# US 10,766,823 B2 · Cutting elements and tools comprising interbonded grains of diamond and related methods

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- Number: US 10,766,823 B2
- Document ID: US10766823B2
- Status: Granted
- Kind: B2
- Application number: 15/400,617
- Filed: 2017-01-06
- Published: 2017-04-27
- Granted: 2020-09-08
- Earliest claimed: 2011-02-22
- Assignees: Baker Hughes, A Ge Company, LLC
- Applicants: Baker Hughes, a GE company, LLC
- Inventors: Anthony A. DiGiovanni
- Web page: https://patentgrep.com/patent/US10766823B2

## CPC

- C04B 35/52: based on carbon, e.g. graphite
- B22F 3/10: Sintering only
- B22F 3/14: simultaneously
- B22F 5/00: Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F 7/008: {characterised by the composition}
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B22F 9/04: starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C)
- B24D 3/04: and being essentially inorganic
- B24D 18/0009: {using moulds or presses}
- B24D 99/005: {Segments of abrasive wheels}
- C04B 35/528: obtained from carbonaceous particles with or without other non-organic components
- C04B 35/645: Pressure sintering
- C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes}
- E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- E21B 10/5735: {Interface between the substrate and the cutting element}
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B22F 2301/15: Nickel or cobalt
- B22F 2302/406: Diamond
- B22F 2302/45: Others, including non-metals
- B22F 2998/10: Processes characterised by the sequence of their steps
- C04B 2235/3201: Alkali metal oxides or oxide-forming salts thereof
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3227: Lanthanum oxide or oxide-forming salts thereof
- C04B 2235/405: Iron group metals
- C04B 2235/427: Diamond
- C04B 2235/428: Silicon
- C04B 2235/445: Fluoride containing anions, e.g. fluosilicate
- C04B 2235/85: Intergranular or grain boundary phases
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS

## Abstract

Methods of forming a polycrystalline compact using at least one metal salt as a sintering aid. Such methods may include forming a mixture of the at least one metal salt and a plurality of grains of hard material and sintering the mixture to form a hard polycrystalline material. During sintering, the metal salt may melt or react with another compound to form a liquid that acts as a lubricant to promote rearrangement and packing of the grains of hard material. The metal salt may, thus, enable formation of hard polycrystalline material having increased density, abrasion resistance, or strength. The metal salt may also act as a getter to remove impurities (e.g., catalyst material) during sintering. The methods may also be employed to form cutting elements and earth-boring tools.

## Claims

### Claim 1

A cutting element comprising:
a sintered diamond table comprising interbonded grains of diamond, the interbonded grains of diamond defining interstitial spaces within the sintered diamond table; and
lithium fluoride within the interstitial spaces of the sintered diamond table.

### Claim 2 (depends on 1)

The cutting element of claim 1, wherein the cutting element further comprises silicon within the interstitial spaces of the sintered diamond table.

### Claim 3 (depends on 1)

The cutting element of claim 1, further comprising a substrate, wherein the sintered diamond table is secured to a surface of the substrate.

### Claim 4 (depends on 1)

The cutting element of claim 1, further comprising, within the interstitial spaces of the sintered diamond table, at least one metallic element selected from the group consisting of the elements of Group VIII of the Periodic Table of the Elements.

### Claim 5 (depends on 1)

The cutting element of claim 1, further comprising, within the interstitial spaces of the sintered diamond table, at least one material selected from the group consisting of carbonates, sulfates, hydroxides, and fullerenes.

### Claim 6 (depends on 1)

An earth-boring tool, comprising:
a body; and
at least one of the cutting element of claim 1 secured to the body.

### Claim 7 (depends on 6)

The earth-boring tool of claim 6, wherein the at least one cutting element is secured within a pocket defined by the body.

### Claim 8 (depends on 6)

The earth-boring tool of claim 6, wherein the earth-boring tool comprises a tool selected from the group consisting of fixed-cutter rotary drill bits, roller cone drill bits, percussion bits, core bits, eccentric bits, bicenter bits, reamers, expandable reamers, mills, and hybrid bits.

### Claim 9 (depends on 6)

The earth-boring tool of claim 6, wherein the cutting element further comprises silicon within the interstitial spaces of the sintered diamond table.

### Claim 10 (depends on 6)

The earth-boring tool of claim 6, wherein the at least one cutting element further comprises, within the interstitial spaces of the sintered diamond table, at least one metallic element selected from the group consisting of the elements of Group VIII of the Periodic Table of the Elements.