CN108349067A - Polycrystalline diamond, method, cutting element and the earth-boring tools for forming polycrystalline diamond - Google Patents

Polycrystalline diamond, method, cutting element and the earth-boring tools for forming polycrystalline diamond Download PDF

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Publication number
CN108349067A
CN108349067A CN201680060883.2A CN201680060883A CN108349067A CN 108349067 A CN108349067 A CN 108349067A CN 201680060883 A CN201680060883 A CN 201680060883A CN 108349067 A CN108349067 A CN 108349067A
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diamond
alloy
diamond particles
particles
iridium
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Chinese (zh)
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M·W·伯德
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Ge (ge) Beck Hughes Ltd
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Ge (ge) Beck Hughes Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0009Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C26/00Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001Cutting tools, earth boring or grinding tool other than table ware
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps

Abstract

The present invention relates to it is a kind of formed polycrystalline diamond method, the method includes:In at least partially offer alloy of multiple diamond particles;And the multiple diamond particles are made to be subjected to high-temperature high-pressure craft to be formed in the polycrystalline diamond material with particle linkage between adjacent diamond particles.The alloy includes iridium and nickel, and at least about the 92% of the total volume that the volume of the diamond particles is the alloy and the diamond particles.The polycrystalline diamond material includes at least about diamond of 92 volume %.Composite polycrystal-diamond includes the alloy in the diamond crystals being bonded to each other by particle linkage and the clearance space being arranged between the diamond crystals.The diamond crystals account at least the 94% of the volume of the composite polycrystal-diamond.Earth-boring tools may include drill main body and such composite polycrystal-diamond.

Description

Polycrystalline diamond, method, cutting element and the earth-boring tools for forming polycrystalline diamond
Priority claim
This application claims September in 2015 submit within 8th about " POLYCRYSTALLINE DIAMOND, METHODS OF The U.S. Patent Application Serial Number 14/ of FORMING SAME, CUTTING ELEME NTS, AND EARTH-BORING TOOLS " The equity of 847,586 applying date.
Technical field
The embodiment of the disclosure relate generally to polycrystalline diamond, cutting element, earth-boring tools and formed such material, The method of cutting element and tool.
Background technology
Earth-boring tools for forming pit shaft in subsurface formations may include multiple cutting elements fixed to main body.Example Such as, it includes (also referred to as " drag bit ") multiple cutting elements that fixed cutting tooth, which bores ground rotary drilling-head, these cutting elements are fixed Ground is attached to the drill main body of drill bit.Similarly, it includes being mounted on to prolong from the supporting leg of drill main body that cutter, which bores ground rotary drilling-head, Gear wheel on the bearing pin of stretching so that each gear wheel can surround the bearing pin installed above for having gear wheel and rotate.It can incite somebody to action Multiple cutting elements are installed on each gear wheel of drill bit.
The cutting element used in earth-boring tools generally includes composite polycrystal-diamond (commonly referred to as " PDC ") cutting Tooth, these cutting tooths are to include the cutting element of polycrystalline diamond (PCD) material.By under high pressure and high temperature conditions, usually When there are catalyst (such as cobalt, iron, nickel or its alloy or mixture), relatively small diamond crystals or crystal are sintered And be combined together to form polycrystalline diamond material layer in cutting element substrate, such polycrystalline diamond cutting can be formed Element.These processes are commonly known as high pressure, high temperature (or " HPHT ") technique.Catalyst material is mixed with diamond crystals with By the amount of oxygen and carbon dioxide oxidized diamond and promote the combination of diamond and diamond during reducing HPHT techniques.
Cutting element substrate can include cermet material (that is, ceramic-metal composite material), such as cobalt-sintering carbon Change tungsten.In such cases, the cobalt in cutting element substrate (or other catalyst materials) can be drawn into gold in sintering process In hard rock crystal grain or crystal, and as the catalyst material by diamond crystals or Crystallization diamond table.In other methods In, before crystal grain or crystal being together sintered in HPHT techniques, by powdered catalytic materials and diamond crystals or Crystal mixes.
When forming diamond table using HPHT techniques, catalyst material can be retained in gained polycrystalline diamond platform In clearance space between diamond crystals or crystal.Due to the friction at the contact point between cutting element and stratum, During use when hot machining element, the presence of the catalyst material in diamond table may lead to the heat waste in diamond table Wound.
Traditional PDC performances depend on the catalyst alloy of the input diamonds of inswept compacting during HPHT is synthesized.It passes The catalyst alloy of system is cobalt-based, containing different amounts of nickel, tungsten and chromium, the Buddha's warrior attendant between diamond to promote compacting Stone symbiosis.However, other than promoting the formation that diamond is combined with diamond during HPHT is sintered, these alloys also help In forming graphite by diamond during probing.The formation of graphite can destroy diamond necked-in region (that is, crystal boundary), because turning There are about 57% volume expansions during change.This phase transformation is referred to as " reverse transformation " or " reversed graphitization ", and usually exists Occur close at 600 DEG C to 1,200 DEG C of temperature (close to the cutting temperature undergone during DRILLING APPLICATION).This mechanism, with gold The mismatch of the coefficient of thermal expansion of symbolic animal of the birth year and diamond is combined, it is considered to be the pith of general performance standard, referred to as " heat is steady It is qualitative ".From experiment abrasive conditions in terms of, reverse transformation seems to make the thermal stability of PDC to occupy an leading position, to promote cutting edge and The premature degradation of performance.
In order to reduce to the different heat expansion rate and the related problem of reverse transformation in polycrystalline diamond cutting element, Develop so-called " thermostabilization " polycrystalline diamond (TSD) cutting element.It can be by using such as acid from diamond table Catalyst material (for example, cobalt) is leached in clearance space between diamond crystals to form TSD cutting elements.It can be from Buddha's warrior attendant Shitai County removes essentially all of catalyst material.It is reported that wherein essentially all catalyst material is soaked from diamond table The TSD cutting elements gone out are heat-staple at a temperature of being up to about 1,200 DEG C.However it is reported that the diamond leached completely Platform is relatively more crisp than the diamond table not leached and is easily influenced by shear stress, compression stress and tensile stress.In order to carry For with relative to do not leach diamond table it is more thermally stable but relative to the diamond table leached completely it is also relatively less crisp And the cutting element of the diamond table less easily influenced by shear stress, compression stress and tensile stress, there has been provided It has for example been leached adjacent to the cutting face of platform from diamond table including wherein only a part catalyst material, and from cutting face edge The cutting element of the diamond table of the side surface leaching of platform.
Invention content
In some embodiments, a kind of method forming polycrystalline diamond includes:Multiple diamond particles at least Alloy is provided on part;And multiple diamond particles is made to be subjected to high-temperature high-pressure craft to be formed between adjacent diamond particles Polycrystalline diamond material with particle linkage.The alloy includes iridium and nickel, and the volume of diamond particles is alloy and gold At least about the 92% of the total volume of hard rock particle.Polycrystalline diamond material includes at least about diamond of 92 volume %.
In other embodiments, a kind of method forming polycrystalline diamond includes:Multiple diamond particles at least Alloy is provided on part;And multiple diamond particles is made to be subjected at least pressure of 5GPa and at least 1,400 DEG C of temperature with shape At the porous composite polycrystal-diamond with particle linkage between adjacent diamond particles.The alloy is comprising nickel and at least about The iridium of 10 moles of %.
In certain embodiments, composite polycrystal-diamond includes the diamond crystals being bonded to each other by particle linkage And the alloy being arranged in the clearance space between diamond crystals.The alloy includes iridium and nickel, and is from about 1 mole of % Iridium of the iridium to about 99 moles of %.Diamond crystals account at least the 94% of the volume of composite polycrystal-diamond.Earth-boring tools can be with Including drill main body and such composite polycrystal-diamond.
Brief description
Although it is considered as the disclosure that claims of specification conclusion part, which particularly point out and which is distinctly claimed in, Embodiment, but when read in conjunction with the accompanying drawings, from can more easily be determined to the description of the embodiment of the disclosure below The various feature and advantage of the embodiment of the disclosure, in attached drawing:
Fig. 1 is the implementation of the cutting element (that is, glomerocryst composite sheet) of the polycrystalline diamond comprising certain volume in substrate Perspective view after the part excision of scheme;
Fig. 2 is how the microstructure of the polycrystalline diamond for the cutting element for showing Fig. 1 can show under magnification Simplification view;
Fig. 3 with showing the brill including cutting element as described herein rotary drilling-heads;
Fig. 4 is can be used to form such as the cutting element of Fig. 1 and Fig. 2 according to some embodiments of methods described herein The simplification figure of coated particle;
Fig. 5 is can be used to form such as the cutting element of Fig. 1 and Fig. 2 according to some embodiments of methods described herein The simplification figure of another coated particle;
Fig. 6 is the simplified cross-sectional view for the material for showing the cutting element for being used to form Fig. 1 in container, and the container is accurate It is standby to be subjected to HPHT sintering process;
Fig. 7 is the curve graph of the Carbon Solubility under 1 bar in iridium and nickel alloy;And
Fig. 8 is the curve graph of the liquidus curve of the iridium and nickel alloy that are saturated with carbon under 1 bar.
Specific implementation mode
Diagram provided herein is not the actual view of any specific cutting element or tool, and is only for describing this public affairs The idealization for the embodiment opened indicates.In addition, the element shared between attached drawing can keep identical digital number.
As used herein, term " particle " means and includes average-size to be about 500 μm or times of smaller solid matter What coherent body, the either material as particle, powder or any other type.Crystal grain (for example, crystal) and coating crystal grain For a plurality of types of particles.As used herein, term " nano particle " means and includes average grain diameter to be about 500nm or smaller Any particle.Nano particle includes that the average grain size in composite polycrystal-diamond is about 500nm or smaller crystal grain.
As used herein, term " particle linkage " means and any between the atom that is included in the neighboring die of material Direct atom key (for example, covalent bond, ionic bond, metallic bond etc.).
As used herein, term " Nano diamond " and " diamond nano-particles " mean and include nanocrystalline carbon material Any monocrystalline or glomerocryst or aggregation, it includes the mixture of sp-3 and sp-2 bonded carbons, wherein each particle or crystal (no matter It is a part for monocrystalline or aggregation) mainly it is made of sp-3 keys.Commercial Nano diamond is typically derived from detonation source (example Such as, ultra-dispersed diamond or UDD) and crushing source, and can be natural or synthetic manufacture.It is naturally occurring to receive Rice diamond includes the natural lonsdaleite phase identified with meteoric body deposit.
As used herein, term " polycrystalline diamond " means and includes comprising by interparticle diamond-diamond key Any material of the multiple diamond crystals or crystal that are directly joined together.The crystal structure of each crystal grain of polycrystalline diamond It can be randomly oriented in the space in polycrystalline diamond.
As used herein, term " polycrystalline diamond combination " means and includes any structure for including polycrystalline diamond, The polycrystalline diamond includes the particle linkage key formed by some technique, and the technique is related to precursor material or is used for shape Apply pressure (for example, compacting) at the material of composite polycrystal-diamond.
As used herein, term " earth-boring tools " means and includes times for the drilling well during the formation or expansion of pit shaft The drill bit or tool of what type, and include for example rotary drilling-head, drill hammer, coring bit, off-balance bit, Double Circular Bit, Reamer, milling cutter, drag bit, rock bit, Mixed drilling bit and other drill bits known in the art and tool.
Fig. 1 shows cutting element 100, which can form as disclosed herein.Cutting element 100 Including polycrystalline diamond 102.Optionally, cutting element 100 can also include substrate 104, and polycrystalline diamond 102 can be incorporated into The substrate, or form polycrystalline diamond 102 on this substrate under the conditions of above-mentioned HPHT.For example, substrate 104 can be with The general cylindrical main body of tungsten carbide material including cobalt sintering, although the base of different geometries and composition can also be used Bottom.Polycrystalline diamond 102 can be in substrate 104 in the form of the platform (that is, layer) of polycrystalline diamond 102, as shown in Figure 1.It is poly- Diamond 102 can be arranged on the surface of (for example, be formed in or be fixed to) substrate 104.In a further embodiment, Cutting element 100 can be only the polycrystalline diamond 102 of the certain volume with any desired shape, and may not include Any substrate 104.Cutting element 100 is properly termed as " glomerocryst composite sheet ", or if polycrystalline diamond 102 includes diamond, Then it is known as " composite polycrystal-diamond ".
As shown in Fig. 2, polycrystalline diamond 102 may include forming the alternate of three dimensional diamond network and be combineding with each other Crystal grain.Optionally, in some embodiments, the crystal grain of polycrystalline diamond 102 can have multimodal (for example, bimodal, three peaks, Deng) size distribution.For example, polycrystalline diamond 102 may include the multimodal size distribution as disclosed at least one of following:It is beautiful The publication on November 12nd, 8,579,052,2013 of state's patent No., entitled " Polycrystalline Compacts Including In-Situ Nucleated Grains, Earth-Boring Tools Including Such Compacts, and Methods of Forming Such Compacts and Tools ";U.S. Patent number 8,727,042, On May 20th, 2014 is issued, entitled " Polycrystalline Compacts Having Material Disposed in Interstitial Spaces Therein, and Cutting Elements Including Such Compacts ";With And U.S. Patent number publication on July 30th, 8,496,076,2013, entitled " Polycrystalline Compacts Including Nanoparticulate Inclusions, Cutting Elements and Earth-Boring Tools Including Such Compacts, and Methods of Forming Such Compacts ";Wherein each patent Disclosure be all incorporated herein by reference in their entirety.
For example, in some embodiments, polycrystalline diamond 102 can include larger crystal grain 106 and smaller crystal grain 108.The average particle size particle size (for example, average diameter) of larger crystal grain 106 and/or smaller crystal grain 108 can be less than 0.5mm, it is less than 0.1mm, is less than 0.01mm, is less than 1 μm, is less than 0.1 μm or even less than 0.01 μm.That is, larger Crystal grain 106 and smaller crystal grain 108 can include respectively that (average particle size range is about 1 μm to about 500 μm for the particle of micron-scale The crystal grain of (0.5mm)), the particle (crystal grain that average particle size range is about 500nm (0.5 μm) to about 1 μm) of submicron-scale and/ Or nano particle (average grain diameter is about 500nm or smaller particles).In some embodiments, larger crystal grain 106 can be with For the diamond particles of micron-scale, smaller crystal grain 108 can be the diamond particles or diamond nano-particles of sub-micron. In some embodiments, larger crystal grain 106 can be the diamond particles of sub-micron, and smaller crystal grain 108 can be gold Hard rock nano particle.In other embodiments, the crystal grain of polycrystalline diamond 102 can have monomodal grit distribution.Glomerocryst gold Hard rock 102 may include the direct particle linkage 110 between crystal grain 106,108, as being represented by dashed line in Fig. 2.If crystal grain 106,108 be diamond particles, then direct particle linkage 110 can be diamond-diamond key.In polycrystalline diamond 102 The crystal grain 106,108 be combineding with each other between there are clearance spaces.In some embodiments, some in these clearance spaces May include the gap 113 in polycrystalline diamond 102, wherein there is no solids or liquid substance (although may be deposited in gap In the gas of such as air).Alloy material 112 can reside between the crystal grain 106,108 not by polycrystalline diamond 102 occupies In the part in gap space, and can be in the form of the coating around the crystal grain 106,108 of polycrystalline diamond 102.
As used herein, term " crystallite dimension " means and includes from the geometry measured across the two-dimensional section of bulk material Average diameter.The geometric mean diameter of one group of particle can be determined using techniques known in the art, in such as following documents Those of illustrate technology:Ervin E.U nderwood, QUANTITATIVE STEREOLOGY, 103-105 (Addison- Wes ley Publishing Company, Inc., 1970), the disclosure of which is incorporated herein by reference in their entirety.In this field In it is known that the average crystal grain ruler of the crystal grain in microstructure can be determined by measuring the crystal grain of micro-structure under magnification It is very little.It is, for example, possible to use scanning electron microscope (SEM), field emission scanning electron microscope (FESEM) or saturating transmitted electron are aobvious Micro mirror (TEM) come observe or be imaged polycrystalline diamond 102 surface (for example, polycrystalline diamond 102 polishing and etching surface). Commercially available vision system is usually used together with such microscopic system, and these vision systems can measure it is microcosmic The average grain size of crystal grain in structure.
Referring again to Fig. 2, alloy material 112 may include the formation of promotion particle linkage 110 and wherein carbon is soluble Material.For example, alloy material can include iridium and nickel.The alloy of iridium and nickel can show carbon dissolution more higher than only nickel Degree, and therefore can quickly promote the formation of particle linkage 110 than only nickel.It is shown in FIG. 7 in iridium and nickel alloy 1 The curve graph of Carbon Solubility under bar.With the increase (that is, along increase of the x-axis of Fig. 7) of iridium molar percentage, carbon is in the alloy Solubility increase.The Carbon Solubility of carbon in certain Ir-Ni alloys could possibly be higher than the solubility of carbon in cobalt.For example, at 1 bar Under, the Ir-Ni alloys that the molar percentage of iridium is greater than about 15% can have Carbon Solubility more higher than cobalt.
The alloy of iridium and nickel can be shown between the fusing point (2,446 DEG C) of pure iridium and the fusing point (1,455 DEG C) of pure nickel Liquidus curve (that is, fusing point).Have less than about 2,000 DEG C, less than about 1,800 DEG C for example, alloy material 112 can be formulated into Or it is even less than about 1,600 DEG C such as about 1,550 DEG C or about 1,525 DEG C of liquidus curve.When alloy material 112 contains carbon, liquid Phase line is depressed based on concentration of carbon.For example, liquidus curve of the nickel being saturated with carbon under 1 bar is about 1,326 DEG C.The iridium being saturated with carbon Liquidus curve under 1 bar is about 2,286 DEG C.The song of the liquidus curve of the iridium and nickel alloy that are saturated with carbon under 1 bar is shown in FIG. 8 Line chart.With the increase (that is, along increase of the x-axis of Fig. 8) of iridium molar percentage, the liquidus curve of alloy increases.
In some embodiments, alloy material 112 can include carbon, iridium and nickel.That is, carbon is soluble in alloy material In 112.Alloy material 112 can also include other elements.Can by during HPHT is sintered by carbon spread to alloy material Alloy material 112, the binary mixture of such as iridium and nickel are formed in 112 precursor.Because iridium and nickel show as unlimited each other It is solvable, therefore respective relative quantity can be selected to adjust fusion temperature (liquidus curve), the carbon content of alloy material 112, carbon is molten Solution degree or any other property.As non-limitative example, alloy material 112 can be formed by a kind of mixture, the mixture packet Containing from the iridium of about 1.0 moles of % to the iridium of about 99.0 moles of %, from the iridium of about 5 moles of % to the iridium of about 40 moles of %, from about 10 The iridium of mole % to the such as about 22 moles % of iridium of about 35 moles of % iridium.In some embodiments, it is used to form alloy material The remainder of the mixture of material can be substantially nickel.In other embodiments, it can also include other elements.
Alloy material 112 can have the composition substantially similar with above-mentioned precursor, but this is because carbon is burnt in HPHT It may be had diffused into alloy material 112 during knot.The amount of carbon in alloy material 112 can depend under hpht conditions The solubility of carbon in alloy material 112.For example, alloy material 112 can contain the carbon for being up to about 15 moles of %, such as about The carbon of 10 moles of % to about 14 moles of % carbon.The amount of carbon in alloy material 112 can be higher than composite polycrystal-diamond The Carbon Solubility of conventional metallic solvent catalyst metals and alloy used in formation.For example, cobalt (is used to form glomerocryst Buddha's warrior attendant The common metal solvent catalyst of stone) Carbon Solubility with about 11.4 moles of % carbon.In the conventional polycrystalline Buddha's warrior attendant of certain volume Shi Zhong, due to comprising clearance space, diamond usually account for the total volume of diamond table less than 100%.It is described herein simultaneously The polycrystalline diamond 102 shown in fig. 1 and 2 has alloy material 112 in clearance space, with traditional glomerocryst gold Hard rock composite sheet is compared, and relatively high diamond volume percent is can express out.For example, polycrystalline diamond 102 can include At least about diamond of 92 volume %, at least about diamond of 94 volume %, at least about diamond of 95 volume %, at least about 96 The diamond of the diamond of volume %, at least about diamond of 97 volume % or even at least about 99 volume %.In general, have There is the composite sheet of the diamond of more high-volume fractional that can show better wearability and improved resistance to thermal degradation.
In addition, clearance space may include one or more gaps 113, which is defined as glomerocryst platform The interior volume without solid or fluent material.Therefore, clearance space may include the volume occupied by alloy material 112 and by sky The volume that gap 113 occupies.The volume of alloy material 112 can be less than about the 50% of clearance space, all such as less than clearance spaces About 30%, it is less than about 20% or even less than about 10%.In some embodiments, most of gap 113 can be interconnected with shape At the Three-dimensional Open porous network extended through polycrystalline diamond 102.In other embodiments, most of gap 113 can be with It closes and is isolated each other.
The embodiment of cutting element 100 (Fig. 1) comprising the polycrystalline diamond 102 to manufacture as described herein, it can be with It is mounted to earth-boring tools and for removing subsurface formations material.Fig. 3 shows that fixed cutting tooth bores ground rotary drilling-head 160.It bores First 160 include drill main body 162.One or more cutting element 100 can be installed in the brill of drill bit 160 as described herein In head main body 162.Cutting element 100, which can be brazed or be otherwise secured to, to be formed in the outer surface of drill main body 162 In pit.Glomerocryst Buddha's warrior attendant can not also be leached before on drill main body before on drill main body Stone 102.Other kinds of earth-boring tools rock bit, drill hammer, Mixed drilling bit, reamer etc. can also include such as this Cutting element 100 described in text.
In some embodiments, the method for forming polycrystalline diamond may include to diamond particles and alloy material into Row HPHT sintering between diamond particles to form particle linkage.Diamond and alloy material can be set before sintering In being in contact with each other.For example, can alloy material be provided on diamond crystals or particle (for example, as painting before sintering Layer).Referring now to Fig. 4, diamond crystals 202 can be at least partially coated with alloy material 204 to form coating crystal grain 206.Although being shown as fully enclosed crystal grain 202 in Fig. 4, alloy material 204 can only cover the one of the outer surface of crystal grain 202 Part.Multiple crystal grain 202 can be uniformly coated.In some embodiments, crystal grain 202 can have a certain amount of on it Alloy material 204 distribution.For example, alloy material 204 can cover the table of the particle 202 in the granulate mixture to be sintered At least about 30% average value in face region.In some embodiments, it is mixed can to cover the particle to be sintered for alloy material 204 Close at least about the 90% of the surface region of about 70% to about 100% or crystal grain 202 of the surface region of the crystal grain 202 in object Average value.Alloy material 204 can be continuously formed on each crystal grain 202 so that even if alloy material 204 is not coated by entirely " island " of crystal grain 202, alloy material 204 can also be little or no disconnected with remaining alloy material 204 of on crystal grain 202 It opens.
Alloy material 204 can be formed to have any selected thickness, although relatively thin and uniform painting may be needed Layer.For example, the average thickness of alloy material 204 can be about 1 nanometer (nm) to about 50nm, about 5nm to about 20nm or about 10nm To about 15nm.
Can for example, by sputtering, physical vapour deposition (PVD) (PVD), chemical vapor deposition (CVD), plating or it is known in the art Any other technique come formed coating crystal grain 206.In some embodiments, it can be formed and be coated by PVD coating processes Crystal grain 206.PVD process can preferably control the composition and thickness of alloy material 204 than other coating processes.In addition, passing through PVD process carries out coating can provide high-purity alloy material 204 without damaging crystal grain 202 or alloy material on crystal grain 202 204.Alloy material 204 can be provided to PVD system as pre-alloyed materials or as individual business simple metal (for example, powder End, ingot etc.).PVD system can make alloy material 204 on crystal grain 202 with substantially uniform thickness deposition (for example, The thickness of alloy material 204 can be less than about 50%, be less than about 20%, be less than about 10% or be even less than about 5%).
PVD process can occur under initial high vacuum, such as less than about 10-7Under the pressure of support.Increase can be passed through Or argon gas or other inert gas flow velocities are reduced to change operating pressure.The deposition rate of material is (for example, pre-alloyed materials or a Other business pure element) it can change in this way as needed and formed and/or thickness with controlling.If the alloy material to be deposited It provides in powder form, then can promote uniform coating layer thickness, conjunction using the equipment of continuous rotation in situ during deposition Gold composition and powder surface coverage.For example, crystal grain 202 can be placed in the ball mill with abrasive media or be placed In the autogenous tumbling mill of not abrasive media.Grinder can be subjected to vacuum, and when the mill rotates, and alloy material 204 can To deposit on crystal grain 202.
In some embodiments, and as shown in figure 5, diamond crystals 212 may include the non-gold that can be described as carbon shell Hard rock carbon coating 216 or layer.Non-diamond carbon coating 216 may include for example graphite, graphene, fullerene, amorphous carbon or Any other carbon phase or form.Alloy material 204 can be formed on non-diamond carbon coating 216.Alloy material 204 can be as Above with respect to being formed like that described in Fig. 4.Although non-diamond carbon coating 216 and alloy material 204 are shown as complete in Figure 5 Diamond crystals 212 are encapsulated, but in other embodiments, non-diamond carbon coating 216 and/or alloy material 204 can be only Partly diamond coated crystal grain 212.Diamond crystals 212 may include single diamond crystal or diamond crystal cluster.
Non-diamond carbon coating 216 can be reacted with alloy material 204 to form alloy material 112 shown in Fig. 2.One In a little embodiments, at least part of non-diamond carbon coating 216 can undergo atomic structure during or before sintering Variation.Some carbon atoms in non-diamond carbon coating 216 can spread and enter the diamond crystal knot of diamond crystals 212 Structure (that is, contributing to the grain growth of diamond crystals 212).For example, the carbon atom from non-diamond carbon coating 216 can be " neck " of diamond is formed (that is, non-diamond carbon between adjacent diamond crystals 106,108 (Fig. 2) during sintering Diamond can be converted into).Some carbon atoms in non-diamond carbon coating 216 can spread and enter alloy material 204, In some can then be converted into diamond.
In some embodiments, crystal grain 202 (Fig. 4) or crystal grain 212 (Fig. 5) can roll poly- to decompose with inert media Collective simultaneously promotes uniformly coating.Assembled and in coating procedure with reducing furthermore it is possible to be pre-processed to crystal grain 202,212 Improve the flowing of crystal grain 202,212.For example, crystal grain 202,212 can be pre-processed with hydrogen with remove it is oxygen-containing, nitrogenous and Aqueous surface impurity and/or it is functionalized these surfaces with methyl or methylene.Additional functionalization, such as long alkyl chain or fluorine Compound can be used for Nano diamond particle.Coating crystal grain 202,212 may include unimodal nanometer or micron diamond charging or The composite blend for nanometer and the micron diamond charging that person's Nano diamond composition is about 1 weight % to about 99 weight %. The crystal grain coated by PVD process can have relatively uniform coating thickness in wide particle size range, this can be by alloy Material 204 be more evenly distributed into alloy material 204 during sintering advantageous position (that is, the contact point between neighboring die Place).Other multimodal Nano diamond or multimodal micron diamond charging can also be coated and then it is dry-mixed, formed it is compound total Mixed object.As discussed in more detail below, the feed product finally coated can be sintered under hpht conditions.
With reference to figure 6, the particle 302 of the diamond with alloy material can be located at container 304 (for example, metal can) above It is interior.Particle 302 may include such as diamond crystals or crystal (for example, diamond gravel), will be finally in the glomerocryst of sintering Crystal grain 106,108 is formed in diamond 102 (Fig. 2).Particle 302 may include the painting for being for example formed with alloy material 204 above Flip grain 202,212 (Fig. 4 and Fig. 5).Container 304 may include the inner cup 306 that can wherein provide particle 302.In some realities Apply in scheme, substrate 104 (for example, as shown in Figure 1) can also optionally be arranged in inner cup 306 on particle 302 or Under, and can finally be encapsulated in container 304.Container 304 may further include head cover 308 and bottom cover 310, the top Lid and the bottom cover can be assembled and be combined together (for example, forging combines) has particle 302 and optional substrate wherein Around 104 inner cup 306.
In container 304, particle 302 can have the filling fraction of about 45% to about 99% (that is, its void space accounts for totality Long-pending about 55% to about 1%), the filling fraction of such as about 50% to about 70% (that is, void space of the total volume about 50% to About 30%).
Wherein the container 304 with particle 302 can be subjected to HPHT techniques to form polycrystalline diamond (for example, institute in Fig. 1 The polycrystalline diamond 102 shown).For example, container 304 can be subjected at least about pressure of 5.5GPa and at least about 1,000 DEG C of temperature Degree.In some embodiments, container 304 can be subjected at least about 6.0GPa, or the pressure of even at least about 6.5GPa.Example Such as, container 304 can be subjected to the pressure of about 5.5GPa to about 10.0GPa or about 6.5GPa to about 8.0GPa.Container 304 can be through By at least about 1,600 DEG C, at least about 1,800 DEG C, at least about 2,000 DEG C or even at least about 2,500 DEG C of temperature.
In sintering process, the alloy material 204 being deposited on crystal grain 202,212 can be fused into liquid phase.Alloy material 204 can show as metal-solvent catalyst material to promote between the particle between crystal grain 202,212 (for example, diamond-Buddha's warrior attendant Stone) key formation, to by crystal grain 202,212 form glomerocryst composite sheet.It completes and is cooled to less than sintering temperature in sintering process When spending, cure in the clearance space between crystal grain 202,212 of the alloy material 204 in polycrystalline diamond 102.
The use of alloy material 204 as described herein can assign polycrystalline diamond 102 (Fig. 1 and Fig. 2) certain benefit Place.(include iridium and nickel) for example, alloy material 204 and can have Carbon Solubility more higher than traditional cobalt-base alloys.Not by appoint What specific theory fetters, and the carbon of higher concentration can correspond to the shape faster or evenly of particle linkage 110 in alloy material At.Therefore, compared with the sintering carried out with conventional catalyst, HPHT sintering can be within the shorter period or in lower pressure It is carried out under power.During sintering, the carbon of non-diamond forms can be converted into diamond, to increase particle linkage 110.
Further, since alloy material 204 can be applied on individual crystal grain 202,212, therefore alloy material 204 exists Entire polycrystalline diamond 102 need not be diffused through during sintering.Therefore, average diffusion distance is (that is, from any during sintering Average distance of the individual crystal grain to alloy material 204) it can be from such as 1mm (for example, the thickness of polycrystalline diamond 102 is aobvious Part) it is reduced to about 1 μm or even smaller.In some embodiments, average diffusion distance can be about 100nm or more It is small.
In addition, the use of alloy material 204 can allow in the place needed most as described herein, each particle that Alloy material 204 is provided at the point of this contact.Therefore, the volume without crystal grain or alloy material 204 is likely to become glomerocryst Buddha's warrior attendant Gap 113 in stone 102, and may not be needed to leach to form this gap 113.Therefore, it is formed by polycrystalline diamond 102 can have the metal than traditional polycrystalline diamond composite sheet lower concentration not leached.Since alloy material 204 can To be placed near the position for needing to form particle linkage, thus crystal grain 202,212 can more closely be filled without It has a negative impact to sintering process.The volume fraction of diamond may be than relatively higher in conventional material, this is at least partly Because clearance space can form than relatively smaller in conventional material.When fully sintered, polycrystalline diamond 102 can be It is porous, because the amount for the alloy material 204 being arranged on crystal grain 202,212 may be than the alloy material in conventional polycrystalline material Amount it is lower.
An advantage using iridium as the component of alloy material 204, which is iridium, can promote fine grain micro-structure, this can be with Promote thickness thin and the deposition of uniform coating.Quality control (that is, thickness and uniformity) can for the alloy containing iridium It more opposite than other alloys can be easier.For example, the diamond particles that crystallite dimension is about 10nm to about 0.5 μm can pass through PVD Relatively evenly coat harder with the alloy material 204 comprising iridium or iridium alloy.Power, gas pressure (etc. can be controlled Gas ions) and sedimentation time selected formed and thickness with generate alloy material 204.
It is used as coating by providing alloy material 112 or its precursor on crystal grain 106,108, it is possible to reduce pass through crystal grain 106, the time needed for 108 inswept alloy materials 112 and distance.Therefore, crystal grain 106,108 can be provided with lower be averaged certainly By journey and therefore there is higher filling fraction.This may cause polycrystalline diamond 102 that there are relatively high final densities (to burn Density after knot).For example, across crystal grain 106,108 mean free path may be about polycrystalline diamond 102 micro-structure crystal grain 106,108 diameter (for example, from about 1nm to about 20 μm), without being about the thickness of polycrystalline diamond 102 (for example, from about 1mm To 3.5mm), the ability without filling clearance space to alloy material 112 adversely affects.Furthermore, it is possible to alloyage Material 112 to avoid aoxidizing in air.Traditional diamond crystals can in air at a temperature of about 750 DEG C or In inert atmosphere reversal is proceeded by a temperature of about 1,200 DEG C.There is provided above with coating material crystal grain 106, At least some of 108 can limit crystal grain 106,108 is exposed to air or the time of other gases in HPHT techniques, to Limit the time (for example, carbon is converted to by diamond) that crystal grain 106,108 may degrade.It is closed in addition, crystal grain 106,108 can be used Golden material 112 more uniformly coats, and therefore can be more opposite than conventional polycrystalline material more resistant to degradation.
The other non-restrictive illustrative embodiment of the disclosure is described below.
Embodiment 1:A method of polycrystalline diamond is formed, the method includes:Multiple diamond particles extremely Alloy is provided in small part;And so that multiple diamond particles is subjected to high-temperature high-pressure craft be formed in adjacent diamond particles it Between with particle linkage polycrystalline diamond material.The alloy include iridium and nickel, and the volume of diamond particles be alloy and At least about the 92% of the total volume of diamond particles.Polycrystalline diamond material includes at least about diamond of 92 volume %.
Embodiment 2:According to the method described in embodiment 1, wherein at least partially carrying in multiple diamond particles It include at least the 30% of the surface region of alloy covering diamond particles for alloy.
Embodiment 3:According to the method described in embodiment 2, wherein at least partially carrying in multiple diamond particles It include at least the 75% of the surface region of alloy covering particle for alloy.
Embodiment 4:Method according to any one of embodiment 1 to 3, wherein multiple diamond particles extremely It includes that the thickness of alloy is formed on diamond particles as from about 1nm to the layer of about 50nm that alloy is provided in small part.
Embodiment 5:According to the method described in embodiment 4, wherein at least partially carrying in multiple diamond particles It is layers of the about 2nm to about 5nm for the thickness that alloy includes the formation alloy on diamond particles.
Embodiment 6:Method according to any one of embodiment 1 to 5, wherein multiple diamond particles extremely It includes providing the iridium comprising about 5 moles of % to the alloy of the iridium of about 40 moles of % that alloy is provided in small part.
Embodiment 7:According to the method described in embodiment 6, wherein at least partially carrying in multiple diamond particles Include providing the iridium comprising about 10 moles of % to the alloy of the iridium of about 35 moles of % for alloy.
Embodiment 8:Method according to any one of embodiment 1 to 7, wherein multiple diamond particles extremely It includes by alloy preparation at being substantially made of iridium and nickel that alloy is provided in small part.
Embodiment 9:Method according to any one of embodiment 1 to 8, wherein multiple diamond particles extremely Offer alloy includes by alloy preparation into the liquidus curve shown under atmospheric pressure less than about 1,600 DEG C in small part.
Embodiment 10:Method according to any one of embodiment 1 to 9, wherein in multiple diamond particles It includes that the alloy with multimodal size distribution is provided on multiple diamond particles at least partially to provide alloy.
Embodiment 11:Method according to any one of embodiment 1 to 10, wherein in multiple diamond particles It includes providing alloy on multiple diamond nano-particles at least partially to provide alloy.
Embodiment 12:Method according to any one of embodiment 1 to 11, wherein multiple diamond particles is made to pass through Included pressing for the temperature for making multiple diamond particles be subjected at least about 1,400 DEG C and at least about 5.0GPa by high-temperature high-pressure craft Power.
Embodiment 13:Method according to any one of embodiment 1 to 12, wherein multiple diamond particles is made to pass through Included the pressure for making multiple diamond particles be subjected between about 6.5GPa and 10GPa by high-temperature high-pressure craft.
Embodiment 14:Method according to any one of embodiment 1 to 13, wherein in multiple diamond particles It includes at least partially offer conjunction by physical gas-phase deposition in multiple diamond particles at least partially to provide alloy Gold.
Embodiment 15:Method according to any one of embodiment 1 to 14, wherein multiple diamond particles is made to pass through Included forming the polycrystalline diamond material for limiting at least one gap without therefrom leaching alloy by high-temperature high-pressure craft.
Embodiment 16:A method of polycrystalline diamond is formed, the method includes:Multiple diamond particles extremely Alloy is provided in small part;And make multiple diamond particles be subjected at least pressure of 5GPa and at least 1,400 DEG C of temperature with It is formed in the porous composite polycrystal-diamond with particle linkage between adjacent diamond particles.The alloy is comprising nickel and at least The iridium of about 10 moles of %.
Embodiment 17:According to the method described in embodiment 16, wherein multiple diamond particles at least partially It includes sputtering alloy on multiple diamond particles to provide alloy.
Embodiment 18:According to the method described in embodiment 16 or embodiment 17, wherein in multiple diamond particles At least partially provide alloy include with alloy cover diamond particles surface region at least 30%.
Embodiment 19:According to the method described in embodiment 18, wherein multiple diamond particles at least partially There is provided alloy includes the surface region that particle is covered with alloy at least 75%.
Embodiment 20:Method according to any one of embodiment 16 to 19, wherein in multiple diamond particles At least partially provide alloy include on diamond particles formed alloy thickness be from about 1nm to the layer of about 20nm.
Embodiment 21:According to the method described in embodiment 20, wherein multiple diamond particles at least partially Offer alloy includes that the thickness of the formation alloy on diamond particles is layers of the about 2nm to about 5nm.
Embodiment 22:Method according to any one of embodiment 16 to 21, wherein in multiple diamond particles The alloy that at least partially provides include that the alloy shown under atmospheric pressure less than about 1,600 DEG C of liquidus curve is provided.
Embodiment 23:Method according to any one of embodiment 16 to 22, wherein in multiple diamond particles At least partially provide alloy include on multiple diamond particles provide with multimodal size distribution alloy.
Embodiment 24:Method according to any one of embodiment 16 to 23, wherein making multiple diamond particles It includes forming the polycrystalline diamond material for limiting at least one gap to be subjected at least pressure of 5GPa and at least 1,400 DEG C of temperature Material, wherein at least one gap accounts for about the 1% to about 5% of the volume of composite polycrystal-diamond.
Embodiment 25:According to the method described in embodiment 24, wherein forming the glomerocryst gold for limiting at least one gap Hard rock material includes forming the polycrystalline diamond material for limiting at least one gap without therefrom leaching alloy.
Embodiment 26:Method according to any one of embodiment 16 to 25, wherein in multiple diamond particles At least partially offer alloy include that substantially uniform alloy-layer is formed on multiple diamond particles.
Embodiment 27:A kind of composite polycrystal-diamond, the composite polycrystal-diamond include:Pass through particle linkage The diamond crystals being bonded to each other;And the alloy in the clearance space between diamond crystals is set.The alloy includes iridium And nickel, and be the iridium from the iridium of about 1 mole of % to about 99 moles of %.Diamond crystals account for the volume of composite polycrystal-diamond At least 92%.
Embodiment 28:According to the composite polycrystal-diamond described in embodiment 27, wherein alloy table under atmospheric pressure Reveal the liquidus curve below about 1,600 DEG C.
Embodiment 29:According to the composite polycrystal-diamond described in embodiment 27 or embodiment 28, wherein Buddha's warrior attendant Stone crystal grain includes Nano diamond.
Embodiment 30:Composite polycrystal-diamond according to any one of embodiment 27 to 29, wherein alloy It is substantially free of iron and cobalt.
Embodiment 31:Composite polycrystal-diamond according to any one of embodiment 27 to 30, wherein glomerocryst Diamond compact includes at least diamond of 94 volume %.
Embodiment 32:According to the composite polycrystal-diamond described in embodiment 31, wherein composite polycrystal-diamond Including at least diamond of 94 volume %.
Embodiment 33:Composite polycrystal-diamond according to any one of embodiment 27 to 32, wherein alloy Account for about the 10% to about 90% of the total volume of clearance space.
Embodiment 34:Composite polycrystal-diamond according to any one of embodiment 27 to 33, wherein Buddha's warrior attendant Stone crystal grain shows multimodal size distribution.
Embodiment 35:A kind of earth-boring tools, the earth-boring tools include drill main body and according to embodiment 27 to 34 Any one of described in composite polycrystal-diamond.
Although describing the present invention, those skilled in the art about the embodiment of certain illustrations herein It will recognize and appreciate that the present invention is not limited thereto.But do not depart from the scope of the invention as claimed and its In the case of legal equivalents, many increases can be carried out to the embodiment of illustration, deletes and changes.In addition, an implementation The feature of scheme can be combined with the feature of another embodiment, remain at by it is considered as desirable by the inventor to invention scope It is interior.In addition, the embodiment of the disclosure can be used for the tool and material of different various types and configuration.

Claims (20)

1. a kind of method forming polycrystalline diamond, including:
In at least partially offer alloy of multiple diamond particles, wherein the alloy includes iridium and nickel, and it is wherein described The volume of diamond particles is at least about the 92% of the total volume of the alloy and the diamond particles;And
The multiple diamond particles are made to be subjected to high-temperature high-pressure craft to be formed between adjacent diamond particles between particle The polycrystalline diamond material of key, wherein the polycrystalline diamond material includes at least about diamond of 92 volume %.
2. according to the method described in claim 1, including wherein using in at least partially offer alloy of multiple diamond particles The alloy covers at least the 30% of the surface region of the diamond particles.
3. according to the method described in claim 1, being wherein included in at least partially offer alloy of multiple diamond particles The thickness that the alloy is formed on the diamond particles is from about 1nm to the layer of about 50nm.
4. according to the method described in claim 1, including wherein carrying in at least partially offer alloy of multiple diamond particles For the iridium comprising about 5 moles of % to the alloy of the iridium of about 40 moles of %.
5. according to the method described in claim 4, including wherein carrying in at least partially offer alloy of multiple diamond particles For the iridium comprising about 10 moles of % to the alloy of the iridium of about 35 moles of %.
6. according to the method described in claim 1, including wherein inciting somebody to action in at least partially offer alloy of multiple diamond particles The alloy preparation iridium and nickel at being substantially made of.
7. according to the method described in claim 1, including wherein inciting somebody to action in at least partially offer alloy of multiple diamond particles The alloy preparation is at the liquidus curve shown under atmospheric pressure less than about 1,600 DEG C.
8. according to the method described in claim 1, being wherein included in at least partially offer alloy of multiple diamond particles The alloy with multimodal size distribution is provided on multiple diamond particles.
9. according to the method described in claim 1, being wherein included in at least partially offer alloy of multiple diamond particles The alloy is provided on multiple diamond nano-particles.
10. according to the method described in claim 1, it includes making so that the multiple diamond particles is subjected to high-temperature high-pressure craft The multiple diamond particles are subjected to the pressure of at least about 1,400 DEG C of temperature and at least about 5.0GPa.
11. according to the method described in claim 1, it includes making so that the multiple diamond particles is subjected to high-temperature high-pressure craft The multiple diamond particles are subjected to the pressure between about 6.5GPa and 10GPa.
12. according to the method described in claim 1, including wherein logical in at least partially offer alloy of multiple diamond particles Cross physical gas-phase deposition multiple diamond particles at least partially offer alloy.
13. according to the method described in claim 1, it includes shape so that the multiple diamond particles is subjected to high-temperature high-pressure craft At the polycrystalline diamond material at least one gap of restriction without therefrom leaching the alloy.
14. a kind of composite polycrystal-diamond, including:
The multiple diamond crystals being bonded to each other by particle linkage are answered wherein the diamond crystals account for the polycrystalline diamond Close at least the 92% of the volume of piece;And
Alloy in clearance space between the diamond crystals is set, and the alloy includes iridium and nickel, wherein the conjunction Gold is comprising from the iridium of about 1 mole of % to the iridium of about 99 moles of %.
15. composite polycrystal-diamond according to claim 14, wherein the alloy shows to be less than under atmospheric pressure About 1,600 DEG C of liquidus curve.
16. composite polycrystal-diamond according to claim 14, wherein the alloy-based originally not iron content and cobalt.
17. composite polycrystal-diamond according to claim 14, wherein the alloy accounts for the totality of the clearance space Long-pending about 10% to about 90%.
18. composite polycrystal-diamond according to claim 14, wherein the alloy also includes carbon.
19. composite polycrystal-diamond according to claim 14, wherein the composite polycrystal-diamond is not leached.
20. a kind of earth-boring tools, including:
Drill main body;And
Composite polycrystal-diamond according to claim 14.
CN201680060883.2A 2015-09-08 2016-09-08 Polycrystalline diamond, method, cutting element and the earth-boring tools for forming polycrystalline diamond Pending CN108349067A (en)

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