Polycrystalline diamond compact with gradient interfacial layer

Patent metadata

Field	Value
Publication number	US-2018087134-A1
Application number	US-201515562020-A
Country	US
Kind code	A1
Filing date	Apr 28, 2015
Priority date	Apr 28, 2015
Publication date	Mar 29, 2018
Grant date	—

Abstract

The present disclosure relates to a polycrystalline diamond compact (PDC) including a gradient interfacial layer between a thermally stable diamond (TSP) table and a base, such as a substrate or an earth-boring drill bit body. The gradient interfacial layer has a gradient of coefficients of thermal expansion between that of the diamond and the base. The disclosure also relates to methods of forming a gradient interfacial layer and a PDC containing such a layer.

First claim

What is claimed is:

1 . A method of forming a polycrystalline diamond compact (PDC), the method comprising:
forming a gradient interfacial layer having a gradient of coefficients of thermal expansion (CTEs) ranging between the CTE of a thermally stable diamond (TSP) table and the CTE of a base by forming a plurality of sublayers, at least two of which have different CTEs, and attaching the plurality of sublayers to one another; attaching the gradient interfacial layer to the TSP table; and attaching the gradient interfacial layer to the base.

2 . The method of claim 1 , wherein the gradient of coefficients of thermal expansion forms a CTE profile, which may be linear, non-linear, or sigmoidal.

3 . The method of claim 2 , wherein the CTE profile is non-linear and is step-wise by sublayer.

4 . The method of claim 1 , wherein each sublayer of the gradient interfacial layer, at least at a time of initial formation, comprises diamond grains, a catalyst, and a sacrificial binder.

5 . The method of claim 4 , wherein the sublayer is subjected to a high temperature high pressure (HTHP) process after initial formation to form a sintered sublayer.

6 . The method of claim 5 , wherein the sintered sublayer comprises diamond grains and catalyst.

7 . The method of claim 5 , wherein the sintered sublayer is leached to remove at least a portion of the catalyst from at least a portion of the sublayer.

8 . The method of claim 4 , wherein at least one sublayer is formed using additive manufacturing method.

9 . The method of claim 8 , wherein the additive manufacturing method comprises three dimensional (3D) printing.

10 . The method of claim 1 , wherein attaching the gradient interfacial layer to the TSP table or attaching the gradient interfacial layer to the base includes performing a high temperature high pressure (HTHP) process.

11 . The method of claim 1 , wherein forming the gradient interfacial layer and attaching the gradient interfacial layer to the base occur in the same step.

12 . A polycrystalline diamond compact (PDC) comprising:
a thermally stable diamond (TSP) table having a TSP coefficient of thermal expansion (CTE); a base having a base CTE; and a gradient interfacial layer bonded to the TSP and the base, the gradient interfacial layer having a CTE gradient between the TSP CTE and the base CTE.

13 . The PDC of claim 12 , wherein the base comprises a substrate and the PDC comprises a cutter for an earth-boring drill bit.

14 . The PDC of claim 12 , wherein the base comprises a cemented carbide.

15 . The PDC of claim 12 , wherein the gradient interfacial layer comprises a plurality of sublayers.

16 . The PDC of claim 12 , wherein the proportion of diamond grains in the gradient interfacial layer decreases as CTE increases.

17 . The PDC of claim 12 , wherein the CTE gradient forms a CTE profile, which may be linear, non-linear, or sigmoidal.

18 . An earth-boring drill bit comprising:
a bit body; and a polycrystalline diamond compact (PDC) comprising:
a thermally stable diamond (TSP) table having a TSP coefficient of thermal expansion (CTE);
a base having a base CTE; and
a gradient interfacial layer bonded to the TSP and the base, the gradient interfacial layer having a CTE gradient between the TSP CTE and the base CTE.

19 . The earth-boring drill bit of claim 18 , wherein the PDC comprises a PDC cutter coupled to the bit body.

20 . The earth-boring drill but of claim 18 , wherein the bit body comprises the base.

Assignees

• Halliburton Energy Services Inc

Inventors

• Chang Andy Cheng
• Saini Gagan
• Liang Qi
• Lively Paul B
• Atkins William Brian

Classifications

• E21C35/1835

  Chemical composition or specific material · CPC title

• B22F2207/11

  Gradients other than composition gradients, e.g. size gradients · CPC title

• C22C2204/00

  End product comprising different layers, coatings or parts of cermet · CPC title

• B22F3/14

  simultaneously · CPC title

• C22C26/00 Primary

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title