Polycrystalline diamond materials having improved abrasion resistance, thermal stability and impact resistance

Publication number           US20130067827 A1

Application number           13/676,070

Publication date                    Mar 21, 2013

Filing date                                  Nov 13, 2012

Inventors          Madapusi K. Keshavan, Youhe Zhang, Yuelin Shen, Anthony Griffo, Michael Janssen

Applicant               Smith International, Inc.

 

ABSTRACT

PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm

 

SELECTED CLAIMS

What is claimed is:

1. A method for making a diamond construction comprising the steps of:

heating a volume of diamond grains to form graphite;

subjecting the volume of diamond grains to a high pressure/high temperature condition in the presence of a catalyst material to form a fully-sintered polycrystalline diamond body; and

treating at least a first region of the diamond body extending from a working surface to render the first region substantially free of the catalyst material while allowing the catalyst material to remain in an untreated second region of the diamond body.

10. A method for making a polycrystalline diamond cutting element comprising the steps of:

subjecting a volume of diamond grains to a high-temperature condition sufficient to form graphite on the diamond grains;

sintering the volume of diamond grains under high pressure/high temperature conditions in the presence of a catalyst material to form a polycrystalline diamond body;

treating a first region of the diamond body extending a depth from a working surface of the body to render the first region substantially free of the catalyst material, wherein a remaining second region of the diamond body retains the catalyst material; and

joining the diamond body to a substrate to form the polycrystalline diamond cutting element.

19. A method for making a bit for drilling an earthen formation comprising;

heating a volume of diamond grains to a temperature of from about 1,200 to 1,500° C. to form graphite thereon;

subjecting the volume of diamond grains comprising the graphite to a high pressure/high temperature condition in the presence of a catalyst material to form a fully-sintered polycrystalline diamond body;

treating a first region of the diamond body extending a partial depth from a body working surface to render the first region substantially free of the catalyst material, wherein the catalyst material remains in an untreated second region of the diamond body;

Joining the diamond body to substrate to form a polycrystalline diamond cutting element; and

attaching the polycrystalline diamond cutting element to a portion of the bit to engage an earthen formation during a drilling operation.

 

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