Polycrystalline diamond compacts and applications therefor
AssigneeUS Synthetic Cor poration
InventorsBrandon Paul Linford, Cody William Knuteson, Jason Dean Blackburn, Daniel Call Mortensen, Steven Swan
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Abstract
Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
Claims20
A polycrystalline diamond compact produced by a process comprising:
- mixing a plurality of diamond particles having an at least trimodal distribution including:
- a first amount being about 10 weight % to about 30 weight % of the plurality of diamond particles that exhibits a first average particle size of about 0.5 μm to about 5 μm;
- a second amount being about 55 weight % to about 65 weight % of the plurality of diamond particles that exhibits a second average particle size that is greater than the first average particle size and is about 12 μm to about 30 μm;
- and
- a third amount of about 5 weight % to about 35 weight % of the plurality of diamond particles that exhibits a third average particle size that is greater than the first average particle size and the second average particle size and is about 20 μm to about 45 μm;
- enclosing the plurality of diamond particles in a pressure transmitting medium to form a cell assembly;
- and
- subjecting the cell assembly to a high-pressure/high-temperature process to form a polycrystalline diamond body comprising the at least trimodal distribution of the plurality of the particles.
A polycrystalline diamond compact comprising:
- a polycrystalline diamond body comprising diamond grains having at least a trimodal distribution including:
- a first amount being about 20 weight % to about 30 weight % of the diamond grains that exhibits a first average grain size of about 0.5 μm to about 5 μm;
- a second amount being about 55 weight % to about 65 weight % of the diamond grains that exhibits a second average grain size that is about 12 μm to about 30 μm;
- and
- a third amount of about 0 weight % to about 25 weight % of the diamond grains that exhibits a third average grain size that is about 25 μm to about 35 μm.
A polycrystalline diamond compact comprising:
- a polycrystalline diamond body comprising diamond grains having at least a trimodal distribution including:
- a first amount being about 10 weight % to about 30 weight % of the diamond grains that exhibits a first average grain size of about 0.5 μm to about 5 μm;
- a second amount being about 55 weight % to about 65 weight % of the diamond grains that exhibits a second average grain size that is greater than the first average grain size and is about 12 μm to about 30 μm;
- and
- a third amount of about 10 weight % to about 20 weight % of the diamond grains that exhibits a third average grain size that is greater than the first average grain size and the second average grain size and is about 20 μm to about 45 μm.
Dependencies are inferred from the claim text.