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US 12,296,435 B2Granted
Leached superabrasive elements and systems, methods and assemblies for processing superabrasive materials
AssigneeUS Synthetic Corporation
InventorsDaniel Marin Scott, Daren Nathaniel Heaton, Jeremy Brett Lynn, Mark Pehrson Chapman, Oakley D. Bond
Life of this patent
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Abstract
A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table.
Claims20
A superabrasive element comprising:
- a polycrystalline diamond table comprising:
- a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table;
- an unleached volume including the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table;
- and
- a leached volume where at least some of the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table has been removed with a leaching process,
- wherein at least a portion of a cobalt material has been removed from the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table while a tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table, and
- wherein the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table includes a ratio of the cobalt material relative to the tungsten material that is greater than a ratio of a cobalt material relative to a tungsten material in the unleached volume of the polycrystalline diamond table.
4 more elements
A superabrasive element comprising:
- a polycrystalline diamond table comprising:
- a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table;
- an unleached volume including the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table;
- and
- a leached volume where at least some of the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table has been removed with a leaching process,
- wherein at least a portion of a cobalt material has been removed from the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table while a tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table, and
- wherein:
- an amount of the tungsten material in the interstitial spaces in the leached volume of the polycrystalline diamond table is similar to another amount of tungsten material in the interstitial spaces in the unleached volume of the polycrystalline diamond table;
- or
- the metallic material from a portion of the polycrystalline diamond table has been leached to a first depth relative to a superabrasive face of the superabrasive element, and wherein the metallic material from an external side region of the polycrystalline diamond table has been leached to a second depth relative to the superabrasive face of the superabrasive element, the second depth being greater than the first depth.
7 more elements
A superabrasive element comprising:
- a polycrystalline diamond table comprising:
- a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table;
- an unleached volume including the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table;
- and
- a leached volume where at least some of the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table has been removed with a leaching process,
- wherein at least a portion of a cobalt material has been removed from the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table while a tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table;
- wherein the leaching process comprises:
- exposing at least a portion of the polycrystalline diamond table to a processing solution;
- and
- applying a charge to the processing solution to generate a voltage between the polycrystalline diamond table and an electrode via the processing solution;
- and
- wherein the processing solution includes an organic acid and a divalent metal salt.
9 more elements
A superabrasive element comprising:
- a polycrystalline diamond table comprising:
- a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table;
- an unleached volume including the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table;
- and
- a leached volume where at least some of the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table has been removed with a leaching process,
- wherein at least a portion of a cobalt material has been removed from the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table while a tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table;
- and
- wherein the interstitial spaces in the leached volume of the polycrystalline diamond table substantially lacks the cobalt material while the tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table.
5 more elements
A superabrasive element comprising:
- a polycrystalline diamond table comprising:
- a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table;
- an unleached volume including the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table;
- and
- a leached volume where at least some of the metallic material disposed in the interstitial spaces defined within the polycrystalline diamond table has been removed with a leaching process;
- a substrate attached to the polycrystalline diamond table;
- and
- a protective layer surrounding at least the substrate,
- wherein at least a portion of a cobalt material has been removed from the metallic material in the interstitial spaces in the leached volume of the polycrystalline diamond table while a tungsten material remains in the interstitial spaces in the leached volume of the polycrystalline diamond table.
6 more elements
Dependencies are inferred from the claim text.