Positive relief forming of polycrystalline diamond structures and resulting cutting tools

Patent metadata

Field	Value
Publication number	US-9533398-B2
Application number	US-201414463587-A
Country	US
Kind code	B2
Filing date	Aug 19, 2014
Priority date	Aug 19, 2014
Publication date	Jan 3, 2017
Grant date	Jan 3, 2017

Abstract

Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.

First claim

What is claimed is:

1. A method of making a polycrystalline diamond (“PCD”) structure, the method comprising:
providing a substrate having a surface;
positioning at least one diamond material flute volume including at least one diamond material tube including diamond particles, the at least one diamond material tube in contact with a portion of the surface of the substrate; and
subjecting the substrate and the at least one diamond material flute volume to a high-pressure/high-temperature (“HPHT”) process effective to sinter the diamond particles to form a PCD flute volume and bond the PCD flute volume.

2. The method of claim 1 , wherein the at least one diamond material tube includes a cobalt-containing tube.

3. The method of claim 1 , further comprising attaching at least one portion of the PCD flute volume to the substrate using at least one of induction heating, laser tacking, adhesive, or a binder material.

4. The method of claim 1 , wherein the at least one diamond material flute volume includes a plurality of shear compacted diamond particles.

5. The method of claim 1 , wherein positioning the at least one diamond material flute volume includes positioning at least one preformed diamond volume generally helically around at least a portion of the substrate.

6. The method of claim 1 , further comprising:
removing mold material from around the PCD flute volume and the substrate;
processing the PCD flute volume to a final dimension using at least one of milling, grinding, lapping, electro-discharge machining, or lasing; and
at least partially leaching the PCD flute volume to a selected depth therein.

Assignees

• Us Synthetic Corp

Inventors

• Miess David P

Classifications

• B23C5/10

  Shank-type cutters, i.e. with an integral shaft · CPC title

• E21B10/573

  characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element · CPC title

• B24D18/0009 Primary

  using moulds or presses · CPC title

• B23G5/06

  Taps (chucks therefor B23B31/00) · CPC title

• B22F7/06

  of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} · CPC title