different diameters.

28. A polycrystalline diamond compact, comprising:
a substrate; and
a polycrystalline diamond table bonded to the substrate, the polycrystalline diamond table including a plurality of diamond grains bonded together that define a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one catalyst disposed therein, the polycrystalline diamond table further including an upper surface including one or more recesses extending inwardly therefrom to a selected depth, the one or more recesses at least partially filled with one or more sacrificial materials;
wherein the one or more sacrificial materials are substantially free of the at least one catalyst;
wherein the one or more recesses exhibit a decreasing diameter with increasing distance from the substrate.

Assignees

• Us Synthetic Corp

Inventors

• Miess David P

Classifications

• E21B10/5735

  Interface between the substrate and the cutting element · CPC title

• B24D99/005

  Segments of abrasive wheels · CPC title

• B24D3/00 Primary

  Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• E21B10/567

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title