# US 2014/0360103 A1 · Polycrystalline diamond compacts, cutting elements and earth-boring tools including such compacts, and methods of forming such compacts and earth-boring tools > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0360103 A1 - Document ID: US20140360103A1 - Status: Published application - Kind: A1 - Application number: 14/466,073 - Filed: 2014-08-22 - Published: 2014-12-11 - Earliest claimed: 2010-04-28 - Assignees: Baker Hughes Incorporated; Element Six Limited - Applicants: Baker Hughes Incorporated; Element Six Limited - Inventors: Anthony A. DiGiovanni; Iain P. Goudemond - Web page: https://patentgrep.com/patent/US20140360103A1 ## CPC - B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives - B24D 18/0009: {using moulds or presses} - B24D 18/0027: {by impregnation} - B24D 99/005: {Segments of abrasive wheels} - C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} - E21B 10/006: {providing a cutting edge which is self-renewable during drilling} - E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - Y10T 428/219: Edge structure - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - C22C: ALLOYS (treatment of alloys C21D, C22F) - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Methods of forming a polycrystalline diamond compact for use in an earth-boring tool include forming a body of polycrystalline diamond material including a first material disposed in interstitial spaces between inter-bonded diamond crystals in the body, removing the first material from interstitial spaces in a portion of the body, selecting a second material promoting a higher rate of degradation of the polycrystalline diamond compact than the first material under similar elevated temperature conditions and providing the second material in interstitial spaces in the portion of the body. Methods of drilling include engaging at least one cutter with a formation and wearing a second region of polycrystalline diamond material comprising a second material faster than the first region of polycrystalline diamond material comprising a first material. Polycrystalline diamond compacts and earth-boring tools including such compacts are also disclosed. ## Claims ### Claim 1 A method of forming a polycrystalline diamond compact cutting element for an earth-boring tool, comprising: forming a diamond table comprising a polycrystalline diamond material and a first material disposed in interstitial spaces between inter-bonded diamond crystals of the polycrystalline diamond material; at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in a first portion of the diamond table; selecting a second material formulated to promote a higher rate of degradation of the inter-bonded diamond crystals responsive to exposure to an elevated temperature than a rate of degradation of the diamond material having the first material at least substantially removed from the interstitial spaces under a substantially equivalent elevated temperature; and introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in a second portion of the diamond table. ### Claim 2 (depends on 1) The method of claim 1, further comprising subjecting the diamond table to a high temperature/high pressure (HTHP) process prior to at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in the first portion of the diamond table. ### Claim 3 (canceled) ### Claim 4 (depends on 1) The method of claim 1, wherein selecting a second material to promote a higher rate of degradation of the inter-bonded diamond crystals responsive to exposure to an elevated temperature than a rate of degradation of the diamond material having the first material at least substantially removed from the interstitial spaces comprises selecting the second material to comprise at least one of cobalt, nickel, iron, and alloys thereof. ### Claim 5 (depends on 1) The method of claim 1, wherein the second portion of the diamond table extends annularly along a periphery of the diamond table. ### Claim 6 (depends on 5) The method of claim 5, wherein the second portion of the diamond table extends radially inward from a peripheral sidewall of the diamond table a distance between about 50 microns and about 400 microns. ### Claim 7 (depends on 1) The method of claim 1, wherein at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in the first portion of the diamond table comprises leaching the first material from the interstitial spaces in the polycrystalline diamond material in the first portion of the diamond table. ### Claim 8 (depends on 1) The method of claim 1, further comprising at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in the second portion of the diamond table prior to introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in the second portion of the diamond table. ### Claim 9 (depends on 1) The method of claim 1, wherein introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in a second portion of the diamond table comprises: masking the diamond table except for an unmasked portion overlying the second portion of the diamond table; and introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in the unmasked portion of the diamond table. ### Claim 10 (depends on 9) The method of claim 9, wherein introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in the unmasked portion of the diamond table comprises depositing the second material into the unmasked portion of the diamond table using one or more of a physical vapor deposition process (PVD), a chemical vapor deposition process (CVD), and a plasma-enhanced chemical vapor deposition process (PECVD). ### Claim 11 (depends on 9) The method of claim 9, wherein introducing the second material into the interstitial spaces between the inter-bonded diamond crystals in the unmasked portion of the diamond table comprises: filling the unmasked portion of the diamond table with the second material; and subjecting the diamond table to a high temperature/high pressure (HTHP) process until the second material infiltrates the second portion of the diamond table. ### Claim 12 (depends on 1) The method of claim 1, wherein at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in a first portion of the diamond table comprises at least substantially removing the first material from the interstitial spaces in the polycrystalline diamond material in an annular region adjacent a sidewall of the diamond table. ### Claim 13 (depends on 12) The method of claim 12, further comprising removing the first material from a cutting face of the diamond table. ### Claim 14 (depends on 1) The method of claim 1, wherein the first material comprises cobalt. ### Claim 15 (depends on 14) The method of claim 14, wherein the second material comprises iron. ### Claim 16 (depends on 1) The method of claim 1, wherein selecting the second material formulated to promote a higher rate of degradation of the inter-bonded diamond crystals responsive to exposure to an elevated temperature than a rate of degradation of the first material under a substantially equivalent elevated temperature comprises selecting the second material to comprise a stronger catalyst than the first material. ### Claim 17 (depends on 1) The method of claim 1, wherein the second portion of the diamond table is configured to wear faster than the first portion of the diamond table when the diamond table is exposed to friction-induced heating during an earth-boring operation. ### Claim 18 (depends on 17) The method of claim 17, wherein the second portion of the diamond table is configured for formation of a recess in the second portion of the diamond table when the diamond table is exposed to friction during an earth-boring operation. ### Claim 19 (depends on 1) The method of claim 1, wherein the first portion of the diamond table extends from a cutting face of the diamond table to an end surface of the diamond table adjacent a substrate. ### Claim 20 (depends on 1) The method of claim 1, wherein the first portion of the diamond table extends from a cutting face of the diamond table to a top sidewall of the second portion of the diamond table. ### Claim 21 (depends on 20) The method of claim 20, wherein the diamond table further comprises another portion extending radially inward from the second portion of the diamond table and extending longitudinally between the first portion of the diamond table and an end surface of the diamond table adjacent a substrate.