POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS WITH ENGINEERED POROSITY AND METHOD FOR MANUFACTURING SUCH CUTTING ELEMENTS
First Claim
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1. A method of forming a thermally stable polycrystalline diamond cutting element, comprising:
- mixing diamond particles and a filler material to create a diamond powder mixture, wherein the diamond powder mixture comprises a first portion with the filler material and a second portion with less filler material than the first portion, the first portion being at least 25% of a volume of the diamond powder mixture;
sintering the diamond powder mixture at high temperature and high pressure to form a polycrystalline diamond material;
removing the filler material from the polycrystalline diamond material to form a thermally stable polycrystalline diamond material having a differential porosity of at least 1.6% between the first and second portions; and
bonding the thermally stable material to a substrate, wherein bonding comprises infiltrating the first portion with an infiltrant material from the substrate.
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Abstract
A method for facilitating infiltration of an infiltrant material into a TSP material during re-bonding of the TSP material to a substrate, by enhancing the porosity of the TSP material near the interface with the substrate is provided. Cutting elements formed by such method and downhole tools including such cutting elements are also provided.
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Citations
34 Claims
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1. A method of forming a thermally stable polycrystalline diamond cutting element, comprising:
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mixing diamond particles and a filler material to create a diamond powder mixture, wherein the diamond powder mixture comprises a first portion with the filler material and a second portion with less filler material than the first portion, the first portion being at least 25% of a volume of the diamond powder mixture; sintering the diamond powder mixture at high temperature and high pressure to form a polycrystalline diamond material; removing the filler material from the polycrystalline diamond material to form a thermally stable polycrystalline diamond material having a differential porosity of at least 1.6% between the first and second portions; and bonding the thermally stable material to a substrate, wherein bonding comprises infiltrating the first portion with an infiltrant material from the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A cutting element comprising:
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a substrate; and a thermally stable polycrystalline diamond body bonded to the substrate, wherein the thermally stable polycrystalline diamond body comprises; a working surface opposite the substrate; a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material; a first portion of the material microstructure proximate the substrate and having a porosity; and a second portion of the material microstructure proximate the working surface and having a porosity, wherein the first portion occupies at least 25% of a volume of the polycrystalline diamond body, wherein the first portion comprises an infiltrant material in one or more of the pores between the diamond crystals, and wherein the material microstructure has a differential porosity of at least 1.6% between the first and second portions when said porosities are measured without said infiltrant. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A cutting element comprising:
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a substrate; and a thermally stable polycrystalline diamond body bonded to the substrate, wherein the thermally stable polycrystalline diamond body comprises; a working surface opposite the substrate; a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material; a first portion of the material microstructure proximate the substrate having a porosity and comprising a projection; and a second portion of the material microstructure proximate the working surface having a porosity and comprising a depression receiving said projection, wherein the first portion comprises an infiltrant material in one or more of the pores between the diamond crystals, and wherein the material microstructure has a differential porosity between the first and second portions when said porosities are measured without said infiltrant. - View Dependent Claims (29, 30, 31, 32, 33, 34)
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Specification