CN110267758A - 超硬构造及其制造方法 - Google Patents
超硬构造及其制造方法 Download PDFInfo
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- CN110267758A CN110267758A CN201780085819.4A CN201780085819A CN110267758A CN 110267758 A CN110267758 A CN 110267758A CN 201780085819 A CN201780085819 A CN 201780085819A CN 110267758 A CN110267758 A CN 110267758A
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- Prior art keywords
- superhard
- crystal grain
- grade
- diamond
- construction
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- UFMZWBIQTDUYBN-UHFFFAOYSA-N cobalt dinitrate Chemical compound [Co+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O UFMZWBIQTDUYBN-UHFFFAOYSA-N 0.000 description 2
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- QIJNJJZPYXGIQM-UHFFFAOYSA-N 1lambda4,2lambda4-dimolybdacyclopropa-1,2,3-triene Chemical compound [Mo]=C=[Mo] QIJNJJZPYXGIQM-UHFFFAOYSA-N 0.000 description 1
- BVPWJMCABCPUQY-UHFFFAOYSA-N 4-amino-5-chloro-2-methoxy-N-[1-(phenylmethyl)-4-piperidinyl]benzamide Chemical compound COC1=CC(N)=C(Cl)C=C1C(=O)NC1CCN(CC=2C=CC=CC=2)CC1 BVPWJMCABCPUQY-UHFFFAOYSA-N 0.000 description 1
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- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
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- 229910052719 titanium Inorganic materials 0.000 description 1
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- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B22F7/06—Manufacture 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
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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Abstract
公开了一种超硬多晶构造,包含:超硬材料的本体,其具有在第二粒级超硬晶粒的基质中的第一粒级的超硬晶粒。第一粒级的平均晶粒尺寸是第二粒级的平均晶粒尺寸的约1.5至约10倍,并且第一粒级占本体内超硬材料晶粒的约5体积%至约30体积%。
Description
技术领域
本发明涉及超硬构造(construction)以及制造此类构造的方法,特别地但不专门涉及包含附着在基底上的多晶金刚石(PCD)结构的构造,以及包含此类构造的工具,特别地但不专门用于岩石降解(degradation)或钻凿,或用于钻地。
发明背景
多晶超硬材料,例如多晶金刚石(PCD)和多晶立方氮化硼(PCBN)可用于多种工具,用来切削、机加工、钻孔或破碎硬质材料或磨蚀性材料如岩石、金属、陶瓷、复合材料和含木材料。特别地,包括PCD材料的切削元件形式的工具嵌体广泛用于开采石油或天然气的钻地钻头。超硬工具嵌体(insert)的工作寿命可受到超硬材料的断裂(包括由剥落和碎裂)或工具嵌体的磨损的限制。
切削元件,如用于岩石钻头或其它切削工具的切削元件,典型具有基底形式的本体,该基底具有界面端/表面和超硬材料,该超硬材料通过例如烧结过程形成与基底的界面表面结合的切削层。基底典型由碳化钨-钴合金(有时称为碳化钨硬质合金)形成,并且超硬材料层典型为多晶金刚石(PCD)、多晶立方氮化硼(PCBN)、或热稳定产品TSP材料,例如热稳定多晶金刚石。
多晶金刚石(PCD)是超硬材料(也称为超研磨材料)的例子,其包含大量实质上交互生长的(inter-grown)金刚石晶粒,从而形成骨架物质,该骨架物质限定出介于金刚石晶粒之间的间隙。PCD材料典型包含至少约80体积%的金刚石并且传统上通过使金刚石晶粒的聚集物质经受例如大于约5GPa的超高压力和至少约1200℃的温度来制造。全部或部分地填充所述间隙的材料可被称为填料或粘合剂材料。
典型在烧结助剂如钴的存在下形成PCD,所述烧结助剂促进金刚石晶粒的交互生长。适于PCD的合适烧结助剂通常也称为金刚石的溶剂-催化剂材料,这是由于它们的在一定程度上溶解金刚石并催化其再沉淀的功能。用于金刚石的溶剂-催化剂可被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-金刚石交互生长的材料。因此,在烧结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。最典型地,经常在钴结碳化钨硬质合金基底上形成PCD,该基底为PCD提供钴溶剂-催化剂的源。
钻地领域中改善生产率的不断增加的驱动对用于切削岩石所用的材料提出了越来越高的要求。具体而言,需要耐磨损性和耐冲击性改善的PCD材料以实现更快的切削速率和更长的工具寿命。
用于岩石钻凿和其它操作的切削元件需要高的耐磨损性和耐冲击性。限制多晶金刚石(PCD)研磨刀具成功的因素之一是由于PCD和加工材料之间的摩擦而产生热量。该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金刚石向石墨的反向转变引起磨料磨损增加,从而增加刀具的磨损速率。
用于改善PCD复合材料的耐磨损性的方法通常导致复合材料的耐冲击性的降低。因此,需要一种具有改善的耐冲击性同时具有良好的耐磨损性的多晶超硬复合构造以及形成此类构造的方法。
发明概述
从第一方面来看,提供一种超硬多晶构造,包含:
超硬材料的本体,其具有在第二粒级超硬晶粒的基质中的第一粒级的超硬晶粒;其中:
第一粒级的平均晶粒尺寸是第二粒级的平均晶粒尺寸的约1.5至约10倍;和
第一粒级占本体内超硬材料晶粒的约5体积%至约30体积%。
从第二方面看,提供一种形成超硬多晶构造的方法,该方法包括:
形成预烧结组装件,其包含:
第一批超硬材料的晶粒或颗粒;
第二批超硬材料的晶粒或颗粒;第一批超硬晶粒的平均晶粒尺寸为第二批晶粒的平均晶粒尺寸的约1.5至约10倍;和
基底;该方法进一步包括以下步骤:
在约5GPa或更大的超高压力和使超硬材料的晶粒结合在一起的温度下处理该预烧结组装件,以便形成与基底结合的相互结合的多晶超硬材料本体,该第一批形成第一粒级,该第一粒级占本体内超硬材料晶粒的约5体积%至约30体积%。
从另一方面看,提供一种工具,该工具包含上面定义的超硬多晶构造,该工具用于切削、铣削、磨制、钻孔、钻地、岩石钻凿或其它研磨应用。
该工具可包括,例如用于钻地或岩石钻凿的钻头,用于石油和天然气钻探工业的旋转式固定刀片钻头、或者牙轮钻头、开孔工具、扩张工具、铰刀或其它钻地工具。
从另一方面看,提供一种钻头或刀具或其部件,其包含上面定义的超硬多晶构造。
附图说明
现在将通过实例并参照附图描述各种型式,其中:
图1是用于钻地钻头的PCD切削元件或构造的实例的透视图;
图2是PCD微观结构的常规部分的示意性横截面,其中在相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3是超硬构造的第一实施例的横截面,示出该构造的微观结构;
图4是显示三个实施例刀具与两个常规PCD切削元件相比较的立式镗床试验(vertical borer test)的结果的曲线图;
图5是显示两个实施例刀具与四个常规PCD元件的立式镗床试验的结果的曲线图;和
图6是显示实施例刀具与五个常规PCD元件的立式镗床试验的结果的曲线图。
在所有附图中,相同的附图标记表示相同的一般特征。
发明详述
如本文所用,“超硬材料”是维氏硬度为至少约28GPa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”是指包含多晶超硬材料本体的构造。在此类构造中,基底可附着在其上。
如本文所用,多晶金刚石(PCD)是指包含大量金刚石晶粒的一类多晶超硬(PCS)材料,它的大部分是彼此直接相互结合(交互生长)的,并且其中金刚石的含量为该材料的至少约80体积%。在PCD材料的一个实例中,金刚石晶粒之间的间隙直接在烧结后可至少部分填充有包含用于金刚石的催化剂的粘合剂材料。如本文所用,“间隙”或“间隙区域”是指PCD材料的金刚石晶粒之间的区域。
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“基底”是指在其上形成超硬材料层的任何基底。例如,如本文所用的“基底”可以是在另一基底上形成的过渡层。
如本文所用的术语“整体形成”是指区域或部分彼此邻接地产生并且未被不同种类的材料分开。
图1是常规PCD超硬构造例如切削元件1的实例的示意图,该切削元件包括基底3,在基底3上形成有超硬材料层2。基底3可由诸如碳化钨硬合金的硬质材料形成。超硬材料2可以是例如包含至少80体积%的相互结合(交互生长)的金刚石晶粒的高密度多晶金刚石(PCD)。切削元件1可被安装到钻头本体中,例如刮刀钻头本体(未示出),并且可适合例如作为用于钻地的钻头的刀具嵌体。
超硬材料的与基底相对的暴露顶表面形成切削面4,也称为工作表面,其是在使用中与其边缘6一起进行切削的表面。
在基底3的一端是界面表面8。如图1所示,基底3大体为圆柱形的并且具有外周表面10和外周上边缘12。
多晶复合构造1的工作表面或“前刀面”4是当使用刀具从本体切削材料时被切材料的切屑流过的表面,前刀面4引导新形成的切屑的流动。该前刀面4通常也被称为切削元件的顶面或工作表面,因为工作表面4是在使用中与其边缘6一起用于进行本体切削的表面。应理解,如本文所用的术语“切削刃”是指在刀具磨损发展直至刀具失效的任何特定阶段或多于一个阶段的实际切削刃(在功能上如上定义),所述刀具包括但不限于处于基本上未磨损或未使用状态的刀具。
如本文所用,“切屑”是在使用中由多晶复合物构造1从被切本体的工作表面去除的本体的碎屑。
如本文所用,“磨痕”是由于刀具的磨损由一定量刀具材料的去除而在使用中形成的刀具的表面。后刀面可包含磨痕。由于刀具在使用中磨损,材料可逐渐从邻近的切削刃去除,从而随着磨痕的形成,不断地重新限定切削刃、前刀面和后刀面的位置和形状。
基底3典型由硬材料形成,例如硬质合金材料,如碳化钨硬质合金。
如图2所示,在形成常规的多晶复合构造1的过程中,在PCD的情形中,诸如金刚石晶粒的超硬材料的相互结合晶粒22之间的间隙24可至少部分填充有非超硬相材料。这种非超硬相材料(也称为填充材料)可包括残余的催化剂/粘合剂材料,例如钴。
在第一实施例中,如图3的超硬材料的微观结构所示,实施例的多晶超硬材料包括在HPHT介质中使用钴金属催化剂烧结的细晶粒(例如平均晶粒尺寸为约10微米)的基质,其中嵌入另外的大晶粒(例如平均颗粒尺寸为约30微米)。
用于形成超硬材料的层或区域的各实施例的超硬材料可以是例如多晶金刚石(PCD)和/或多晶立方氮化硼(PCBN)和/或六角金刚石(lonsdalite),并且超硬颗粒或晶粒可为天然来源和/或合成来源。
实施例的基底可由硬材料例如硬质合金材料形成,并且可包括例如碳化钨硬质合金、碳化钽硬质合金、碳化钛硬质合金、碳化钼硬质合金或其混合物。适于形成基底的用于此类碳化物的粘合剂金属可以是例如镍、钴、铁或含有这些金属中一种或多种的合金,并且可包括其它材料的另外元素或化合物,例如铬或钒。该粘合剂的存在量可以是例如10-20质量%,但其可低至6质量%或更低。
在一些实施例中,超硬材料的层或区域可包含PCBN。包含PCBN的部件主要用于机械加工金属。PCBN材料包含立方氮化硼(cBN)晶粒的烧结物质。PCBN材料的cBN含量可以为至少约40体积%。当PCBN中的cBN含量为至少约70体积%时,cBN晶粒之间可存在大量直接接触。当cBN含量为坯块的约40体积%至约60体积%时,cBN晶粒之间的直接接触程度是有限的。可通过使一批cBN颗粒与粉末状基质相一起经受cBN在热力学上比氮化硼(hBN)的六方形式更稳定的温度和压力来制造PCBN。PCBN的耐磨性低于PCD,这使其适合于不同于PCD的应用。
如本文所用,PCD或PCBN等级是PCD或PCBN材料,其特征在于金刚石晶粒的体积含量和尺寸(在PCD的情况下)或cBN晶粒的体积含量和尺寸(在PCBN的情况下)、晶粒之间的间隙区域的体积含量、以及可存在于间隙区域内的材料的组成。一种等级的超硬材料可通过包括以下步骤的方法制造:提供具有适于该等级的尺寸分布的超硬晶粒的聚集物质,任选地将催化剂材料或添加剂材料引入该聚集物质中,并且在用于超硬材料的催化剂材料源存在下使所述聚集物质经受一定压力和温度,在该压力和温度下超硬晶粒比石墨(在金刚石的情况下)或hBN(在CBN的情况下)更加热力学稳定,并且在该压力和温度下催化剂材料为熔融的。在这些条件下,熔融的催化剂材料可从该源渗透到聚集物质中,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,以形成多晶超硬结构。该聚集物质可包含松散的超硬晶粒或由粘合剂材料保持在一起的超硬晶粒。在金刚石的情况下,金刚石晶粒可以是天然的或合成的金刚石晶粒。
特别地,超硬材料的晶粒可以是例如金刚石晶粒或颗粒。在烧结之前的起始混合物中,它们可以是例如双模态的,即进料包括粗粒级金刚石晶粒和细粒级金刚石晶粒的混合物。在一些实施例中,粗粒级的平均颗粒/晶粒尺寸的范围可以是例如约10-60微米。“平均颗粒或晶粒尺寸”是指各颗粒/晶粒具有一定范围的尺寸,平均颗粒/晶粒尺寸表示“平均”。细粒级的平均颗粒/晶粒尺寸小于粗粒级的平均颗粒/晶粒尺寸。例如,粗粒级的平均晶粒尺寸可以为细粒级尺寸的至少1.5倍,并且在一些实施例中,为细粒级尺寸的至少2倍或者为细粒级尺寸的至多约10倍,例如约7倍的尺寸。
在一些实施例中,粗金刚石粒级与细金刚石粒级的体积比可以为约5%至约30%粗金刚石,并且细金刚石粒级的体积比可以是约70%至约95%。
一些实施例由超硬材料的粗粒级和细粒级之间的宽双模态尺寸分布组成,但是一些实施例可包括三甚或四或更多的尺寸模态。
可通过已知方法,例如较大金刚石晶粒的喷射磨等,将金刚石颗粒/晶粒分级为细粒级、粗粒级、或其间的其它尺寸。
在一些实施例中,硬质合金基底可例如在组成上为常规的,因此可包括任何IVB、VB或VIB族金属,在钴、镍或铁、或其合金的粘合剂存在下对其进行压制和烧结。在一些实施例中,金属碳化物是碳化钨。
在一些实施例中,基底可以使是预成形的,例如通过将诸如碳化钨的硬质材料颗粒的生坯压制成期望的形状,包括在其一个自由端处的界面特征,以及烧结所述生坯以形成基底元件。在替代实施例中,基底界面特征可由硬质材料的烧结圆柱体机加工而成,以形成界面特征的期望几何形状。基底可例如包含与催化剂材料(如钴、镍或铁或其混合物)结合的WC颗粒。如本领域所公知,用于超硬构造的生坯,其包含预成形的基底和超硬材料的颗粒(例如金刚石颗粒或立方氮化硼颗粒),可放置在基底上,以形成可被包封在用于超高压炉的包壳中的预烧结组装件。特别地,将超耐磨颗粒(例如以粉末形式)放置在由例如铌、钽或钛形成的金属杯内。将预成形的基底放置在杯内,并静压入超硬粉末中,使得必需的粉末物质被压在预成形的碳化物基底的界面特征周围以形成预复合物。然后在约1050℃下将预复合物脱气。通过在另一端放置第二个杯来封闭预复合物,并通过冷等静压或EB焊接密封预复合物。然后烧结预复合物以形成烧结体。
在一些实施例中,超硬晶粒可以是金刚石晶粒,并且基底可以是钴结碳化钨硬质合金。预烧结组装件可包含另外的催化剂材料源,例如含有催化剂材料如钴的圆盘或围绕杯,其可被放置在预复合物组装件中的金刚石晶粒附近和/或周围。
在一个实施例中,该方法可包括将包含预烧结组装件的包壳装入压机中,并使生坯经受超高压力和超硬材料热力学稳定的温度,以烧结超硬晶粒。在一些实施例中,生坯可包含金刚石晶粒,并且组装件经受的压力是至少约5GPa,且温度为至少约1300℃。在一些实施例中,组装件可经受的压力是约5.5-6GPa,但在一些实施例中,其可以是约7.7GPa或更大。此外,在一些实施例中,烧结过程中使用的温度可以在约1400℃至约1500℃的范围内。
在烧结之后,可将多晶超硬构造研磨成一定尺寸,并且如果需要,在如此产生的多晶超硬材料的本体上可包括约0.4mm高的45°倒角。
可通过各种方法将用于金刚石的溶剂/催化剂引入金刚石晶粒的聚集物质中,包括在烧结步骤之前或作为烧结步骤的一部分,将粉末形式的溶剂/催化剂材料与金刚石晶粒混合,将溶剂/催化剂材料沉积到金刚石晶粒的表面上,或将溶剂/催化剂材料从基底以外的材料源渗透到所述聚集物质中。将用于金刚石的溶剂/催化剂(例如钴)沉积到金刚石晶粒表面上的方法在本领域中是公知的,并且包括化学气相沉积(CVD)、物理气相沉积(PVD)、溅射涂覆、电化学方法、化学涂覆方法、和原子层沉积(ALD)。应理解,各自的优点和缺点取决于烧结助剂材料的性质和待沉积的涂层结构,以及晶粒的特性。
在一个实施例中,可通过以下方法将粘合剂/催化剂(例如钴)沉积在金刚石晶粒的表面上:首先沉积前体材料,然后将前体材料转化成包含单质金属钴的材料。例如,在第一步中,可使用以下反应将碳酸钴沉积在金刚石晶粒表面上:
Co(NO3)2+Na2CO3->CoCO3+2NaNO3
用于金刚石的钴或其它溶剂/催化剂的碳酸盐或其它前体的沉积可通过PCT专利公开号WO2006/032982中描述的方法实现。然后可将碳酸钴转化为钴和水,例如,通过诸如以下的热解反应:
CoCO3->CoO+CO2
CoO+H2->Co+H2O
在另一个实施例中,可以将钴粉末或钴的前体(例如碳酸钴)与金刚石晶粒混合。在使用溶剂/催化剂(例如钴)的前体的情况下,可能需要对材料进行热处理,以便在烧结聚集物质之前进行反应以生成单质形式的溶剂/催化剂材料。
在一些实施例中,硬质合金基底可以由通过粘合剂材料结合在一起的碳化钨颗粒形成,粘合剂材料包括Co、Ni和Cr的合金。碳化钨颗粒可形成基底的至少70重量%和至多95重量%。粘合剂材料可包含约10-50重量%的Ni,约0.1-10重量%的Cr,并且剩余重量百分比包括Co。
为了使多晶超硬材料的层或区域更加热稳定,可对烧结的刀具构造进行浸出处理过程,以便从该层或区域去除可触及的残余催化剂粘合剂材料,例如沸腾HCl酸浸出处理。
下面更详细地描述实施例,本文提供这些实施例仅用于说明而并不意图进行限制。
实施例:
通过在Retsch行星式球磨机中在10克液体甲醇中用125克WC球以90rpm将颗粒尺寸为约2微米的1克球形颗粒钴粉末研磨10分钟来制备起始粉末。然后将84克细晶粒金刚石材料(在该情形中具有10微米的平均颗粒尺寸)与20克甲醇和125克WC球一起加入到研磨过的混合物中。以120rpm将混合物研磨另外20分钟。在另一阶段中,将14克粗金刚石进料(在该情形中金刚石颗粒具有30微米的平均颗粒尺寸)与10克甲醇一起加入到研磨过的混合物中,并将以90rpm该组合研磨另外20分钟,从而形成浆料。
然后在旋转蒸发仪中于70℃使浆料干燥以除去溶剂(甲醇),并形成干燥粉末,然后使所述干燥粉末过106微米筛。
为制备预复合物,将约两克干燥粉末放入铌杯中。将WC基底引入杯中并压在粉末上。可通过手动式或液压式压机或者通过振动压实将预复合物压实。
然后在真空下在约1100℃将预复合物脱气5小时。然后通过电子束焊接将脱气后的预复合物密封以形成预复合物组装件。然后使组装件经受高于1450℃的温度和高于约6GPa的压力下的HPHT(高压和高温)烧结过程以烧结所述复合物。
根据上述方法,以表1中列出的细粒颗粒和粗粒颗粒的百分比制备另外的实施例2-4、6和7。
表1
为了制备根据上表中的实施例5的样品,在Retsch行星式球磨机在30克液体甲醇中用125克WC球以90rpm将颗粒尺寸约2微米的1克球形颗粒钴粉末与69.3克平均颗粒尺寸为4微米的细金刚石颗粒一起研磨10分钟。然后将14克平均颗粒尺寸为15微米的金刚石粉末与10克甲醇和125克WC球一起加入到研磨过的混合物中。然后以90rpm将混合物研磨另外20分钟。然后加入14克粗金刚石进料(在该情形中颗粒具有30微米的平均颗粒尺寸)连同10克甲醇,并以90rpm研磨另外20分钟,从而形成浆料。
在旋转蒸发仪中于70℃使浆料干燥以除去溶剂(甲醇),并将干燥粉末过106微米筛。为了制备预复合物,将约两克的干燥粉放入铌杯中。将WC基底引入杯中并压在粉末上。可通过手动式或液压式压机或者通过振动压实将预复合物压实。然后在真空下于约1100℃将预复合物脱气5小时。然后通过电子束焊接将脱气后的预复合物密封以形成预复合物组装件,然后在HPHT介质中在高于1450℃的温度和高于6GPa的压力下使组装件经受HPHT处理。
根据上述实施例制备的刀具构造在烧结和完全加工后回收。还使用SEM成像技术分析样品,其显示烧结晶粒的尺寸比率和尺寸在烧结过程中得以保留,因此对应于起始材料中的原始尺寸。在一些实施例中,处理所述构造以除去烧结构造的相互结合的金刚石晶粒之间的间隙空间中的一些或所有的可触及残余催化剂粘合剂材料。这可通过例如以下方式来实现:使刀具构造进行沸腾HCl酸浸出处理以便从PCD结构中除去所有的可触及催化材料,也可使用其它常规的浸出技术。
然后使实施例的刀具构造进行立式转塔车床试验,一些由常规PCD材料制成的参比刀具也进行该试验。结果在图4-6中示出。
在该试验中,测量磨平面积随刀具元件钻入工件的道次数的变化。结果提供总磨痕面积相对于切削长度的指示。如图4所示,由附图标记102、104和106表示的实施例刀具能够实现比由附图标记100和108表示的常规刀具更长的抗剥落性能,由更长的加工寿命所指示。
类似地,如图5中的结果所示,其示出了两个实施例刀具(由附图标记208和210表示)与四个常规PCD刀具(附图标记200,202,204,206,212和214)比较的立式镗床试验的结果),实施例刀具能够实现比常规刀具更长的抗剥落性能,这由更长的工作寿命所指示。图6显示了实施例刀具(附图标记310)与五个常规PCD刀具(300,302,304,306,308)的立式镗床试验的结果,这进一步证实实施例刀具能够实现比常规刀具更长的抗剥落性能,这由更长的工作寿命所指示。
因此,可以看出,根据实施例形成的超硬构造能够实现大的切削长度和小的磨痕面积,表明该构造具有长的工作寿命。
实施例的超硬构造可通过例如研磨来完成,以提供超硬元件,该元件是大体上圆柱形并且具有基本上平坦的工作表面,或大体为球顶形、尖形、圆锥形或截头圆锥形的工作表面。该超硬元件可适用于例如钻地用的旋转剪切(或刮刀)钻头、用于冲击钻头、或用于采矿或沥青降解的截齿(pick)。
虽然已经参照多个实施例描述了各种具体实施方案,但是本领域技术人员将理解,可进行各种改变,并且可用等效物替换其要素,并且这些实施例不旨在限制所公开的特定型式。例如,尽管所描述的实施例具有超硬材料的单一层,但在其它实施例中,仅一部分切削体积可由实施例的超硬材料构成,并且切削体积的其余部分可由不同的材料构成,例如常规PCD或具有不同金刚石等级的组合物或陶瓷材料。此外,在一些实施例中,粗粒级颗粒可以是例如金刚石砂粒的单晶颗粒或多晶聚集物、CVD破碎的颗粒、通过PVD方法获得的金刚石、和/或天然金刚石或合成金刚石。另外,虽然颗粒尺寸的比率可以是关于基质中粗颗粒的等效直径与细颗粒的等效直径,但应理解颗粒尺寸比率也可以是大颗粒的体积分数除以构造的超硬区域中包含主基质的细颗粒的体积分数的比率。
Claims (22)
1.一种超硬多晶构造,包含:
超硬材料的本体,其具有在第二粒级超硬晶粒的基质中的第一粒级的超硬晶粒;其中:
第一粒级的平均晶粒尺寸是第二粒级的平均晶粒尺寸的约1.5至约10倍;和
第一粒级占本体内超硬材料晶粒的约5体积%至约30体积%。
2.根据权利要求1所述的构造,其中第一粒级的平均晶粒尺寸是第二粒级的平均晶粒尺寸的约2至约7倍。
3.根据前述权利要求中任一项所述的构造,其中第一粒级的超硬晶粒包含下列任何一种或多种:金刚石砂粒的单晶颗粒或多晶聚集物、CVD破碎的颗粒、通过PVD方法获得的金刚石、天然金刚石、合成来源的金刚石、或cBN。
4.根据前述权利要求中任一项所述的构造,其中第二粒级的超硬晶粒包含金刚石晶粒和/或cBN晶粒。
5.根据前述权利要求中任一项所述的构造,其中第二粒级的超硬晶粒包含多个交互生长的超硬材料晶粒。
6.根据前述权利要求中任一项所述的构造,其中所述本体具有至少一个基本上不含用于金刚石的催化剂材料的区域,所述区域形成热稳定区域。
7.根据权利要求6所述的构造,其中所述本体包含至多3重量%的用于金刚石的催化剂材料。
8.根据前述权利要求中任一项所述的构造,进一步包含沿界面与超硬材料的本体结合的基底。
9.根据权利要求8所述的构造,其中所述基底包含硬质合金材料。
10.根据权利要求9所述的构造,其中所述硬质合金材料包括碳化钨硬质合金。
11.根据前述权利要求中任一项所述的构造,其中所述本体还包含具有不同于第一粒级和第二粒级的组成的区域。
12.根据权利要求11所述的构造,其中所述区域包含相互结合的超硬材料,所述超硬材料具有与所述第一粒级和/或第二粒级不同的平均超硬晶粒尺寸或元素组成。
13.一种用于钻地的旋转剪切钻头或用于冲击钻头的超硬多晶构造,其包含如前述权利要求中任一项所述的超硬多晶构造。
14.一种工具,其包含根据权利要求1-13中任一项所述的超硬多晶构造,所述工具用于切削、铣削、磨制、钻孔、钻地、岩石钻凿或其它研磨应用。
15.根据权利要求14所述的工具,其中所述工具包含用于钻地或岩石钻凿的钻头。
16.根据权利要求14所述的工具,其中所述工具包含用于石油和天然气钻探用旋转式固定刀片钻头。
17.根据权利要求14所述的工具,其中所述工具为牙轮钻头、开孔工具、膨胀工具、铰刀或其它钻地工具。
18.一种钻头或刀具或其部件,包含根据权利要求1-13中任一项所述的超硬多晶构造。
19.一种形成超硬多晶构造的方法,该方法包括:
形成预烧结组装件,其包含:
第一批超硬材料的晶粒或颗粒;
第二批超硬材料的晶粒或颗粒;第一批超硬晶粒的平均晶粒尺寸为第二批晶粒的平均晶粒尺寸的约1.5至约10倍;和
基底;该方法进一步包括以下步骤:
在约5GPa或更大的超高压力和使超硬材料的晶粒结合在一起的温度下处理该预烧结组装件,以便形成与基底结合的相互结合的多晶超硬材料本体,该第一批形成第一粒级,该第一粒级占本体内超硬材料晶粒的约5体积%至约30体积%。
20.根据权利要求19所述的方法,还包括处理所述多晶超硬构造,以便从所述超硬材料的相互结合晶粒之间的至少一些间隙空间中除去可触及的残余催化剂/粘合剂材料。
21.根据权利要求19或20中任一项所述的方法,其中形成所述预烧结组装件的步骤包括:
提供一批金刚石晶粒或颗粒和/或立方氮化硼晶粒或颗粒以形成第一批超硬材料的晶粒或颗粒。
22.根据权利要求19-21中任一项所述的方法,其中形成所述预烧结组装件的步骤包括:
提供钴源作为超硬晶粒的催化材料。
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CN111705250A (zh) * | 2020-06-30 | 2020-09-25 | 中南大学 | 深海矿产资源和干热岩开采用硬质合金及其制备方法和应用 |
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GB201919482D0 (en) * | 2019-12-31 | 2020-02-12 | Element Six Uk Ltd | Sensor elements for a cutting tool and methods of making and using same |
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US11794245B2 (en) | 2023-10-24 |
WO2018122161A1 (en) | 2018-07-05 |
US20190381569A1 (en) | 2019-12-19 |
US20220184693A1 (en) | 2022-06-16 |
GB201721707D0 (en) | 2018-02-07 |
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