Polycrystalline diamond partially depleted of catalyzing material

• US 6,589,640 B2
• Filed: 11/01/2002
• Issued: 07/08/2003
• Est. Priority Date: 09/20/2000
• Status: Expired due to Term

• Current Assignee: Reedhycalog UK (National Oilwell Varco Incorporated)
• Original Assignee: Reedhycalog UK (National Oilwell Varco Incorporated)
• Inventors: Griffin, Nigel Dennis, Hughes, Peter Raymond
• Primary Examiner(s): TURNER, ARCHENE A
• Application Number:
  US10/065,602
• Publication Number:
  US 20030035957A1
• Time in Patent Office: 249 Days
• Field of Search: 428/408, 428/332, 428/212
• US Class Current: 428/212
• CPC Class Codes: C04B 37/021 in a direct manner, e.g. direct copper bonding [DCB]
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
• CPC Class Codes: Y10T 407/27 comprising tool of specific chemical composition
• CPC Class Codes: Y10T 428/12493 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/12625 Free carbon containing component
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

The present invention provides a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material. This translates to higher wear resistance in cutting applications, higher heat transfer capacity in heat sink applications, and has advantages in numerous other applications including hollow dies, indentors, tool mandrels, and wear elements.

Claims

1. A polycrystalline diamond element comprising a body with a working surface, wherein a first volume of the body remote from the working surface contains a catalyzing material, a second volume of the body adjacent to the working surface is substantially free of the catalyzing material, wherein the second volume extends to a depth of at least about 0.1 mm from the working surface.

2. The polycrystalline diamond element of claim 1, wherein the second volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.

3. The polycrystalline diamond element of claim 1, wherein the second volume of the body has a diamond density higher than elsewhere in the body.

4. The polycrystalline diamond element of claim 1, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of diamond crystals.

5. The polycrystalline diamond element of claim 1, wherein an amount of catalyzing material within the second volume of the body increases with distance from the working surface.

6. The polycrystalline diamond element of claim 5, wherein the amount of catalyzing material within the second volume increases in steps.

7. The polycrystalline diamond element of claim 1, wherein the body comprises a plurality of partially bonded diamond crystals and an interstitial matrix, and wherein the part of the interstitial matrix located within the first volume contains the catalyzing material, and the part of the interstitial matrix located within the second volume is substantially free of the catalyzing material.

8. The polycrystalline diamond element of claim 7, wherein the second volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.

9. The polycrystalline diamond element of claim 7, wherein the second volume of the body has a diamond density higher than elsewhere in the body.

10. The polycrystalline diamond element of claim 7, wherein a majority of diamond crystals located within the second volume of the body have a surface which is substantially free of catalyzing material.

11. The polycrystalline diamond element of claim 7, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of the diamond crystals.

12. The polycrystalline diamond element of claim 7, wherein the diamond crystals in the second volume remote from the first volume have less catalyzing material adhering to their surfaces than the diamond crystals in the second volume which are adjacent to the first volume.

13. The polycrystalline diamond element of claim 7, wherein an amount of catalyzing material within the second volume of the body increases with distance from the working surface.

14. The polycrystalline diamond element of claim 13, wherein the amount of catalyzing material within the second volume increases in steps.

15. An element comprising a plurality of partially bonded diamond crystals, a catalyzing material, and an interstitial matrix, and a body with a working surface, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of at least about 0.1 mm from the working surface.

16. The element of claim 15, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of between about 0.2 mm and 0.3 mm from the working surface.

17. The element of claim 15, wherein the interstitial matrix in the body adjacent to the working surface of the body has a diamond density higher than elsewhere in the body.

18. The element of claim 15, wherein a majority of the catalyzing material remaining in the interstitial matrix in the body adjacent to the working surface of the body adheres to surfaces of diamond crystals.

19. The element of claim 15, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body increases with distance from the working surface.

20. The element of claim 19, wherein the amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface increases in steps.

21. A polycrystalline diamond element comprising a catalyzing material, an interstitial matrix, and a body with a working surface, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of at least about 0.1 mm from the working surface.

22. The polycrystalline diamond element of claim 21, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of between about 0.2 mm and 0.3 mm from the working surface.

23. The polycrystalline diamond element of claim 21, wherein the interstitial matrix in the body adjacent to the working surface of the body has a diamond density higher than elsewhere in the body.

24. The polycrystalline diamond element of claim 21, wherein a majority of the catalyzing material remaining in the interstitial matrix in the body adjacent to the working surface of the body adheres to surfaces of diamond crystals.

25. The polycrystalline diamond element of claim 21, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body continuously decreases with distance from the remaining interstitial matrix.

26. The polycrystalline diamond element of claim 25, wherein the amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface increases in steps.

27. A polycrystalline diamond element comprising a plurality of superhard crystals, a catalyzing material, and a body with a working surface, wherein a majority of the crystals in the body within at least a 0.1 mm depth from the working surface have a surface which is substantially free of the catalyzing material, the remaining crystals contact the catalyzing material.

28. The polycrystalline diamond element of claim 27, wherein said majority of the crystals in the body are within between about 0.2 mm and 0.3 mm depth from the working surface.

29. An element comprising a plurality of partially bonded diamond crystals, a catalyzing material, and a body with a working surface, wherein a volume of the body adjacent the working surface has a substantially higher diamond density than elsewhere in the body, and the volume is substantially free of the catalyzing material, wherein the volume extends to a depth of at least about 0.1 mm from the working surface.

30. The element of claim 29, wherein the volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.

31. The element of claim 29, wherein a majority of diamond crystals located within the volume of the body have a surface which is substantially free of catalyzing material.

32. The element of claim 29, wherein a majority of the catalyzing material remaining in the volume of the body adheres to surfaces of the diamond crystals.

33. A polycrystalline diamond element comprising a body with a working surface, wherein a volume of the body adjacent the working surface has a diamond density substantially higher than elsewhere in the body, and the volume is substantially free of a catalyzing material, wherein the volume extends to a depth of at least about 0.1 mm from the working surface.

34. The polycrystalline diamond element of claim 33, wherein the volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.

35. The polycrystalline diamond element of claim 33, wherein a majority of diamond crystals located within the volume of the body have a surface which is substantially free of catalyzing material.

36. The polycrystalline diamond element of claim 33, wherein a majority of the catalyzing material remaining in the volume of the body adheres to surfaces of the diamond crystals.

37. A polycrystalline diamond element comprising a body with a working surface, wherein a diamond density adjacent the working surface is higher than elsewhere in the body, and is substantially free of a catalyzing material, and extends to a depth of at least about 0.1 mm from the working surface.

38. The polycrystalline diamond element of claim 37, wherein the body comprises a plurality of partially bonded diamond crystals and an interstitial matrix, and wherein a part of the interstitial matrix located within a first volume contains the catalyzing material, and a part of the interstitial matrix located within a second volume is substantially free of the catalyzing material.

39. The polycrystalline diamond element of claim 38, wherein the second volume extends to a depth of at least between about 0.2 mm and 0.3 mm from the working surface.

40. The polycrystalline diamond element of claim 38, wherein the second volume of the body has a diamond density higher than elsewhere in the body.

41. The polycrystalline diamond element of claim 38, wherein a majority of diamond crystals located within the second volume of the body have a surface which is substantially free of catalyzing material.

42. The polycrystalline diamond element of claim 38, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of the diamond crystals.

43. The polycrystalline diamond element of claim 38, wherein an amount of catalyzing material within the second volume of the body increases with distance from the working surface.