US 8,689,912 B2 · Polycrystalline diamond constructions having optimized material composition

Abstract

Diamond bonded constructions include a diamond body comprising intercrystalline bonded diamond and interstitial regions. The body has a working surface and an interface surface, and may be joined to a metallic substrate. The body has a gradient diamond volume content greater about 1.5 percent, wherein the diamond content at the interface surface is less than 94 percent, and increases moving toward the working surface. The body may include a region that is substantially free of a catalyst material otherwise disposed within the body and present in a gradient amount. An additional material may be included within the body and be present in a changing amount. The body may be formed by high-pressure HPHT processing, e.g., from 6,200 MPa to 10,000 MPa, to produce a sintered body having a characteristic diamond volume fraction v. average grain size relationship distinguishable from that of diamond bonded constructions form by conventional-pressure HPHT processing.

Claims41

Dependent claims

A diamond bonded construction comprising a diamond body comprising a matrix phase of intercrystalline bonded-together diamond crystals and a plurality of interstitial regions dispersed among the bonded-together diamond crystals, the diamond body having a working surface at one location and an interface surface positioned at another location, the body having a diamond volume content with a gradient of greater than about 1.5 percent, the diamond body comprising a catalyst material and a material selected from the group consisting of carbides, nitrides, borides, oxides and combinations thereof disposed within the interstitial regions, and wherein the diamond body has a diamond volume content at the working surface of 98 percent or less according to one of the following criteria:

the diamond volume fraction is greater than (0.9077)·(the average diamond grain size [^0.0221]0.0221);
or
the diamond volume fraction is greater than (0.9187)·(the average diamond grain size [^0.0183]0.0183);
or
the diamond volume fraction is greater than (0.9291)·(the average diamond grain size [^0.0148]0.0148), wherein the average diamond grain size is provided micrometers.

2 more elements

A bit for drilling subterranean formations comprising:

a body;
and
a plurality of cutting elements operatively attached to the body, at least one cutting element comprising a polycrystalline diamond construction comprising:
a diamond body comprising a matrix phase of bonded together diamond crystals and a plurality of dispersed regions interstitially disposed within the matrix phase, the diamond body having a working surface at one location and an interface surface at another location, wherein a catalyst material and a carbide material is disposed within the interstitial regions and the volume content of the catalyst material decreases in a gradient manner within the body moving from the interface surface to the working surface, and wherein the volume content of the catalyst material at the working surface is less than about 6 percent;
and
a substrate joined to the diamond body at the interface surface, wherein the substrate is selected from the group of materials consisting of ceramic materials, metallic materials, cermet materials, and combinations thereof.

3 more elements

Dependencies are inferred from the claim text.

Polycrystalline diamond constructions having optimized material composition

Life of this patent

Polycrystalline diamond constructions having optimized material composition

Life of this patent

Abstract

Claims41