POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A CARBONATE-CATALYZED POLYCRYSTALLINE DIAMOND TABLE AND APPLICATIONS THEREFOR
First Claim
1. A polycrystalline diamond compact, comprising:
- a substrate; and
a preformed polycrystalline diamond table bonded to the substrate, the preformed polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the preformed polycrystalline diamond table further including;
an upper surface;
a back surface bonded to the substrate;
at least one lateral surface extending between the upper surface and the back surface;
a first region extending inwardly from the upper surface and the at least one lateral surface, the first region exhibiting a first interstitial region concentration and including at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, the at least one interstitial constituent present in at least a residual amount, the at least one interstitial constituent including at least one metal carbonate and/or at least one metal oxide; and
a second bonding region adjacent to the substrate and extending inwardly from the back surface, the second bonding region exhibiting a second interstitial region concentration that is greater than the first interstitial region concentration and including a metallic infiltrant therein disposed in at least a portion of the interstitial regions thereof.
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Accused Products
Abstract
In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.
23 Citations
33 Claims
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1. A polycrystalline diamond compact, comprising:
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a substrate; and a preformed polycrystalline diamond table bonded to the substrate, the preformed polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the preformed polycrystalline diamond table further including; an upper surface; a back surface bonded to the substrate; at least one lateral surface extending between the upper surface and the back surface; a first region extending inwardly from the upper surface and the at least one lateral surface, the first region exhibiting a first interstitial region concentration and including at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, the at least one interstitial constituent present in at least a residual amount, the at least one interstitial constituent including at least one metal carbonate and/or at least one metal oxide; and a second bonding region adjacent to the substrate and extending inwardly from the back surface, the second bonding region exhibiting a second interstitial region concentration that is greater than the first interstitial region concentration and including a metallic infiltrant therein disposed in at least a portion of the interstitial regions thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of manufacturing a polycrystalline diamond compact, comprising:
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assembling a polycrystalline diamond table with a substrate; wherein the polycrystalline diamond table including a plurality of bonded diamond grains defining a plurality of interstitial regions; wherein the polycrystalline diamond table includes an upper surface, a back surface, and at least one lateral surface extending between the upper surface and the back surface,; wherein the polycrystalline diamond table further includes; a first region extending inwardly from the upper surface and the at least one lateral surface, the first region including at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, the at least one interstitial constituent present in at least a residual amount, the at least one interstitial constituent including at least one metal carbonate and/or at least one metal oxide; and a second bonding region adjacent to the substrate and extending inwardly from the back surface, the second bonding region exhibiting an interstitial region concentration that is greater than the first region; infiltrating at least a portion of the interstitial regions of the second bonding region of the polycrystalline diamond table with a metallic infiltrant effective to bond the polycrystalline diamond table to the substrate. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A rotary drill bit, comprising:
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a bit body configured to engage a subterranean formation; and a plurality of polycrystalline diamond cutting elements affixed to the bit body, at least one of the polycrystalline diamond cutting elements including; a substrate; and a preformed polycrystalline diamond table bonded to the substrate, the preformed polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the preformed polycrystalline diamond table further including; an upper surface; a back surface bonded to the substrate; at least one lateral surface extending between the upper surface and the back surface; a first region extending inwardly from the upper surface and the at least one lateral surface, the first region exhibiting a first interstitial region concentration and including at least one interstitial constituent disposed in at least a portion of the interstitial regions thereof, the at least one interstitial constituent present in at least a residual amount, the at least one interstitial constituent including at least one metal carbonate and/or at least one metal oxide; and a second bonding region adjacent to the substrate and extending inwardly from the back surface, the second bonding region exhibiting a second interstitial region concentration that is greater than the first interstitial region concentration and including a metallic infiltrant therein disposed in at least a portion of the interstitial regions thereof.
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Specification