Polycrystalline diamond cutters having non-catalytic material addition and methods of making the same

Patent metadata

Field	Value
Publication number	US-2017175453-A1
Application number	US-201615379883-A
Country	US
Kind code	A1
Filing date	Dec 15, 2016
Priority date	Dec 16, 2015
Publication date	Jun 22, 2017
Grant date	—

Abstract

Polycrystalline diamond cutters for rotary drill bits and methods of making the same are disclosed. A polycrystalline diamond compact includes a polycrystalline diamond body having a working surface, an interface surface, and a perimeter surface. The polycrystalline diamond compact also includes a substrate bonded to the polycrystalline diamond body along the interface surface. A non-diamond volume fraction of the polycrystalline diamond body is greater at the interface surface than at the working surface.

First claim

What is claimed is:

1 . A polycrystalline diamond compact, comprising:
a polycrystalline diamond body comprising a working surface, an interface surface, and a perimeter surface; a substrate bonded to the polycrystalline diamond body along the interface surface, wherein a non-diamond volume fraction of the polycrystalline diamond body is greater at the interface surface than at the working surface.

2 . The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond body exhibits a concentration of non-catalytic material that is lower at the working surface than at the interface surface.

3 . The polycrystalline diamond compact of claim 2 , wherein the substrate is free of the non-catalytic material.

4 . The polycrystalline diamond compact of claim 2 , wherein the non-catalytic material is selected from the group consisting of bismuth, indium, lead, lithium, magnesium, tellurium, thallium and alloys, nitrides, carbides and carbonitrides thereof.

5 . The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond body comprises a uniform particle size distribution of inter-bonded diamond particles.

6 . The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond body comprises voids between inter-bonded diamond grains, wherein the voids have larger volumes at the interface surface than at the working surface.

7 . The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond body comprises voids between inter-bonded diamond grains, wherein the interface surface exhibits a greater quantity of voids than the working surface.

8 . A polycrystalline diamond compact, comprising:
a polycrystalline diamond body comprising a working surface, an interface surface, and a perimeter surface; a substrate bonded to the polycrystalline diamond body along the interface surface, wherein the polycrystalline diamond body exhibits a concentration of non-catalytic material that is lower at the working surface than at the interface surface.

9 . The polycrystalline diamond compact of claim 8 , wherein the substrate is free of the non-catalytic material.

10 . The polycrystalline diamond compact of claim 8 , wherein the non-catalytic material is selected from the group consisting of bismuth, indium, lead, lithium, magnesium, tellurium, thallium and alloys, nitrides, carbides and carbonitrides thereof.

11 . The polycrystalline diamond compact of claim 8 , wherein the polycrystalline diamond body comprises a uniform particle size distribution of inter-bonded diamond particles.

12 . The polycrystalline diamond compact of claim 8 , wherein the polycrystalline diamond body and the substrate each comprise a catalytic material, wherein the non-catalytic material has less than about 3 at. % solubility in the catalyst material.

13 . The polycrystalline diamond compact of claim 8 , wherein catalytic material from the substrate bonds the polycrystalline diamond body to the substrate.

14 . A method of producing a polycrystalline diamond compact, comprising:
assembling a formation cell assembly comprising:
diamond particles positioned within a cup;
a first substrate comprising a catalytic material, the first substrate positioned proximate to the diamond particles; and
pressure transferring medium surrounding the cup and the first substrate;
subjecting the formation cell assembly and its contents to a first high pressure high temperature process to sinter the diamond particles in inter-diamond bonds and to form a polycrystalline diamond composite comprising a polycrystalline diamond body that is bonded to the first substrate, wherein the polycrystalline diamond composite comprises an intermediate-step interface surface positioned proximate to the first substrate and an intermediate-step working surface positioned distally from the first substrate; removing substantially all of the first support substrate from the polycrystalline diamond body; leaching at least a portion of accessible catalytic material from the polycrystalline diamond body; positioning the polycrystalline diamond body such that the intermediate-step working surface is positioned proximate to a second substrate; and subjecting the polycrystalline diamond body and the second substrate to a second high pressure high temperature process to bond the polycrystalline diamond body to the second substrate along an interface surface.

15 . The method of claim 14 , wherein the polycrystalline diamond body is inverted with respect to the second substrate as compared to the first substrate.

16 . The method of claim 14 , wherein a non-diamond volume fraction of the polycrystalline diamond body is greater at the interface surface than at the working surface.

17 . The method of claim 14 , wherein the polycrystalline diamond body comprises voids between inter-bonded diamond grains, wherein the voids have larger volumes at the interface surface than at the working surface.

18 . The method of claim 14 , wherein the polycrystalline diamond body comprises voids between inter-bonded diamond grains, wherein the interface surface exhibits a greater quantity of voids than the working surface.

19 . The method of claim 14 , further comprising the combining diamond particles with a non-catalytic material to distribute the non-catalytic material with the diamond particles.

20 . The method of claim 19 , wherein the polycrystalline diamond body exhibits a concentration of non-catalytic material that is lower at the working surface than at the interface surface.

21 . The method of claim 19 , wherein the second substrate is free of the non-catalytic material.

22 . The method of claim 19 , wherein the non-catalytic material is selected from the group consisting of bismuth, indium, lead, lithium, magnesium, tellurium, thallium and alloys, nitrides, carbides and carbonitrides thereof.

Assignees

• Diamond Innovations Inc

Inventors

• Zhang Kai

Classifications

• B22F3/14 Primary

  simultaneously · CPC title

• C04B2235/3852

  Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride · CPC title

• C04B2235/401

  Alkaline earth metals · CPC title

• E21B10/5735 Primary

  Interface between the substrate and the cutting element · CPC title

• C04B2235/3856

  Carbonitrides, e.g. titanium carbonitride, zirconium carbonitride · CPC title