Use of gradient layers and stress modifiers to fabricate composite constructs
First Claim
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1. A method for making a sintered polycrystalline diamond compact comprising the steps of:
- selecting a substrate containing a desired solvent metal,placing a first gradient layer of diamond adjacent said substrate,placing a second gradient layer of diamond adjacent said first gradient layer of diamond,exposing the assembly of said substrate and said first and second gradient diamond layers to high pressure and temperature in a press,sweeping said solvent metal from said substrate through said first and second gradient layers of diamond in order to solvate said diamond in said solvent metal and to then resolidify said gradient diamond layers and said substrate into a sintered polycrystalline diamond compact.
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Abstract
Use of gradient layers and stress modifiers in superhard constructs.
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Citations
46 Claims
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1. A method for making a sintered polycrystalline diamond compact comprising the steps of:
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selecting a substrate containing a desired solvent metal, placing a first gradient layer of diamond adjacent said substrate, placing a second gradient layer of diamond adjacent said first gradient layer of diamond, exposing the assembly of said substrate and said first and second gradient diamond layers to high pressure and temperature in a press, sweeping said solvent metal from said substrate through said first and second gradient layers of diamond in order to solvate said diamond in said solvent metal and to then resolidify said gradient diamond layers and said substrate into a sintered polycrystalline diamond compact. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for making a sintered polycrystalline diamond compact comprising the steps of:
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providing a first gradient layer of diamond, placing a second gradient layer of diamond adjacent said first gradient layer of diamond, providing a simulated substrate that provides a controlled release and limited supply of CoCrMo as a solvent metal, exposing the assembly of said simulated substrate and first and second gradient diamond layers to high pressure and temperature in a press, and sweeping said solvent metal from said simulated substrate through said second gradient layer of diamond in order to solvate said diamond in said solvent metal and then resolidify said first and second gradient diamond layers and said simulated substrate into a sintered polycrystalline diamond compact. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method for making a sintered polycrystalline diamond compact comprising the steps of:
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selecting a CoCr inner core, placing a titanium layer around said inner core, placing a first diamond outer layer against said titanium layer, the first diamond outer layer comprising CoCr as a sweep source of solvent metal, placing a second diamond outer layer against said first diamond outer layer, using said titanium layer as a diliatory source that offsets CTE from said solid CoCrMo inner layer and prevents it from pulling away from the titanium/CoCrMo interface as the sintering pressure and temperature goes from high pressure and high temperature to room temperature and ordinary barometric pressure, exposing said inner core, said titanium layer, said first diamond outer layer, and said second diamond outer layer to high pressure and high temperature in order to sinter a polycrystalline diamond compact.
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26. A method for making a sintered polycrystalline diamond compact comprising the steps of:
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selecting a substrate containing a desired solvent metal, said substrate having a CTE similar to that of diamond, placing a first gradient layer of diamond adjacent said substrate, placing a second gradient layer of diamond adjacent said first gradient layer of diamond, exposing the assembly of said substrate and said first and second gradient layers of diamond to high pressure and temperature in a press, and sweeping said solvent metal from said substrate through said first and second gradient layers of diamond in order to solvate said diamond in said solvent metal and then resolidify said gradient diamond layers and said substrate into a sintered polycrystalline diamond compact. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46)
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Specification