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AssigneeGrant Prideco, L.P.
InventorsTerry R. Matthias, Nigel Dennis Griffin, Peter Raymond Hughes
Estimating the term…
Disclosed is a polycrystalline diamond or diamond-like element with greatly improved wear resistance without loss of impact strength. These elements are formed with a binder-catalyzing material in a high-temperature, high-pressure (HTHP) process. The PCD element has a body with a plurality of bonded diamond or diamond-like crystals forming a continuous diamond matrix that has a diamond volume density greater than 85%. Interstices among the diamond crystals form a continuous interstitial matrix containing a catalyzing material. The diamond matrix table is formed and integrally bonded with a metallic substrate containing the catalyzing material during the HTHP process. The diamond matrix body has a working surface, where a first portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and a second portion of the interstitial matrix in the body adjacent to the working surface contains the catalyzing material. The first portion of the interstitial matrix and the second portion of the interstitial matrix have substantially the same impact strength.
A PCD element comprising a body of bonded diamonds integrally formed with a metallic substrate, the body having a working surface and at least an 85% by volume diamond density, wherein a first volume of the body adjacent to the working surface contains a catalyzing material, a second volume of the body adjacent to the working surface is substantially free of the catalyzing material, and wherein the first volume and the second volume have substantially the same impact strength.
A preform cutting element comprising a body of a superhard polycrystalline material comprising a plurality of partially bonded superhard crystals integrally formed with a metallic substrate, a plurality of interstitial regions among the superhard crystals and a catalyzing material, the body having at least an 85% by volume diamond density and a cutting surface, wherein the interstitial regions adjacent to at least a first portion of the cutting surface are substantially free of the catalyzing material, the interstitial regions adjacent to a second portion of the cutting surface contain the catalyzing material, and the interstitial regions where the body contacts the substrate contain the catalyzing material and have an average thickness greater than 0.15 mm, and wherein the first portion of the cutting surface and the second portion have substantially the same impact strength.
A PCD element comprising a diamond containing body integrally formed with a metallic substrate, the body having at least an 85% by volume diamond density and an interstitial matrix, a first portion of the interstitial matrix in the body adjacent to a working surface is substantially free of the catalyzing material, a second portion of the interstitial matrix in the body adjacent to a working surface contains the catalyzing material, and the interstitial matrix where the body contacts the substrate contains the catalyzing material and has an average thickness greater than 0.15 mm, and wherein the first portion of the interstitial matrix and the second portion of the interstitial matrix have substantially the same impact strength.
A PCD element comprising a body integrally formed with a metallic substrate, the body comprising a plurality of bonded diamond crystals having surfaces and a catalyzing material, the body having at least an 85% by volume diamond density, wherein at least 30% of the crystals in the body contact the catalyzing material and the surfaces of a majority of the remaining crystals that are within at least a 0.1 mm depth from a working surface are substantially free of the catalyzing material, wherein the body has a substantially uniform impact strength.
A method of manufacture of a PCD element comprising a body integrally formed with a metallic substrate, the body comprising bonded diamond crystals and a catalyzing material, by treating the body to render a volume thereof substantially free of the catalyzing material while permitting the catalyzing material to remain in at least some of the remaining volume of the body, and while permitting the substrate to remain substantially unaffected when treating the body, and while also providing the body with a substantially uniform impact strength.
Dependencies are inferred from the claim text.