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US 8,277,722 B2Granted
Production of reduced catalyst PDC via gradient driven reactivity
AssigneeBaker Hughes Incorporated
InventorAnthony A. DiGiovanni
Life of this patent
Estimating the term…
Abstract
A method of forming a PDC cutter having solvent metal catalyst located adjacent the diamond and/or in the diamond and a layer of reactive material on the layer of diamond, the layer of reactive material for promoting the flow of the solvent metal catalyst material from the layer of diamond under high pressure and high temperature.
Claims23
A method of making a compact comprising:
- depositing catalyst material on a substrate;
- depositing diamond powder on the catalyst material;
- depositing a reactive material on the diamond powder, the reactive material formulated to remove catalyst from the diamond powder under high pressure and high temperature;
- and
- pressing and heating the reactive material, the diamond powder, the catalyst material, and the substrate to form a polycrystalline diamond compact from at least a portion of the diamond powder.
2 more elements
A method of making a compact comprising:
- depositing a catalyst material on a substrate;
- depositing a first diamond powder on the catalyst material;
- depositing a second diamond powder on the first diamond powder;
- depositing a reactive material on the second diamond powder, the reactive material formulated to remove catalyst from the first diamond powder and the second diamond powder under pressure and temperature;
- and
- sintering the reactive material, the second diamond powder, the first diamond powder, the catalyst material, and the substrate under high pressure and high temperature to form a polycrystalline diamond compact from the first diamond powder.
3 more elements
A method of forming a polycrystalline diamond compact, comprising:
- forming a diamond layer over a substrate;
- forming a sacrificial layer on the diamond layer;
- forming a reactive layer on the sacrificial diamond layer, the reactive layer comprising a reactive material formulated to be more reactive with catalyst material of the substrate than is a material of the diamond layer;
- performing a sintering process to diffuse at least a portion of the catalyst material into each of the diamond layer, the sacrificial diamond layer, and the reactive layer and form a polycrystalline diamond compact from the diamond layer;
- and
- removing the reactive layer and the sacrificial diamond layer after performing the sintering process.
3 more elements
Dependencies are inferred from the claim text.