CN108472731A - 超硬构造及其制造方法 - Google Patents

超硬构造及其制造方法 Download PDF

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Publication number
CN108472731A
CN108472731A CN201680077032.9A CN201680077032A CN108472731A CN 108472731 A CN108472731 A CN 108472731A CN 201680077032 A CN201680077032 A CN 201680077032A CN 108472731 A CN108472731 A CN 108472731A
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Prior art keywords
superhard
construction
glomerocryst
pcd
diamond
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CN108472731B (zh
Inventor
V·坎彦塔
M·米兰达费尔南德斯
J·C·P·祖奈加
X·张
M·S·奥兹贝拉克塔
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Element Six UK Ltd
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Element Six UK Ltd
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    • B22F3/10—Sintering only
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Abstract

一种超硬聚晶构造，其包括聚晶超硬材料本体，所述聚晶超硬材料本体包含包含超硬材料的结构，所述结构具有大于20体积％且至多约80体积％的孔隙率。一种形成这种超硬聚晶构造的方法，所述方法包括形成具有多个空隙的第一材料的骨架结构，用第二材料至少部分地填充所述一些或全部空隙以形成预烧结组件，以及处理所述预烧结组件以将超硬材料的晶粒烧结在一起从而形成包含超硬晶粒的第一区域和互穿第二区域的聚晶超硬材料本体；所述第二区域由所述第一材料或第二材料中不包含所述超硬晶粒的另一者形成；所述超硬晶粒形成孔隙率大于20体积％且至多约80体积％的烧结结构。

Description

超硬构造及其制造方法
技术领域
本公开涉及超硬构造和制造此类构造的方法，具体但非排他地涉及包括附接到基材的聚晶金刚石(PCD)结构并用作用于钻入地下的钻头的刀具插入件或元件的构造。
背景技术
聚晶超硬材料诸如聚晶金刚石(PCD)和聚晶立方氮化硼(PCBN)可在用于切割、机械加工、钻孔或者降解硬质或研磨材料(诸如岩石、金属、陶瓷、复合材料和含木材料)的多种工具中使用。具体地，包含PCD材料的切割元件形式的工具插入件被广泛用于钻头以便钻入地下以提取油或气。超硬工具插入件的使用寿命可能受到超硬材料断裂包括剥落和碎裂的限制，或受到工具插入件磨损的限制。
切割元件诸如用于凿岩钻头或其他切割工具中的那些通常具有基材形式的本体，所述基材具有界面端部/表面和超硬材料，所述超硬材料通过例如烧结工艺形成结合到基材的界面表面的切割层。基材通常由碳化钨-钴合金(有时称为烧结碳化钨)形成，并且超硬材料层通常是聚晶金刚石(PCD)、聚晶立方氮化硼(PCBN)或热稳定产物TSP材料，诸如热稳定聚晶金刚石。
聚晶金刚石(PCD)是超硬材料(也称为超级研磨材料)的实例，其包含大量基本上交互生长的金刚石晶粒，从而形成限定金刚石晶粒之间的间隙的骨架物。PCD材料通常包含至少约80体积％的金刚石，并且常规地通过使金刚石晶粒的聚集物经受例如大于约5GPa的超高压和至少约1,200℃的温度而制成。完全或部分地填充间隙的材料可被称为填料或粘结剂材料。
PCD通常在烧结助剂诸如钴的存在下形成，所述烧结助剂促进金刚石晶粒的交互生长。用于PCD的合适的烧结助剂通常还称为金刚石的溶剂-催化剂材料，这是因为它们在某种程度上溶解金刚石并催化其再沉淀的功能。金刚石的溶剂-催化剂理解为能够在金刚石热力学稳定的压力和温度条件下促进金刚石生长或金刚石晶粒之间的直接金刚石-至-金刚石交互生长的材料。因此，烧结PCD产物内的间隙可全部或部分地填充有残余的溶剂-催化剂材料。最通常地，PCD常常形成在钴结碳化钨硬质合金基材上，其为PCD提供了钴溶剂-催化剂的来源。不促进金刚石晶粒之间的基本连贯(coherent)交互生长的材料本身可能与金刚石晶粒形成牢固的结合，但不是适合用于PCD烧结的溶剂-催化剂。
可用于形成合适基材的烧结碳化钨由碳化物颗粒形成，所述碳化物颗粒通过将碳化钨颗粒/晶粒和钴混合在一起然后加热固化而分散在钴基质中。为了形成具有超硬材料层(诸如PCD或PCBN)的切割元件，在耐火金属外壳(诸如铌外壳)中将金刚石颗粒或晶粒或者CBN晶粒与烧结碳化钨本体相邻地放置并使其经受高压和高温，使得金刚石晶粒或CBN晶粒之间发生晶粒间结合，从而形成聚晶超硬金刚石或聚晶CBN层。
包含PCD材料的切割元件或工具插入件在石油和天然气钻探工业中广泛地在用于钻入地下的钻头中使用。凿岩和其他操作需要高耐磨性和抗冲击性。限制聚晶金刚石(PCD)研磨刀具成功的因素之一是由于PCD与加工材料之间的摩擦产生的热量。这种热量导致金刚石层的热降解。热降解通过增加PCD层的开裂和剥落以及导致增加的研磨性磨损的金刚石向石墨的回转来增加刀具的磨损率。
用于改善PCD复合材料的耐磨性的方法常常导致复合材料的抗冲击性降低。
最高耐磨等级的PCD通常在刀具磨损之前就遭受刀具的灾难性断裂。在使用这些刀具的过程中，裂纹长大直至达到发生灾难性故障的临界长度，即当大部分PCD以脆性方式脱落时。在常规烧结PCD使用过程中遇到的这些长、快速增长的裂纹导致工具寿命缩短。
此外，聚晶金刚石(PCD)材料虽然强度高，但由于其断裂韧性低，通常易受冲击断裂的影响。在不对材料的高强度和耐磨性产生不利影响的情况下提高断裂韧性是一项具有挑战性的任务。
因此需要一种具有良好或改善的磨蚀性、断裂性和冲击抵抗性的聚晶超硬复合材料诸如PCD复合材料以及形成此类复合材料的方法。
发明内容
从第一方面来看，提供了一种超硬聚晶构造，其包括聚晶超硬材料本体，所述聚晶超硬材料本体包含包含超硬材料的结构，所述结构具有大于20体积％且至多约80体积％的孔隙率。
从第二方面来看，提供了一种形成超硬聚晶构造的方法，其包括：
形成第一材料的骨架结构，所述骨架结构具有多个空隙；
用第二材料至少部分地填充骨架结构中的一些或全部空隙以形成预烧结组件；其中第一材料或第二材料中的一者或另一者包含超硬材料的晶粒；以及
在约5GPa或更高的超高压和温度下处理该预烧结组件以将超硬材料晶粒烧结在一起从而形成包括超硬晶粒的第一区域和互穿第二区域的聚晶超硬材料本体；第二区域由第一材料或第二材料中不包含超硬晶粒的另一者形成；超硬晶粒形成孔隙率大于20体积％且至多约80体积％的超硬材料的烧结结构。
附图说明
现在将通过举例以及参考附图来描述各种变体，其中：
图1是用于钻入地下的钻头的示例性超硬刀具元件或构造的透视图；
图2是常规PCD微结构的一部分的示意性横截面，其中交互结合的金刚石晶粒之间的间隙填充有非金刚石相材料；
图3a是根据实例的材料的预烧结复合组件的平面图；
图3b是根据一个实例的烧结复合材料的侧视图；
图3c是示例性复合材料的微结构的图示的平面图；
图4是常规PCD材料的微结构的示意性横截面视图；
图5是根据另一实例的上方透视图和穿过材料的微结构的一部分的放大横截面图；以及
图6是根据另一实例的材料的微结构的一部分的横截面图。
相同的附图标记在所有附图中指代相同的一般特征。
具体实施方式
如本文所用，“超硬材料”是具有至少约28GPa的维氏硬度的材料。金刚石和立方氮化硼(cBN)材料是超硬材料的实例。
如本文所用，“超硬构造”意指包括聚晶超硬材料本体的构造。在这样的构造中，可将基材附接于其，或者可替代地，聚晶材料本体可以是独立式的并且是无背衬的。
如本文所用，聚晶金刚石(PCD)是包含大量金刚石晶粒的聚晶超硬(PCS)材料类型，其相当大部分彼此直接交互结合并且其中金刚石含量为材料的至少约80体积％。在PCD材料的一个实例中，金刚石晶粒之间的间隙可至少部分地填充有包含金刚石催化剂的粘结剂材料。如本文所用，“间隙”或“间隙区域”是PCD材料的金刚石晶粒之间的区域。在PCD材料的实例中，间隙或间隙区域可基本上或部分地填充有除金刚石之外的材料，或者它们可基本上是空的。PCD材料可包括至少一个区域，催化剂材料从所述区域已从间隙中被去除，从而在金刚石晶粒之间留下间隙空隙。
用于超硬材料的“催化剂材料”能够促进超硬材料的生长或烧结。
如本文所用的术语“基材”意指在其上形成超硬材料层的任何基材。例如，如本文所用的“基材”可以是形成在另一基材上方的过渡层。
如本文所用，术语“整体形成的”区域或部分彼此接续地产生并且不被不同种类的材料分开。
在如图1所示的实例中，切割元件1包括基材3，其具有在基材3上形成的超硬材料层2。基材3可由硬材料诸如烧结碳化钨形成。超硬材料2可以是例如聚晶金刚石(PCD)或热稳定产物，诸如热稳定PCD(TSP)。切割元件1可安装在钻头体诸如刮刀钻头体(未示出)中，并且可适合于例如用作用于钻入地下的钻头的刀具插入件。
与基材相对的超硬材料的暴露顶部表面形成切割面4，切割面4是与其边缘6一起在使用中进行切割的表面。
在基材3的一个端部处的是与超硬材料层2形成界面的界面表面8，超硬材料层2在此界面表面处附接于其。如图1所示，基材3通常是圆柱形的并且具有外周表面14和外周顶部边缘16。
如本文所用，PCD等级是以金刚石晶粒的体积含量和尺寸、金刚石晶粒之间的间隙区域的体积含量和可能存在于间隙区域内的材料组成为特征的PCD材料。一定等级的PCD材料可通过包括以下的方法制成：提供具有适合于所述等级的尺寸分布的金刚石晶粒的聚集物，任选地将催化剂材料或添加剂材料引入聚集物中，并且在金刚石的催化剂材料的源存在下使聚集物经受金刚石比石墨更热力学稳定并且催化剂材料熔融的压力和温度。在这些条件下，熔融的催化剂材料可从所述源渗透到聚集物中，并且可能在烧结过程中促进金刚石晶粒之间的直接交互生长，从而形成PCD结构。聚集物可包括松散的金刚石晶粒或由粘结剂材料保持在一起的金刚石晶粒，并且所述金刚石晶粒可以是天然或合成的金刚石晶粒。
不同的PCD等级可具有不同的微结构和不同的机械特性，诸如弹性(或杨氏)模量E、弹性模量、横向破裂强度(TRS)、韧性(诸如所谓的K1C韧性)、硬度、密度和热膨胀系数(CTE)。不同的PCD等级在使用中也可能表现不同。例如，不同PCD等级的磨损率和抗断裂性可能不同。
所有PCD等级均可包括间隙区域，其填充有包含钴金属的材料(这是用于金刚石的催化剂材料的实例)。
PCD结构2可包含一个或多个PCD等级。
图2是穿过常规PCD材料的横截面，所述常规PCD材料可在常规刀具中形成图1的超硬层2。在形成常规聚晶金刚石构造期间，金刚石晶粒22直接交互结合到相邻的晶粒，并且在PCD的情况下超硬材料的晶粒22(诸如金刚石晶粒)之间的间隙24可至少部分地填充有非超硬相材料。这种还称为填料材料的非超硬相材料可包含残余催化剂/粘结剂材料，例如钴、镍或铁。如图2所示，金刚石晶粒22的典型平均晶粒尺寸大于1微米，并且因此相邻晶粒之间的晶界通常在微米尺寸的金刚石晶粒之间。
聚晶金刚石(PCD)是超硬材料(也称为超研磨材料或超级硬材料)的实例，其包含大量基本上交互生长的金刚石晶粒，从而形成限定金刚石晶粒之间的间隙的骨架物。PCD材料通常包含至少约80体积％的金刚石，并且常规地通过使金刚石晶粒的聚集物经受例如大于约5GPa的超高压和至少约1,200℃的温度而制成。完全或部分地填充间隙的材料可被称为填料或粘结剂材料。
PCD通常在烧结助剂诸如钴的存在下形成，所述烧结助剂促进金刚石晶粒的交互生长。用于PCD的合适的烧结助剂通常还称为金刚石的溶剂-催化剂材料，这是因为它们在某种程度上溶解金刚石并催化其再沉淀的功能。金刚石的溶剂-催化剂理解为能够在金刚石热力学稳定的压力和温度条件下促进金刚石生长或金刚石晶粒之间的直接金刚石-至-金刚石交互生长的材料。因此，烧结PCD产物内的间隙可全部或部分地填充有残余的溶剂-催化剂材料。不促进金刚石晶粒之间的基本连贯交互生长的材料本身可与金刚石晶粒形成牢固的结合，但不是适合用于PCD烧结的溶剂-催化剂。
参照图3a至图6描述如图3b所示的用于形成切割元件39以替代常规结构化PCD材料的复合材料的第一实例。这种复合材料的实例包括烧结的交互结合的聚晶超硬材料40(诸如PCD)的三维(3D)连续互穿网络和一种或多种相42，所述相42包含材料诸如陶瓷、金属合金、硬质金属和/或聚合物。在一些实例中，除了用于烧结超硬材料的催化剂之外的所有相应相均是三维连续的。超硬材料40形成复合材料的至少10体积％并且复合材料的至多约80体积％。其他相42填充剩余的体积分数。在制造复合材料以形成其中孔隙率大于20体积％且至多约80体积％的多孔超硬结构之后，第二相(诸如陶瓷、金属合金、硬质金属和聚合物中的任何一种或多种)还可被化学去除。
下面参照以下实施例更详细地讨论如图3a至6所示的材料实例的构造和形成，所述实施例并非旨在限制。
实施例1：
用多个平均颗粒尺寸约15微米的金刚石颗粒渗透如图3a所示的可商购获得的氧化铝泡沫42。在一种方法中，将金刚石颗粒添加到铌杯内部的泡沫顶部上，并且使组件经受机械振动以便迫使金刚石颗粒填充泡沫内部的孔。在另一种方法中，形成金刚石颗粒的浆料并倾倒在泡沫的顶部上以填充孔。然后使组件沉降并干燥。将具有13重量％钴的碳化钨基材放置在铌杯内部的金刚石渗透氧化铝泡沫的顶部上以形成预复合材料组件。然后在从WC-Co基材渗透的钴存在下，将预复合材料在高于5GPa的压力和约1400℃的温度下烧结。这形成具有氧化铝42的三维连续互穿结构的交互生长(交互结合)的PCD骨架40。
实施例2：
通过使用钛粉末的3D激光烧结初始形成钛金属骨架来形成PCD-钛3D连续互穿。将所述骨架引入到铌杯中并添加金刚石粉末以填充钛骨架中的孔。在这种情况下，使用包含约15重量％的平均晶粒尺寸约2微米的金刚石颗粒和85重量％的平均晶粒尺寸约22微米的金刚石颗粒的双模态(bimoda l)金刚石粉末。然后添加具有13重量％钴的碳化钨基材，并使所述组件经受机械振动以确保松散的粉末填充钛骨架中的空的空间。然后在从WC-Co基材渗透的钴存在下，将预复合材料在高于5GPa的压力和约1400℃的温度下烧结以形成具有钛的三维连续互穿结构的交互结合的PCD骨架。
嵌入的金属结构作为裂纹扩展的抑制剂可为有效的，并且由此可能有助于提高复合结构的韧性。
实施例3：
在上述实施例1和2中，制备PCD-陶瓷和PCD-金属3D连续互穿复合材料的过程从形成多孔陶瓷或金属开始，并且然后用金刚石对其进行渗透。然而，还可通过形成多孔金刚石生坯开始，并且然后用陶瓷、金属、聚合物或其组合对其进行渗透。金刚石生坯可通过常规的冷冻铸造技术或其他制造方法诸如注塑、3D喷墨或激光印刷和自动注浆成型(robocas ting)制备。多孔金刚石生坯还可包含含PCD的气凝胶结构，其可从诸如超临界CO2干燥的方法获得。然后用第二相诸如陶瓷、金属、聚合物或其组合渗透多孔生坯，并且如以上关于实施例1和2所述烧结产物。用于除了WC基材之外的PCD的催化剂材料的替代源可用于一个或多个实例，诸如在烧结之前将催化剂诸如Co混入金刚石晶粒中。
实施例4：
PCD和聚合物金属或任何可浸出材料的3D互穿网络通过上述实施例1至3中的任一个来制备。然后通过常规的化学浸出技术或任何其他合适的方法去除第二相42，即金属、聚合物或任何其他可浸出材料中的任何一种或多种，以形成多孔交互生长PCD结构。此孔隙率不小于PCD本体的20体积％，并且可为PCD本体的至多约80体积％。
可使用的第二相材料42的其他实例包括但不限于Ti6Al4V和具有类似特性的其他金属合金，诸如钴铬合金。
在立式镗床测试中将根据实施例1形成的多个PCD复合片与具有与所测试实施例的相同平均金刚石晶粒尺寸的可商购获得的聚晶金刚石刀具元件进行比较。在此测试中，磨损平坦区域作为钻入工件中的刀具元件的通过次数的函数来测量。结果提供了针对切割长度绘制的总磨痕区域的指示。将看到，与经受相同测试以进行比较的常规PCD复合片中出现的切割长度相比，根据实施例形成的PCD复合片能够实现可比的并且在一些情况下更长的切割长度。此外，在这些实施例中，在此测试中实现了比常规PCD复合片更小的磨痕区域，而不会使刀具剥落。
尽管不希望受特定理论的限制，但据信PCD的断裂性能可通过引入第二相而得到改善，所述第二相可有助于阻止裂纹扩展穿过材料和/或有利地使PCD材料中的裂纹转向。包括这种所述类型的第二相材料的互穿网络的PCD材料的应用的最终结果是，在使用中，在磨损速率与裂纹生长速率相当的情况下，在磨痕后面将看不到裂纹，从而形成光滑的磨痕外观，而没有碎屑或晶粒从烧结PCD中拔出。
与常规PCD相比，通过所得的本发明材料中较低的钴含量，添加这种第二相还可具有提高PCD的热稳定性的效果。
可调整第二相42的组成和分布至PCD材料的最终应用。据信可改善抗断裂性而不显著损害材料的整体耐磨蚀性，这对于PCD切割工具是期望的。
因此，据信所述实施方案可提供增韧PCD材料而不损害其高耐磨蚀性的手段。
因此，可形成具有高磨蚀和断裂性能的组合的PCD材料的实例。
参考图3a至6描述的PCD元件39可在烧结之后进一步处理。例如，可从邻近工作表面或侧表面或工作表面和侧表面两者的PCD结构的区域去除催化剂材料。这可通过用酸处理PCD结构以从第二相(42)或金刚石晶粒之间浸出残余的催化剂材料或通过其他方法诸如电化学方法来实现。由此可提供热稳定区域，其可以是基本上多孔的、从PCD结构的表面延伸至少约50微米或至少约100微米的深度，这可进一步增强PCD元件的热稳定性。
此外，包括结合到烧结碳化物支撑体的PCD结构的图3b的结构中的PCD本体可通过例如研磨来产生或完成，以提供基本上为圆柱形且具有基本上平坦的工作表面或大致圆顶的、尖的、圆形圆锥形或截头圆锥形工作表面的PCD元件。PCD元件可适用于例如用于钻入地下的旋转剪切(或刮刀)钻头、用于冲击钻头或用于采矿或沥青退化的挖掘。
尽管已参考多个实施例描述了各种变体，但本领域技术人员将理解可进行各种改变并且可用等同物替换其元素，并且这些实施例并非旨在限制所公开的特定实施例或变体。
例如，在所述方法的一些实施方案中，PCD材料可烧结约1分钟至约30分钟、约2分钟至约15分钟或约2分钟至约10分钟的一段时间。
在所述方法的一些实例中，烧结温度可在约1,200摄氏度至约2,300摄氏度、约1,400摄氏度至约2,000摄氏度、约1,450摄氏度至约1,700摄氏度或约1,450摄氏度至约1650摄氏度的范围内。而且，尽管常规使用催化剂诸如钴来烧结PCD，但可使用包含金属和/或非金属的一系列催化材料。
此外，尽管已在刀具元件的背景下描述了实例，但应理解的是，所述实例提供了多功能增强的物理、机械、热和电特性，并且可等同地用于一系列应用中，诸如切割、机械加工和抛光黑色和有色金属材料。其他应用可能包括但不限于航空航天、汽车和国防工业、加热器耗散器或热空气过滤器中的轻量级结构部件。

Claims (31)

1.一种超硬聚晶构造，其包含聚晶超硬材料本体，所述聚晶超硬材料本体包含包含超硬材料的结构，所述结构具有大于20体积％且至多约80体积％的孔隙率。
2.如权利要求1所述的构造，其还包括位于所述结构中的一个或多个孔中的一种或多种第二相。
3.如权利要求2所述的构造，其中所述一种或多种第二相包含陶瓷、金属合金、硬质金属或聚合物中的任何一种或多种。
4.如权利要求2所述的构造，其中所述一种或多种第二相包含钛、氧化铝、Ti6Al4V或铬与钴的合金中的任何一种或多种。
5.如权利要求2至4中任一项所述的构造，其中所述一种或多种第二相包括穿过所述超硬材料的互穿网络。
6.如权利要求5所述的构造，其中所述互穿网络基本上连续地穿过所述结构。
7.如前述权利要求中任一项所述的构造，其中所述超硬材料包含聚晶金刚石材料。
8.如前述权利要求中任一项所述的构造，其中所述超硬材料形成复合材料的至少10体积％且所述结构的至多约80体积％。
9.如前述权利要求中任一项所述的构造，其还包括沿着界面附接到所述聚晶超硬材料本体的基材。
10.如前述权利要求中任一项所述的构造，其中所述超硬材料包括天然和/或合成金刚石晶粒，所述超硬聚晶构造形成聚晶金刚石(PCD)构造。
11.根据权利要求9所述的构造，其中所述基材包含沿着所述界面结合到所述聚晶材料本体的烧结碳化物基材。
12.根据权利要求11所述的构造，其中所述烧结碳化物基材包含通过粘结剂材料粘合在一起的碳化钨颗粒，所述粘结剂材料包含Co、Ni和Cr的合金。
13.根据权利要求11或12中任一项所述的构造，其中所述烧结碳化物基材包含约8至13重量或体积％的粘结剂材料。
14.根据前述权利要求中任一项所述的构造，其中所述超硬材料本体的至少一部分基本上不含用于金刚石的催化剂材料，所述部分形成热稳定区域。
15.如权利要求14所述的超硬聚晶构造，其中所述热稳定区域包含至多2重量％的用于金刚石的催化剂材料。
16.一种用于钻入地下的旋转剪切钻头或用于冲击钻头的超硬聚晶构造，其包含结合到支撑体的如前述权利要求中任一项所述的构造。
17.一种包含根据权利要求1至15中任一项所述的构造的工具，所述工具用于切割、铣削、研磨、钻孔、钻地、钻岩或其他研磨应用。
18.根据权利要求17所述的工具，其中所述工具包括用于钻地或钻岩的钻头。
19.根据权利要求17所述的工具，其中所述工具包括用于油和/或气钻探的旋转固定刀具钻头。
20.根据权利要求17所述的工具，其中所述工具是滚锥钻头、打孔工具、膨胀工具、铰刀或其他钻地工具。
21.一种钻头或刀具或其部件，其包括根据权利要求1至15中任一项所述的超硬聚晶构造。
22.一种形成超硬聚晶构造的方法，其包括：
形成第一材料的骨架结构，所述骨架结构具有多个空隙；
用第二材料至少部分地填充所述骨架结构中的所述一些或全部空隙以形成预烧结组件；其中所述第一材料或所述第二材料中的一者或另一者包含超硬材料的晶粒；以及
在约5GPa或更高的超高压力和温度下处理所述预烧结组件以将所述超硬材料晶粒烧结在一起从而形成包含超硬晶粒的第一区域和互穿第二区域的聚晶超硬材料本体；所述第二区域由所述第一材料或第二材料中不包含超硬晶粒的另一者形成；所述超硬晶粒形成孔隙率大于20体积％且至多约80体积％的超硬材料的烧结结构。
23.如权利要求22所述的方法，其中形成第一材料的骨架结构的步骤包括形成包含陶瓷、金属合金、硬质金属或聚合物中的任何一种或多种的骨架结构。
24.如权利要求22所述的方法，其中所述第一材料或第二材料中的一者或另一者包含钛、氧化铝、Ti6Al4V或者铬与钴的合金中的任何一种或多种，并且所述第一材料或第二材料中的另一者包含金刚石晶粒，烧结超硬结构包含聚晶金刚石材料。
25.如权利要求22至24中任一项所述的方法，其中所述互穿第二区域基本上连续地穿过所述结构。
26.如权利要求22至15中任一项所述的方法，其中所述超硬材料形成复合材料的至少10体积％且所述结构的至多约80体积％。
27.如权利要求22至26中任一项所述的方法，其还包括处理所述烧结结构以从所述结构去除不包含所述超硬晶粒的所述第一材料或第二材料的至少一部分。
28.如权利要求22所述的方法，其中形成第一材料的骨架结构的步骤包括由氧化铝泡沫形成骨架结构。
29.如权利要求22所述的方法，其中形成第一材料的骨架结构的步骤包括由钛粉末形成骨架结构。
30.一种超硬聚晶构造，其大体上如上文中参考作为在附图的图3至图6中的任何一个或多个中示出的所述实施方案的任何一个实施方案所描述。
31.一种形成超硬聚晶构造的方法，所述超硬聚晶构造大体上如上文中参考作为在附图的图3至图6中的任何一个或多个中示出的所述实施方案的任何一个实施方案所描述。
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WO2022222278A1 (zh) * 2021-04-23 2022-10-27 安泰科技股份有限公司 一种金刚石-金属基复合材料、节块及其制备方法
CN115637345A (zh) * 2022-09-06 2023-01-24 佛山华智新材料有限公司 复合材料的制备方法及复合材料
CN115637345B (zh) * 2022-09-06 2023-12-19 佛山华智新材料有限公司 复合材料的制备方法及复合材料

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US20190009339A1 (en) 2019-01-10
US10737327B2 (en) 2020-08-11
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