US 9,067,304 B2 · Methods of forming polycrystalline compacts

Abstract

Methods for forming cutting elements, methods for forming polycrystalline compacts, and related polycrystalline compacts are disclosed. Grains of a hard material are subjected to a high-pressure, high-temperature process to form a polycrystalline compact. Inclusion of at least one relatively quick spike in system pressure or temperature during an otherwise plateaued temperature or pressure stage accommodates formation of inter-granular bonds between the grains. The brevity of the peak stage may avoid undesirable grain growth. Embodiments of the methods may also include at least one of oscillating at least one system condition (e.g., pressure, temperature) and subjecting the grains to ultrasonic or mechanical vibrations. A resulting polycrystalline compact may include a high density of inter-granularly bonded hard material with a minimized amount of catalyst material, and may provide improved thermal stability, wear resistance, toughness, and behavior during use of a cutting element incorporating the polycrystalline compact.

Claims18

Dependent claims

A method for forming a cutting element comprising a polycrystalline material supported by a supporting substrate, the method comprising:

introducing coarse grains of hard material, fine grains of the hard material, and a catalyst material to a press;
elevating a system temperature to a plateau temperature;
elevating a system pressure to a plateau pressure;
spiking the system temperature from the plateau temperature to a peak temperature;
and
lowering the system temperature from the peak temperature to the plateau temperature,
wherein the acts of spiking the system temperature and lowering the system temperature are accomplished in a total time of less than one minute.

4 more elements

Dependencies are inferred from the claim text.

Methods of forming polycrystalline compacts

Life of this patent

Methods of forming polycrystalline compacts

Life of this patent

Abstract

Claims18