CN105840104A - 一种热稳定型高抗冲击聚晶金刚石复合片及制造方法 - Google Patents
一种热稳定型高抗冲击聚晶金刚石复合片及制造方法 Download PDFInfo
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Abstract
本发明公开了一种热稳定型高抗冲击聚晶金刚石复合片及制造方法，该复合片包括热稳定型的聚晶金刚石层及与聚晶金刚石层相粘结的硬质合金基体；制造热稳定型高抗冲击聚晶金刚石复合片的制造方法，首先将聚晶金刚石层在高温高压条件下预烧结，将预烧结后的聚晶金刚石层进行脱低熔点金属处理，将过渡层在高温高压条件下与硬质合金粘结在一起，得到热稳定型高抗冲击聚晶金刚石复合片。本发明可作为钻头工具的耐磨切削元件，其具有高的耐热性，可承受深层地质下恶劣的高温作业环境，同时过渡层具有高高抗冲击性，可降低此热稳定型高抗冲击聚晶复合片的崩刃、脱层等现象，从而延长钻头使用寿命。
Description
技术领域
本发明涉及超硬复合材料技术领域，尤其涉及一种热稳定型高抗冲击聚晶金刚石复合片及制造方法。
背景技术
聚晶金刚石复合片（PDC）是在高温高压（HTHP）下，由金刚石层与硬质合金基体相互粘结形成的一种复合材料，其是石油、天然气、煤炭等钻采用钻头工具上重要的耐磨切削元件。然而，针对耐磨切削元件的热稳定性、抗冲击性等不断的改善是钻采业快速发展的保障。本领域技术人员及制造商改善PDC性能的方法各不相同，如改善聚晶金刚石层表面结构、界面结构及硬质合金性能等，而通过调整聚晶金刚石层微观结构是改善PDC耐热性及抗冲击性的重要本质手段。
随着天然气、石油开采条件变得愈发苛刻，尤其是页岩气、油等非常规能源的开采，现行常规PDC很难达到低成本作业。由此，本发明提出一种热稳定型高抗冲击聚晶金刚石复合片，其适合于深层复杂地形钻进，且减少提钻次数、缩短钻采周期，从而达到能源低成本开采。
发明内容
本发明的目的在于通过调整聚晶金刚石层的微观结构，提供一种高效率的热稳定型高抗冲击聚晶金刚石复合片，其使用中可延长钻头寿命，大幅度降低钻采作业成本。
本发明采用的技术方案为：一种热稳定型高抗冲击聚晶金刚石复合片，包括聚晶金刚石层及与聚晶金刚石层相粘结的硬质合金基体，所述的聚晶金刚石层为热稳定型，包括渗透层和过渡层。
一种热稳定型高抗冲击聚晶金刚石复合片的制造方法，包括如下步骤：
第一步，将聚晶金刚石层在温度约1450℃、压力约5.5GPa条件下进行高温高压预烧结，烧结完成后得到带支撑物的聚晶金刚石层或不带支撑物的聚晶金刚石层；
第二步，将预烧结后的聚晶金刚石层采用液态酸或酸蒸汽压进行完全或部分脱低熔点金属处理，所述的液态酸为氢氟酸或硝酸，所述的酸蒸汽压为氢氟酸蒸汽或硝酸蒸汽。
第三步，引入过渡层，将20-60%金刚石微粉与40-80%催化剂与硬质合金基体在温度1400-1600℃、压力5.5-6.5GPa的高温高压条件下粘结在一起，所述的催化剂为钴、镍或铁。
进一步，在脱低熔点金属处理后可进行二次渗透处理。
进一步，所述的二次渗透处理方法包括真空熔融渗透法或高温高压渗透法或其组合；所述的真空熔融渗透法的熔融条件在600-1000℃，所述的高温高压渗透法的渗透条件为温度在1400-1600℃、压力为5.5-6.5GPa。
进一步，二次渗透处理所选择合适的物质包括非计量碳化物或碳氮化物、铝、硅、硼等物质中一种或多种物质的组合。
本发明的有益效果为：本发明提供热稳定型高抗冲击聚晶金刚石复合片，在钻采钻进过程中，利用此类聚晶金刚石复合片作为钻头工具的耐磨切削元件，其具有高的耐热性，可承受深层地质下恶劣的高温作业环境；另一方面，此过渡层具有高的抗冲击性，可降低此热稳定型高抗冲击聚晶复合片的崩刃、脱层等现象，从而延长钻头使用寿命。
附图说明
图1是本发明中的结构示意图。
具体实施方式
为了更清楚地理解本发明，下面将结合实施例进一步阐明本发明的内容，但本发明的内容不仅局限于下面的实施例。基于本发明中实施例，本领域普通技术人员在没有做出创造性劳动前体下所获得其它所有实施例，均将属于本发明保护的范畴。
如图1所示，本发明包括聚晶金刚石层100及与其相粘结的硬质合金基体200，聚晶金刚石层100包括渗透层101及过渡层102。
实施例1：
本实施例为直径15.88 mm、高度13.2 mm的热稳定型高抗冲击聚晶金刚石复合片。此PDC的预烧结聚晶金刚石层制造包括第一次HPHT处理，温度约1450℃、压力约5.5GPa的条件下烧结合成无支撑聚晶金刚石体，再将此聚晶体加工，经如氢氟酸、硝酸和盐酸的混合酸后完全脱去低熔点金属，最后在真空下对聚晶金刚石层进行铝的熔融单面渗透，渗透温度在700-900℃，渗透时间为5min-2h。将上述预烧结聚晶金刚石层、粉体过渡层（45%金刚石微粉与65%钴粉）与硬质合金基体在第二次HPHT处理，温度约1400℃、压力约6.0GPa的条件下烧结合成此热稳定型高抗冲击聚晶金刚石复合片。
此热稳定型高抗冲击聚晶金刚石复合片对比常规复合片进行实验室测试，测试结果显示，耐热性提高约80%、抗冲击性提高约200%。
实施例2：
本实施例为直径15.88 mm、高度13.2 mm的热稳定型高抗冲击聚晶金刚石复合片。此PDC的预烧结聚晶金刚石层制造包括第一次HPHT处理，处理温度约1450℃、压力约5.5GPa的条件下烧结合成无支撑聚晶金刚石体，再将此聚晶体加工、经氢氟酸、硝酸和盐酸的混合酸后完全脱去低熔点金属。接着，将非计量碳化钛作为渗透层置于预烧结聚晶金刚石层顶部与粉体过渡层（45%金刚石微粉与65%钴粉）、硬质合金基体在第二次HPHT处理，处理温度约1550℃、压力约6.5GPa的条件下烧结合成此热稳定型高抗冲击聚晶金刚石复合片。
此热稳定型高抗冲击聚晶金刚石复合片对比常规复合片进行实验室测试，测试结果显示，耐热性提高约120%、抗冲击性提高约180%。
以上所述仅为本发明的优选实施例，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明的技术方案前提下，还可做出若干修改或等同替代，这均视为本发明的保护范畴。
Claims (5)
1.一种热稳定型高抗冲击聚晶金刚石复合片，其特征在于：包括聚晶金刚石层及与聚晶金刚石层相粘结的硬质合金基体，所述的聚晶金刚石层为热稳定型，包括渗透层和过渡层。
2.一种热稳定型高抗冲击聚晶金刚石复合片的制造方法，包括如下步骤：
第一步，将聚晶金刚石层在温度约1450℃、压力约5.5GPa条件下进行高温高压预烧结，烧结完成后得到带支撑物的聚晶金刚石层或不带支撑物的聚晶金刚石层；
第二步，将预烧结后的聚晶金刚石层采用液态酸或酸蒸汽压进行完全或部分脱低熔点金属处理，所述的液态酸为氢氟酸或硝酸，所述的酸蒸汽压为氢氟酸蒸汽或硝酸蒸汽；
第三步，引入过渡层，将20-60%金刚石微粉与40-80%催化剂与硬质合金基体在温度1400-1600℃、压力5.5-6.5GPa的高温高压条件下粘结在一起，所述的催化剂为钴、镍或铁。
3.根据权利要求2所述的一种热稳定型高抗冲击聚晶金刚石复合片的制造方法，其特征在于：在脱低熔点金属处理后可进行二次渗透处理。
4.根据权利要求3所述的一种热稳定型高抗冲击聚晶金刚石复合片的制造方法，其特征在于：所述的二次渗透处理方法包括真空熔融渗透法或高温高压渗透法或其组合；所述的真空熔融渗透法的熔融条件在600-1000℃，所述的高温高压渗透法的渗透条件为温度在1400-1600℃、压力为5.5-6.5GPa。
5.根据权利要求4所述的一种热稳定型高抗冲击聚晶金刚石复合片的制造方法，其特征在于：二次渗透处理所选择合适的物质包括非计量碳化物或碳氮化物、铝、硅、硼等物质中一种或多种物质的组合。
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| CN107376786A (zh) * | 2017-08-24 | 2017-11-24 | 河南理工大学 | 一种高硬度聚晶金刚石烧结设备及相应烧结方法 |
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| CN108735617A (zh) * | 2017-04-20 | 2018-11-02 | 中国砂轮企业股份有限公司 | 打线工具 |
| CN107376786A (zh) * | 2017-08-24 | 2017-11-24 | 河南理工大学 | 一种高硬度聚晶金刚石烧结设备及相应烧结方法 |
| CN107376786B (zh) * | 2017-08-24 | 2020-12-18 | 河南理工大学 | 一种高硬度聚晶金刚石烧结设备及相应烧结方法 |
| CN108145384A (zh) * | 2017-12-27 | 2018-06-12 | 武汉锐特金刚石有限公司 | 一种齿面金刚石复合片及其制造方法 |
| CN108147407A (zh) * | 2018-01-05 | 2018-06-12 | 李伟 | 一种优化金刚石复合片及其原料优化方法 |
| CN110090960A (zh) * | 2019-05-29 | 2019-08-06 | 河南四方达超硬材料股份有限公司 | 一种微观结构均匀的聚晶金刚石复合片的制备方法及产物 |
| US11772977B2 (en) | 2019-07-10 | 2023-10-03 | Sf Diamond Co., Ltd. | Polycrystalline diamond compact table with polycrystalline diamond extensions therefrom |
| CN111852344A (zh) * | 2020-07-15 | 2020-10-30 | 广东钜鑫新材料科技股份有限公司 | 聚晶金刚石复合片及其制备方法 |
| CN111852344B (zh) * | 2020-07-15 | 2022-04-08 | 广东钜鑫新材料科技股份有限公司 | 聚晶金刚石复合片及其制备方法 |
| USD997219S1 (en) | 2021-10-14 | 2023-08-29 | Sf Diamond Co., Ltd. | Polycrystalline diamond compact with a double-layer structure |
| USD1006073S1 (en) | 2021-10-14 | 2023-11-28 | Sf Diamond Co., Ltd. | Polycrystalline diamond compact with a raised surface sloping to a peripheral extension |
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| USD1026980S1 (en) | 2021-10-14 | 2024-05-14 | Sf Diamond Co., Ltd. | Polycrystalline diamond compact with a raised surface and groove therein |
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