Disclosed is a polycrystalline diamond or diamond-like element with greatly improved wear resistance without loss of impact strength. These elements are formed with a binder-catalyzing material in a high-temperature, high-pressure (HTHP) process. The PCD element has a body with a plurality of bonded diamond or diamond-like crystals forming a continuous diamond matrix that has a diamond volume density greater than 85%. Interstices among the diamond crystals form a continuous interstitial matrix containing a catalyzing material. The diamond matrix table is formed and integrally bonded with a metallic substrate containing the catalyzing material during the HTHP process. The diamond matrix body has a working surface, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material. Typically, less than about 70% of the body of the diamond matrix table is free of the catalyzing material.

High volume density polycrystalline diamond with working surfaces depleted of catalyzing material

The present invention provides a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material. This translates to higher wear resistance in cutting applications, higher heat transfer capacity in heat sink applications, and has advantages in numerous other applications including hollow dies, indentors, tool mandrels, and wear elements.

Polycrystalline diamond partially depleted of catalyzing material

Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the crystals. A metallic substrate is attached to the diamond body. A working surface is positioned along an outside portion of the diamond body, and the diamond body comprises a first region that is substantially free of a catalyst material, and a second region that includes the catalyst material. The diamond body first region extends from the working surface to depth of at least about 0.02 mm to a depth of less than about 0.09 mm. The diamond body includes diamond crystals having an average diamond grain size of greater than about 0.02 mm, and comprises at least 85 percent by volume diamond based on the total volume of the diamond body.

Thermally stable diamond polycrystalline diamond constructions

Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

Thermally stable ultra-hard material compact constructions

Disclosed is a polycrystalline diamond or diamond-like element with greatly improved wear resistance without loss of impact strength. These elements are formed with a binder-catalyzing material in a high-temperature, high-pressure (HTHP) process. The PCD element has a body with a plurality of bonded diamond or diamond-like crystals forming a continuous diamond matrix that has a diamond volume density greater than 85%. Interstices among the diamond crystals form a continuous interstitial matrix containing a catalyzing material. The diamond matrix table is formed and integrally bonded with a metallic substrate containing the catalyzing material during the HTHP process. The diamond matrix body has a working surface, where a first portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and a second portion of the interstitial matrix in the body adjacent to the working surface contains the catalyzing material. The first portion of the interstitial matrix and the second portion of the interstitial matrix have substantially the same impact strength.

Polycrystalline diamond cutters with working surfaces having varied wear resistance while maintaining impact strength

An enlarged diamond table for use as a cutter (10) in rotating drill bits is provided by disposing a plurality of thermally stable or leached polycrystalline diamond (PCD) rod- like elements (12) within a matrix body (16). In one embodiment the matrix body (16) is impregnated with diamond grit and completely fills the interstitial spaces between the plurality of diamond elements (12). Generally, the diamond elements (12) have their longitudinal axes arranged in a mutually parallel configuration. The bundle of rod-like diamond elements (12) are in one embodiment in a compact touching array and in another embodiment in a spaced-apart array. In the illustrated embodiment, a bundle of rod-like diamond elements are disposed so that their end surfaces are exposed on the cutting face (14) of the cutting slug (10). The slug (10) is then in turn mounted on a stud or directly infiltrated into a matrix body bit (Figure 1).

Alexander K. Meskin

Papers

Multi-component cutting element using consolidated rod-like polycrystalline diamond

Multi-component cutter using rod shaped polycrystalline diamond