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AssigneeReedHycalog UK Ltd
InventorsNigel Dennis Griffin, Peter Raymond Hughes
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A method for forming a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth from the working surface, the remaining interstitial matrix contains the catalyzing material, causing a 950 degrees C. temperature at the working surface to be less than 750 degrees C. at the depth.
A method of forming a polycrystalline diamond element comprising a body with a working surface, wherein a first volume of the body remote from the working surface contains a catalyzing material and a second volume of the body adjacent to the working surface is substantially free of the catalyzing material to a depth from the working surface, by depleting the catalyzing material from the second volume of the body to a depth from the working surface such that a thermal gradient of the bonded diamonds causes a 950 degrees C. temperature at the working surface to be less than 750 degrees C. at the depth.
Dependencies are inferred from the claim text.