HIGH DIAMOND FRAME STRENGTH PCD MATERIALS
First Claim
Patent Images
1. A cutting element comprising:
- a polycrystalline diamond body comprising;
an interface surface;
a top surface opposite the interface surface;
a cutting edge meeting the top surface; and
a material microstructure comprising a plurality of bonded-together diamond crystals and interstitial regions between the diamond crystals, the microstructure having a first region that includes at least a portion of the cutting edge, andwherein the first region comprises a diamond frame strength of about 1200 MPa or greater.
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Abstract
The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having high diamond frame strength and methods for forming and evaluating such polycrystalline diamond bodies. A polycrystalline diamond body is provided, having a top surface, a cutting edge meeting the top surface, and a first region including at least a portion of the cutting edge. The first portion exhibits a diamond frame strength of about 1200 MPa or greater, or about 1300 MPa or greater.
16 Citations
31 Claims
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1. A cutting element comprising:
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a polycrystalline diamond body comprising; an interface surface; a top surface opposite the interface surface; a cutting edge meeting the top surface; and a material microstructure comprising a plurality of bonded-together diamond crystals and interstitial regions between the diamond crystals, the microstructure having a first region that includes at least a portion of the cutting edge, and wherein the first region comprises a diamond frame strength of about 1200 MPa or greater. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A cutting element comprising:
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a substrate; and a polycrystalline diamond body formed over the substrate, the polycrystalline diamond body comprising; an interface surface meeting the substrate at an interface; a top surface opposite the interface surface; a cutting edge meeting the top surface; and a material microstructure comprising a plurality of bonded-together diamond crystals and interstitial regions between the diamond crystals, wherein a first region of the microstructure proximate the top surface has a diamond frame strength of about 1300 MPa or greater and an average sintered grain size of less than 10 microns. - View Dependent Claims (17, 18, 19, 20)
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21. A cutting element comprising:
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a substrate having an interface surface with a height to diameter ratio between 0 and 0.1 and a cobalt content less than 11%; and a polycrystalline diamond body formed over the interface surface of the substrate, the polycrystalline diamond body comprising; an interface surface; a top surface opposite the interface surface; a cutting edge meeting the top surface; and a material microstructure comprising a plurality of bonded-together diamond crystals and interstitial regions between the diamond crystals, wherein a first region of the microstructure has a diamond frame strength of about 1300 MPa or greater, an average sintered grain size of less than 14 microns, and a diamond volume fraction of at least 93%, wherein the first region incorporates the cutting edge.
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22. A method of forming a wear-resistant polycrystalline diamond cutting element, comprising:
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providing a powder mixture comprising a plurality of diamond particles having an average particle size of 20 microns or less; compacting the powder mixture to compress the diamond particles; and subjecting the powder mixture and a catalyst material to a high temperature and high pressure sintering process sufficient to form a polycrystalline diamond body, at least a region of the polycrystalline diamond body comprising a microstructure having a plurality of bonded-together diamond crystals having a diamond frame strength of at least 1200 MPa, wherein the sintering process comprises applying a pressure within the range of approximately 7.0 to 8.2 GPa. - View Dependent Claims (23, 24, 25, 26, 27)
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28. A method of selecting a polycrystalline diamond body for wear-resistant applications, comprising:
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obtaining a polycrystalline diamond body comprising a material microstructure comprising a plurality of bonded-together diamond crystals and interstitial regions between the diamond crystals, the interstitial regions comprising a catalyst material; substantially removing the catalyst material from at least a first region of the diamond body; ascertaining a flexural strength of the first region; and selecting the diamond body for a wear-resistant application based on the flexural strength of the first region of the diamond body, wherein the flexural strength of the first region of the selected diamond body is at least 1300 MPa, and wherein the increased flexural strength results in an increased wear resistance at elevated temperatures. - View Dependent Claims (29, 30)
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31. A method for increasing a wear resistance of a polycrystalline diamond body, comprising:
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obtaining a mixture of diamond particles; sintering the mixture at high temperature and high pressure in the presence of a catalyst material to form a polycrystalline diamond body; and increasing a diamond frame strength of the polycrystalline diamond body to at least 1300 MPa, wherein increasing the diamond frame strength comprises at least one of increasing the pressure for sintering the polycrystalline diamond body to at least 7.0 GPa, or reducing an average particle size of the diamond particles in the mixture to below 16 microns, wherein the increased diamond frame strength results in an increased wear resistance at elevated temperatures.
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Specification