Superabrasive elements

Patent metadata

Field	Value
Publication number	US-2016318154-A1
Application number	US-201514635744-A
Country	US
Kind code	A1
Filing date	Mar 2, 2015
Priority date	Feb 20, 2009
Publication date	Nov 3, 2016
Grant date	—

Abstract

Embodiments of the invention relate to thermally-stable polycrystalline diamond (“PCD”) elements, polycrystalline diamond compacts (“PDCs”), and methods of fabricating such PCD elements and PDCs. In an embodiment, a method of fabricating a thermally-stable PCD element includes providing an at least partially leached PCD body including a plurality of interstitial regions, and infiltrating at least a portion of the interstitial regions of the at least partially leached PCD body with at least a portion of an infiltrant material. The infiltrant material may include at least one member chosen from the group of glass, silicone, and a ceramic having a negative coefficient of thermal expansion.

First claim

What is claimed is:

1 . A superabrasive element, comprising:
a plurality of bonded superabrasive grains defining a plurality of interstitial regions; at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a coefficient of thermal expansion less than that of cobalt; and a catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions.

2 . The superabrasive element of claim 1 wherein the at least one material includes one or more of a ceramic having a negative coefficient of thermal expansion, glass, or silicone.

3 . The superabrasive element of claim 1 wherein the at least one material includes glass, and further wherein the glass includes at least one member selected from the group consisting of a silicate, a borate, and a borosilicate.

4 . The superabrasive element of claim 1 wherein the at least one material includes silicone.

5 . The superabrasive element of claim 1 wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion, and further wherein the ceramic includes at least one member selected from zirconium tungstate, beta spodumene, and beta eucryptite.

6 . The superabrasive element of claim 1 wherein the catalyst includes iron, cobalt, nickel, or alloys thereof.

7 . The superabrasive element of claim 1 wherein the catalyst includes a cobalt alloy.

8 . The superabrasive element of claim 1 wherein the plurality of bonded superabrasive grains include a plurality of bonded diamond grains.

9 . The superabrasive element of claim 1 wherein the at least one material exhibits a negative coefficient of thermal expansion over a temperature range from about −272° C. to about 775° C.

10 . The superabrasive element of claim 1 wherein the plurality of bonded superabrasive grains is at least partially leached of the catalyst.

11 . A superabrasive compact, comprising:
a superabrasive element including:
a working surface;
an interfacial surface;
a side surface extending between the working surface and the interfacial surface;
a plurality of bonded superabrasive grains defining a plurality of interstitial regions;
at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a coefficient of thermal expansion less than that of cobalt;
a catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions; and
a substrate bonded to the interfacial surface of the superabrasive element.

12 . The superabrasive compact of claim 10 wherein the at least one material includes one or more of a ceramic having a negative coefficient of thermal expansion, glass, or silicone.

13 . The superabrasive compact of claim 10 wherein the at least one material includes glass, and further wherein the glass includes at least one member selected from the group consisting of a silicate, a borate, and a borosilicate.

14 . The superabrasive compact of claim 10 wherein the at least one material includes silicone.

15 . The superabrasive compact of claim 10 wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion, and further wherein the ceramic includes at least one member selected from zirconium tungstate, beta spodumene, and beta eucryptite.

16 . The superabrasive compact of claim 10 wherein the catalyst includes iron, cobalt, nickel, or alloys thereof.

17 . The superabrasive compact of claim 10 wherein the catalyst includes a cobalt alloy.

18 . The superabrasive compact of claim 10 wherein the plurality of bonded superabrasive grains include a plurality of bonded diamond grains.

19 . The superabrasive compact of claim 10 wherein the at least one material exhibits a negative coefficient of thermal expansion over a temperature range from about −272° C. to about 775° C.

20 . The superabrasive compact of claim 10 wherein the superabrasive element is at least partially leached of the catalyst.

21 . The superabrasive compact of claim 10 wherein the at least one material is an infiltrant.

22 . A superabrasive element, comprising:
a plurality of bonded diamond grains defining a plurality of interstitial regions; at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a negative coefficient of thermal expansion; and a cobalt alloy catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions.

23 . The superabrasive element of claim 22 wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion.

24 . The superabrasive element of claim 22 wherein the cobalt alloy includes a cobalt-iron alloy.

25 . The superabrasive element of claim 22 wherein the at least one material is an infiltrant.

Assignees

• Us Synthetic Corp

Inventors

• Miess David P
• Cooley Craig H

Classifications

• B24D3/06 Primary

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• B24D3/14

  ceramic, i.e. vitrified bondings · CPC title

• C04B35/52

  based on carbon, e.g. graphite · CPC title

• C04B35/645

  Pressure sintering · CPC title