Methods for manufacturing ultrahard compacts
AssigneeSmith International, Inc.
InventorsChristopher H. Weis, Ronald K. Eyre, Stewart N. Middlemiss, David Iverson
Life of this patent
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Abstract
A method for manufacturing an ultrahard compact includes assembling a mass of ultrahard material with a mass of substrate material such that the mass of ultrahard material extends radially outward a greater extent than the substrate material to compensate for a difference in the radial shrinkage of the ultrahard material compared to the substrate material during a sintering process. The method may further includes subjecting the assembled compact to a high pressure high temperature process that results in the forming of an ultrahard compact including an ultrahard layer integrally bonded with a substrate.
Claims23
A method for forming an ultrahard compact comprising:
- assembling a mass of ultrahard material with a mass of substrate material to form a pre-sintered compact such that the mass of ultrahard material extends further from a central axis of the compact than the mass of substrate material, and the mass of substrate material forms at least part of a side surface of the pre-sintered compact;
- and
- subjecting the pre-sintered compact to a high pressure high temperature process to form an ultrahard compact comprising an ultrahard layer integrally formed with a substrate wherein the subjecting results in the ultrahard layer being formed substantially uniform with the substrate.
A method for forming a compact, comprising:
- assembling a mass of ultrahard material with a mass of substrate material to form a pre-sintered compact such that the mass of ultrahard material extends further from a central axis of the compact than the mass of substrate material, and the mass of substrate material forms at least part of a side surface of the pre-sintered compact;
- wherein the assembling comprises:
- placing the mass of ultrahard material in a first section of a container;
- placing the mass of substrate material in a second section of the container;
- placing the first section of the container in a forming die;
- and
- exerting a force on the mass of ultrahard material in the container to forces a side wall of the container to expand outward in the first section and extend further outward in the first section than in the second section.
A method for forming a compact, comprising:
- assembling a mass of ultrahard material with a mass of substrate material to form a pre-sintered compact such that the mass of ultrahard material extends further from a central axis of the compact than the mass of substrate material, and the mass of substrate material forms at least part of a side surface of the pre-sintered compact;
- wherein the assembling comprises:
- placing the mass of ultrahard material in a first section of a container having a side wall that extends outward an amount further in the first section than in a second section;
- and
- placing the mass of substrate material in the second section of the container.
A method for forming an compact, comprising filling a first section of a generally cylindrical container with ultrahard material;
- filling a second section of the container with substrate material, wherein a diameter of the container in the first section is between about 2% and about 20% larger than the diameter of the container in the second section so that the mass of ultrahard material formed is larger than the mass of substrate material to compensate for a difference in a radial shrinkage during a high pressure, high temperature pressing process;
- and
- subjecting the container to the high pressure, high temperature pressing process to form an ultrahard compact of substantially uniform shape including an ultrahard layer integrally formed with a support substrate.
Dependencies are inferred from the claim text.