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US 11,141,834 B2Granted
Polycrystalline diamond compacts and related methods
AssigneeUS Synthetic Corporation
InventorsMohammad N. Sani, Jair J. Gonzalez, Andrew E. Dadson, Debkumar Mukhopadhyay
Life of this patent
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Abstract
Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating polycrystalline diamond tables and PDCs in a manner that facilitates removal of metal-solvent catalyst used in the manufacture of polycrystalline diamond tables of such PDCs.
Claims22
A subterranean drill bit, comprising:
- a bit body;
- and
- a plurality of polycrystalline diamond compacts affixed to the bit body, at least one of the plurality of polycrystalline diamond compacts, including:
- a substrate including cemented carbide;
- and
- a polycrystalline diamond table including a working surface and an opposing interfacial surface bonded to the substrate, the polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the polycrystalline diamond table further including:
- a first volume extending inwardly from the working surface;
- a second volume extending inwardly from the interfacial surface;
- a metal-solvent catalyst material disposed in at least a portion of the plurality of interstitial regions;
- at least one sacrificial material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one sacrificial material includes a material separate from and different than that of the metal-solvent catalyst material;
- wherein an average particle size of the at least one sacrificial material is about 10 nm to about 10 μm;
- wherein the at least one sacrificial material is present in the first volume and the second volume in a pre-leaching concentration of greater than 0 weight % to about 5 weight % of the first volume and the second volume;
- wherein the first volume exhibits a concentration of the metal-solvent catalyst material of less than 0.85 weight % of the first volume after leaching the first volume;
- and
- wherein the second volume includes the pre-leaching concentration of the at least one sacrificial material, after leaching the first volume.
12 more elements
A rotary drill bit, comprising:
- a bit body, the bit body including a plurality of pockets;
- and
- a plurality of polycrystalline diamond compacts affixed to the bit body in the plurality of pockets, at least one of the plurality of polycrystalline diamond compacts, including:
- a substrate including cemented carbide;
- and
- a polycrystalline diamond table including a working surface and an opposing interfacial surface bonded to the substrate, the polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the polycrystalline diamond table further including:
- a first volume extending inwardly from the working surface;
- a second volume extending inwardly from the interfacial surface;
- a metal-solvent catalyst material disposed in at least a portion of the plurality of interstitial regions;
- at least one sacrificial material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one sacrificial material includes a material separate from and different than that of the metal-solvent catalyst material;
- wherein an average particle size of the at least one sacrificial material is about 10 nm to about 10 μm;
- wherein the at least one sacrificial material is present in the first volume and the second volume in a pre-leaching concentration of greater than 0 weight % to about 5 weight % of the first volume and the second volume;
- wherein the first volume exhibits a concentration of the metal-solvent catalyst material of less than 0.85 weight % of the first volume after leaching the first volume;
- and
- wherein the second volume includes the pre-leaching concentration of the at least one sacrificial material after leaching the first volume.
12 more elements
A rotary drill bit, comprising:
- a bit body, the bit body including a plurality of pockets;
- and
- a plurality of polycrystalline diamond compacts each of which is affixed to the bit body in a corresponding one of the plurality of pockets, at least one of the plurality of polycrystalline diamond compacts, including:
- a substrate including cemented carbide;
- and
- a polycrystalline diamond table including a working surface and an opposing interfacial surface directly bonded to the substrate, the polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the polycrystalline diamond table further including:
- a first volume of the polycrystalline diamond table including the bonded diamond grains extending inwardly from the working surface;
- a second volume of the polycrystalline diamond table including the bonded diamond grains extending inwardly from the interfacial surface;
- a metal-solvent catalyst material disposed in at least a portion of the plurality of interstitial regions, wherein the metal-solvent catalyst material includes at least one of iron, nickel, or cobalt;
- at least one sacrificial material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one sacrificial material includes a material separate from and different than that of the metal-solvent catalyst material, the at least one sacrificial material including a plurality of sacrificial particles, at least one reaction product of the plurality of diamond grains and the plurality of sacrificial particles, or combinations thereof;
- wherein an average particle size of the at least one sacrificial material is about 10 nm to about 10 μm;
- wherein the at least one sacrificial material is present in the first volume and the second volume of the polycrystalline diamond table in a pre-leaching concentration of greater than 0 weight % to about 5 weight % of the first volume and the second volume prior to leaching the first volume;
- wherein the first volume exhibits a post-leaching concentration of the metal-solvent catalyst material of less than 0.85 weight % of the first volume;
- and
- wherein the second volume includes the pre-leaching concentration of the at least one sacrificial material, after leaching the first volume.
12 more elements
Dependencies are inferred from the claim text.