POLYCRYSTALLINE DIAMOND COMPACT INCLUDING AT LEAST ONE MECHANICALLY-STRESSED POLYCRYSTALLINE DIAMOND TABLE AND METHODS OF MAKING THE SAME
First Claim
1. A polycrystalline diamond compact, comprising:
- a substrate including an interfacial surface; and
a mechanically-stressed polycrystalline diamond table coupled to the substrate, the mechanically-stressed polycrystalline diamond table including an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting a mechanical deflection and a concave curvature induced by forced contact between the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate, the forced contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface of the substrate;
wherein, prior to the forced contact, the mechanically-stressed polycrystalline diamond table is not coupled to the substrate.
4 Assignments
0 Petitions
Accused Products
Abstract
Embodiments disclosed herein relate to polycrystalline diamond compacts (“PDCs”) including at least one mechanically-stressed polycrystalline diamond (“PCD”) table having an upper surface that exhibits a compressive stress state. Providing a selected support structure to the mechanically-stressed PCD table and/or generating a favorable stress state in the upper surface of the mechanically-stressed PCD table may improve a toughness and/or a strength of the mechanically-stressed PCD table and the PDC. In an embodiment, a PDC includes a substrate including an interfacial surface and a preformed PCD table attached to the substrate. The preformed PCD table includes an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate. In such an embodiment, the upper surface of the preformed PCD table exhibits a mechanical deflection and a concave curvature induced by deflecting the preformed PCD table toward the substrate. Methods of forming such PDCs including at least one mechanically-stressed PCD table are also disclosed.
0 Citations
25 Claims
-
1. A polycrystalline diamond compact, comprising:
-
a substrate including an interfacial surface; and a mechanically-stressed polycrystalline diamond table coupled to the substrate, the mechanically-stressed polycrystalline diamond table including an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting a mechanical deflection and a concave curvature induced by forced contact between the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate, the forced contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface of the substrate; wherein, prior to the forced contact, the mechanically-stressed polycrystalline diamond table is not coupled to the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
-
-
17. A method of forming a polycrystalline diamond compact, the method comprising:
-
providing an at least partially leached polycrystalline diamond table including an upper surface and a bottom surface; and deflecting the at least partially leached polycrystalline diamond table to form a mechanically-stressed polycrystalline diamond table, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting a mechanical deflection and a concave curvature induced by forcing contact between the bottom surface of the at least partially leached polycrystalline diamond table and an interfacial surface of a substrate, the forcing contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface fo the substrate; wherein, prior to forcing contact, the at least partially leached polycrystalline diamond table is not coupled to the substrate. - View Dependent Claims (18, 19, 20, 21, 22)
-
-
23. A rotary drill bit, comprising:
-
a bit body configured to engage a subterranean formation; and a plurality of polycrystalline diamond cutting elements attached to the bit body, at least one of the plurality of polycrystalline diamond cutting elements including; a substrate including an interfacial surface; and a mechanically-stressed polycrystalline diamond table coupled to the substrate, the mechanically-stressed polycrystalline diamond table including an upper surface spaced from a bottom surface that faces the interfacial surface of the substrate, the upper surface of the mechanically-stressed polycrystalline diamond table exhibiting mechanical deflection induced by forced contact between the bottom surface of the mechanically-stressed polycrystalline diamond table and the interfacial surface of the substrate, the forced contact comprising applying a forcing element to the upper surface under sufficient temperature and pressure to bend the polycrystalline diamond table into contact with the interfacial surface of the substrate; wherein, prior to the forced contact, the mechanically-stressed polycrystalline diamond table is not coupled to the substrate. - View Dependent Claims (24, 25)
-
Specification