Methods of fabricating polycrystalline diamond products using a selected amount of graphite particles
AssigneeUS Synthetic Corporation
InventorMohammad N. Sani
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Abstract
Embodiments of the invention relate to polycrystalline diamond (“PCD”) fabricated by sintering a mixture including diamond particles and a selected amount of graphite particles, polycrystalline diamond compacts (“PDCs”) having a PCD table comprising such PCD, and methods of fabricating such PCD and PDCs. In an embodiment, a method includes providing a mixture including graphite particles present in an amount of about 0.1 weight percent (“wt %”) to about 20 wt % and diamond particles. The method further includes subjecting the mixture to a high-pressure/high-temperature process sufficient to form PCD.
Claims26
A method, comprising:
- providing a first portion adjacent to at least a second portion, the first portion including graphite particles present in a first amount mixed with diamond particles, and the at least a second portion including additional diamond particles mixed with additional graphite particles present in a second amount greater than the first amount;
- and
- subjecting the first portion and the at least a second portion to a high-pressure/high-temperature process in the presence of a catalyst to form polycrystalline diamond, wherein the polycrystalline diamond so formed includes a matrix of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, the catalyst being disposed in at least some of the plurality of interstitial regions.
A method of fabricating a polycrystalline diamond product, comprising:
- placing a first portion between a substrate including a metal-solvent catalyst therein and at least a second portion to form an assembly, wherein the first portion includes graphite particles present in an amount of about 5 weight percent (“wt %”) to about 10 wt % and mixed with diamond particles, and wherein the at least a second portion includes additional diamond particles mixed with additional graphite particles present in another amount less than the amount;
- and
- subjecting the assembly and the substrate to a high-pressure/high-temperature process to infiltrate the first portion and the at least a second portion with a portion of the metal-solvent catalyst from the substrate so that a polycrystalline diamond table forms and bonds to the substrate, wherein the polycrystalline diamond table so formed includes a matrix of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, the portion of the metal-solvent catalyst being disposed in at least some of the plurality of interstitial regions.
A method of fabricating a polycrystalline diamond product, comprising:
- placing a first layer between a substrate including a metal-solvent catalyst therein and at least a second layer to form an assembly, wherein the first layer includes graphite particles present in a first amount mixed with diamond particles, and wherein the at least a second layer includes additional diamond particles mixed with additional graphite particles present in a second amount greater than the first amount;
- and
- subjecting the assembly and the substrate to a high-pressure/high-temperature process to infiltrate the first layer and the at least a second layer with a portion of the metal-solvent catalyst from the substrate so that a polycrystalline diamond table forms and bonds to the substrate, wherein the polycrystalline diamond table so formed includes a matrix of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, the portion of the metal-solvent catalyst being disposed in at least some of the plurality of interstitial regions.
Dependencies are inferred from the claim text.