Methods of fabricating a polycrystalline diamond compact
AssigneeUS Synthetic Corporation
InventorsDebkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
Life of this patent
Estimating the term…
Abstract
Embodiments of the invention relate to methods of forming polycrystalline diamond compacts (“PDCs”), wherein the PDC includes a polycrystalline diamond (“PCD”) table in which at least one Group VIII metal is at least partially alloyed with phosphorus and/or at least one other alloying element to improve the thermal stability of the PCD table. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.
Claims28
A method of fabricating a thermally-stable polycrystalline diamond compact, the method comprising:
- forming a polycrystalline diamond compact including a polycrystalline diamond table adjacent to an interfacial surface of a substrate, the polycrystalline diamond table including an upper surface remote from the interfacial surface of the substrate, at least one lateral surface, and a chamfer extending between the at least one lateral surface and the upper surface, wherein the polycrystalline diamond table includes a plurality of bonded diamond grains defining a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one Group VIII metal disposed therein;
- subjecting the polycrystalline diamond compact and one or more alloying materials including phosphorous to an inert environment;
- and
- while subjected to the inert environment, heating the polycrystalline diamond compact and the one or more alloying materials to an effective temperature and for an effective time to alloy at least some of the at least one Group VIII metal with the phosphorous;
- wherein, prior to alloying the at least one Group VIII metal with the phosphorous, the one or more alloying materials are positioned external to the polycrystalline diamond compact.
A method of fabricating a thermally-stable polycrystalline diamond compact, the method comprising:
- providing a polycrystalline diamond compact including a polycrystalline diamond table bonded to an interfacial surface of a substrate, the polycrystalline diamond table including an upper surface remote from the interfacial surface of the substrate, at least one lateral surface, and a chamfer extending between the at least one lateral surface and the upper surface, wherein the polycrystalline diamond table includes a plurality of bonded diamond grains defining a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one Group VIII metal;
- positioning one or more alloying materials adjacent to at least a portion of the upper surface, the at least one lateral surface, and the chamfer of the polycrystalline diamond table to form an assembly, wherein the one or more alloying materials include phosphorus;
- subjecting the assembly to an inert environment;
- and
- while the assembly is subjected to the inert environment, heating the assembly to an effective temperature and for an effective time to alloy at least some of the at least one Group VIII metal with the phosphorous.
A method of fabricating a thermally-stable polycrystalline diamond compact, the method comprising:
- forming a polycrystalline diamond compact including a polycrystalline diamond table adjacent to an interfacial surface of a substrate, the polycrystalline diamond table including a nonplanar upper surface remote from the interfacial surface of the substrate and at least one lateral surface, wherein the polycrystalline diamond table includes a plurality of bonded diamond grains defining a plurality of interstitial regions, at least a portion of the plurality of interstitial regions including at least one Group VIII metal disposed therein;
- subjecting the polycrystalline diamond compact and one or more alloying materials including phosphorous to an inert environment;
- and
- while subjected to the inert environment, heating the polycrystalline diamond compact and the one or more alloying materials to an effective temperature and for an effective time to alloy at least some of the at least one Group VIII metal with the phosphorous;
- wherein, prior to alloying the at least one Group VIII metal with the phosphorous, the one or more alloying materials are positioned external to the polycrystalline diamond compact.
Dependencies are inferred from the claim text.