Superabrasive elements and related methods for processing and manufacturing using protective layers
AssigneeUS Synthetic Corporation
InventorsDavid P. Miess, Andrew E. Dadson
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Abstract
A method of processing a superabrasive element includes defining a protective layer over a selected portion of a superabrasive element. The method includes exposing at least a portion of the superabrasive element to a leaching solution. A superabrasive element has a superabrasive table that includes a leached volume extending from the superabrasive face to a portion of the chamfer proximate to the superabrasive side surface.
Claims21
-20. (canceled)
A method of manufacturing a polycrystalline diamond element, the method comprising:
- forming a protective layer over a selected portion of a polycrystalline diamond element during sintering of a polycrystalline diamond table of the polycrystalline diamond element;
- and
- leaching at least a portion of the polycrystalline diamond table by:
- exposing a surface of the polycrystalline diamond table to a leaching solution such that the leaching solution contacts an exposed surface of the polycrystalline diamond table;
- and
- exposing the portion of the polycrystalline diamond table to electric current;
- wherein the protective layer is substantially inert to the leaching solution.
A superabrasive element produced by a process comprising:
- providing a superabrasive element sintered within a metal sintering can, the superabrasive element comprising a superabrasive table that comprises a metallic material disposed in interstitial spaces defined within the superabrasive table, the superabrasive table comprising:
- a superabrasive face;
- and
- a superabrasive side surface extending around an outer periphery of the superabrasive face;
- removing a portion of the metal sintering can;
- leaching the metallic material from at least a volume of the superabrasive table to produce a leached volume by:
- applying an electric charge;
- and
- leaching at least a portion of the superabrasive face of the superabrasive table and only a portion of the superabrasive side surface;
- and
- removing the remaining metal sintering can from the superabrasive element.
A method of processing a superabrasive element, the method comprising:
- providing a superabrasive element sintered within a sintering can, the superabrasive element comprising a superabrasive table comprising:
- a superabrasive face;
- and
- a superabrasive side surface;
- removing a portion of the sintering can to expose a portion of the superabrasive side surface;
- forming a chamfer extending between the superabrasive face and the superabrasive side surface;
- and
- exposing at least a portion of the superabrasive element including the chamfer to a leaching solution and an electrical charge such that the leaching solution contacts an exposed surface region of the superabrasive table.
Dependencies are inferred from the claim text.