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US 2018/0238115 A1Published application
Polycrystalline diamond structure
AssigneeElement Six Abrasives S.A.
InventorsNedret CAN, Kaveshini NAIDOO
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AssigneeElement Six Abrasives S.A.
InventorsNedret CAN, Kaveshini NAIDOO
Estimating the term…
A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.
A polycrystalline diamond structure comprising a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains, the first region comprising a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns;
A PCD structure according to any one of the preceding claims, wherein the second region comprises a plurality of layers or strata.
A PCD structure according to any one of the preceding claims, wherein the alternating layers or strata comprise first layers or strata alternating with second layers or strata, the first layers or strata being in a state of residual compressive stress and the second layers or strata being in a state of residual tensile stress.
A PCD structure according to any one of the preceding claims, wherein the first region comprises one or more strata or layers having two or more different average diamond grain sizes.
A PCD structure according to any one of the preceding claims, wherein the first region comprises one or more strata or layers having three or more different average diamond grain sizes.
A PCD structure according to any one of the preceding claims, wherein the first region comprises an external working surface forming the initial working surface of the PCD structure in use.
A PCD structure according to any one of the preceding claims, wherein the second region has a thickness greater than the thickness of the individual strata or layers in the first region.
A PCD structure according to any one of the preceding claims, wherein the alternating layers or strata comprise first layers or strata alternating with second layers or strata, the first layers or strata comprising diamond grains and the second layers or strata comprising diamond grains.
A PCD structure according to any one of the preceding claims, wherein each stratum or layer is formed of one or more respective PCD grades having a TRS of at least 1,000 MPa;
A PCD structure according to any one of the preceding claims, wherein the alternating layers or strata comprise first layers or strata alternating with second layers or strata, the first layers or strata comprising a mixture of diamond grains having a first average grain size or sizes and the second layers or strata comprising a mixture of diamond grains having a second average grain size or sizes.
A PCD structure according to any one of the preceding claims, wherein layers or strata in the first region comprise one or more of:
A PCD structure according to any one of the preceding claims, wherein the PCD structure has a longitudinal axis, the layers or strata in the first region lying in a plane substantially perpendicular to the plane through which the longitudinal axis of the PCD structure extends.
A PCD structure according to any one of the preceding claims, wherein the volume of the first region is greater than the volume of the second region.
A PCD structure according to any one of the preceding claims, wherein one or more of the strata or layers intersect a working surface or side surface of the PCD structure.
A PCD structure as claimed in any of the preceding claims, wherein at least a portion of the first region is substantially free of a catalyst material for diamond, said portion forming a thermally stable region.
A PCD structure according to any one of the preceding claims, wherein the binder material comprises at least 12 volume percent of the PCD material.
A PCD structure according to any one of the preceding claims, wherein the diamond content of the polycrystalline diamond material is at least 80 percent and at most 88 percent of the volume of the polycrystalline diamond material.
A PCD compact or construction comprising the PCD structure of any one of the preceding claims.
A wear element comprising a PCD structure according to any one of the preceding claims.
A PCD element for a rotary shear bit for boring into the earth, or for a percussion drill bit, comprising a PCD structure as claimed in any one of the preceding claims bonded to a cemented carbide support body.
A method for making a polycrystalline diamond (PCD) structure, the method comprising:
A PCD structure substantially as hereinbefore described with reference to any one embodiment as that embodiment is illustrated in the accompanying drawings.
A method of forming a PCD structure substantially as hereinbefore described with reference to any one embodiment as that embodiment is illustrated in the accompanying drawings.
Dependencies are inferred from the claim text.