Polycrystalline diamond elements and systems and methods for fabricating the same

Patent metadata

Field	Value
Publication number	US-10900291-B2
Application number	US-201816133643-A
Country	US
Kind code	B2
Filing date	Sep 17, 2018
Priority date	Sep 18, 2017
Publication date	Jan 26, 2021
Grant date	Jan 26, 2021

Abstract

Polycrystalline diamond includes a working surface and a peripheral surface extending around an outer periphery of the working surface. The polycrystalline diamond includes a first volume including an interstitial material and a second volume having a leached region that includes boron and titanium. A method of fabricating a polycrystalline diamond element includes positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material that includes a group 13 element, and positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of material including the group 13 element than the first volume of diamond particles. Various other articles, assemblies, and methods are also disclosed.

First claim

What is claimed is:

1. Polycrystalline diamond, comprising:
polycrystalline diamond having a working surface and a peripheral surface extending around an outer periphery of the working surface, the polycrystalline diamond comprising:
a first volume comprising an interstitial material; and
a second volume comprising a leached region that comprises boron and titanium, wherein the second volume is disposed between the working surface and the first volume.

2. The polycrystalline diamond of claim 1 , wherein the leached region further comprises a compound comprising two or more of boron, titanium, cobalt, molybdenum, and tungsten.

3. The polycrystalline diamond of claim 2 , wherein the compound in the leached region comprises at least one of a tungsten-cobalt compound, a titanium-cobalt compound, a cobalt-boron compound, a tungsten-cobalt-boron compound, or a titanium-cobalt-boron compound.

4. The polycrystalline diamond of claim 2 , wherein the compound includes the tungsten, and wherein the tungsten comprises an intermetallic compound.

5. The polycrystalline diamond of claim 1 , wherein the leached region comprises non-elemental cobalt.

6. The polycrystalline diamond of claim 1 , wherein at least one of the boron or the titanium in the leached region is located at at least one of the working surface or the peripheral surface.

7. The polycrystalline diamond of claim 1 , wherein the interstitial material of the first volume comprises at least one of boron, titanium, copper, chromium, molybdenum, cobalt, or tungsten.

8. The polycrystalline diamond of claim 1 , wherein the leached region is electrically conductive.

9. The polycrystalline diamond of claim 1 , wherein the leached region exhibits an electrical surface conductivity of at least approximately 700 S/m.

10. The polycrystalline diamond of claim 1 , further comprising a concave boundary between the second volume and the first volume.

11. The polycrystalline diamond of claim 1 , further comprising an arcuate boundary between the second volume and the first volume.

12. The polycrystalline diamond of claim 1 , wherein a portion of the second volume is defined by at least a portion of at least one of the working surface or the peripheral surface.

13. The polycrystalline diamond of claim 1 , wherein the second volume defines at least a portion of the working surface.

14. The polycrystalline diamond of claim 1 , further comprising an arcuate boundary between the leached region and an unleached region, wherein the unleached region is disposed between the first volume and the leached region.

15. The polycrystalline diamond of claim 14 , wherein the arcuate boundary between the leached region and the unleached region generally follows a boundary between the unleached region and the first volume.

16. A method of fabricating a polycrystalline diamond element, the method comprising:
providing the polycrystalline diamond of claim 1 comprising diamond particles;
positioning the first volume of the diamond particles adjacent to a substrate, the first volume of diamond particles including a material comprising a group 13 element;
positioning the second volume of the diamond particles of the polycrystalline diamond adjacent to the first volume of the diamond particles such that the first volume of the diamond particles is disposed between the second volume of the diamond particles and the substrate, the second volume of the diamond particles having a lower concentration of the material comprising the group 13 element than the first volume of the diamond particles;
enclosing the substrate, the first volume of the diamond particles, and the second volume of the diamond particles in a pressure transmitting medium to form a cell assembly; and
subjecting the cell assembly to a high-pressure/high-temperature process to form a polycrystalline diamond table coupled to the substrate.

17. Polycrystalline diamond, comprising:
a working surface;
a peripheral surface extending around an outer periphery of the working surface;
a first volume comprising an interstitial material; and
a second volume comprising a leached region that comprises boron and titanium, wherein the interstitial material of the first volume comprises at least one of boron, titanium, copper, chromium, molybdenum, cobalt, or tungsten, and wherein concentration of at least one of the boron or the titanium in the second volume increases along a direction from a portion of the second volume adjacent the first volume toward the working surface of the polycrystalline diamond.

18. Polycrystalline diamond, comprising:
a working surface;
a peripheral surface extending around an outer periphery of the working surface;
a first volume comprising an interstitial material; and
a second volume comprising a leached region that comprises boron and titanium, wherein the interstitial material of the first volume comprises at least one of BCo, BCo 2 , B 2 Co 3 , Co 2 B, Co 23 B 6 , Co 3 Ti, TiCo 2 , CoW 2 B 2 , Co 21 W 2 B 6 , WC, or TiC.

19. Polycrystalline diamond, comprising:
a working surface;
a peripheral surface extending around an outer periphery of the working surface;
a first volume comprising an interstitial material;
a second volume comprising a leached region that comprises one or more group 13 elements; and
a boundary comprising one of:
an arcuate boundary between the leached region and an unleached region, wherein the unleached region is disposed between the first volume and the leached region;
a concave boundary between the second volume and the first volume; or
an arcuate boundary between the second volume and the first volume.

20. The polycrystalline diamond of claim 19 , wherein the arcuate boundary between the leached region and the unleached region generally follows a boundary between the unleached region and the first volume.

21. The polycrystalline diamond of claim 19 , wherein the second volume at least partially defines the working surface at a location opposing the first volume.

Assignees

• Us Synthetic Corp

Inventors

• Heaton Daren Nathaniel
• Lynn Jeremy Brett

Classifications

• E21B10/5673

  having a non planar or non circular cutting face · CPC title

• C23F1/28

  for etching iron group metals · CPC title

• C23F1/02

  Local etching · CPC title

• E21B10/52

  with chisel- or button-type inserts · CPC title

• E21B10/5676

  having a cutting face with different segments, e.g. mosaic-type inserts · CPC title