US 2009/0152017 A1 · POLYCRYSTALLINE DIAMOND CONSTRUCTION WITH CONTROLLED GRADIENT METAL CONTENT

Abstract

Polycrystalline diamond constructions comprises a diamond body attached to a metallic substrate, and having an engineered metal content. The body comprises bonded together diamond crystals with a metal material disposed interstitially between the crystals. A body working surface has metal content of 2 to 8 percent that increases moving away therefrom. A transition region between the body and substrate includes metal rich and metal depleted regions having controlled metal content that provides improved thermal expansion matching/reduced residual stress. A point in the body adjacent the metal rich zone has a metal content that is at least about 3 percent by weight greater than that at a body/substrate interface. The metal depleted zone metal content increases gradually moving from the body, and has a thickness greater than 1.25 mm. Metal depleted zone metal content changes less about 4 percent per millimeter moving along the substrate.

Claims33

Dependent claims

A polycrystalline diamond construction comprising:

a diamond body comprising a plurality of bonded together diamond crystals and a plurality of interstitial regions disposed among the crystals, the diamond body comprising a metal material disposed within the interstitial regions, the diamond body comprising a working surface positioned along an outside portion of the body, wherein the content of the metal material within the diamond body increases moving away from the working surface;
and
a metallic substrate attached to the diamond body along an interface disposed therebetween;
wherein the diamond body includes a metal rich zone adjacent the substrate, and the substrate includes a metal depleted zone adjacent the diamond body, wherein the metal content at a point in the body adjacent the metal rich zone is at least about 3 percent by weight greater than the metal content at a point in the metal depleted zone.

1 more element

A method for making a polycrystalline diamond construction comprising the steps of:

preparing a polycrystalline diamond body by combining a volume of diamond grains and subjecting the same to high pressure/high temperature conditions of at least about 6,000 MPa in the presence of a metal catalyst to form a diamond bonded body, the body comprising a plurality of bonded together diamond grains with interstitial regions disposed therebetween, wherein the metal catalyst material is disposed within the interstitial regions and wherein the amount of the metal catalyst material varies depending on location within the body, wherein the content of the metal catalyst material disposed along a working surface of the body is less than that at other locations within the body, and wherein the content of the metal catalyst material within the body increases in a gradient manner moving away from the working surface;
and
attaching the body to a metallic substrate, wherein the body and substrate are joined together along an interfacing adjacent surfaces, wherein the construction comprises a metal rich region disposed within the diamond body adjacent the substrate and a metal depleted region disposed within the substrate adjacent the diamond body, wherein the metal content in the metal depleted region increases in a gradient manner moving away from the diamond body and is in the range of from about 4 to 16 percent by weight, and wherein metal content in the metal rich region of the diamond body is at least 3 percent by weight greater than the metal depleted region.

Dependencies are inferred from the claim text.

Polycrystalline diamond construction with controlled gradient metal content

Life of this patent

Polycrystalline diamond construction with controlled gradient metal content

Life of this patent

Abstract

Claims33