Thermally stable diamond polycrystalline diamond constructions

• US 7,608,333 B2
• Filed: 12/22/2004
• Issued: 10/27/2009
• Est. Priority Date: 09/21/2004
• Status: Active Grant

• Current Assignee: Smith International Incorporated (Schlumberger NV)
• Original Assignee: Smith International Incorporated (Schlumberger NV)
• Inventors: Eyre, Ronald K.
• Primary Examiner(s): Turner; Archene
• Application Number:
  US11/022,271
• Publication Number:
  US 20060060390A1
• Time in Patent Office: 1,770 Days
• Field of Search: 428/408, 428/332, 428/469, 407/119, 513/07, 513/09
• US Class Current: 428/408
• CPC Class Codes: B22F 2003/244 Leaching
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 2207/03 of the metallic binder phase in cermets
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B24D 3/10 for porous or cellular structure, e.g. for use with diamonds as abrasives
• CPC Class Codes: C22C 26/00 Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• 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 428/24488 Differential nonuniformity at margin
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• 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 428/30 Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31678 Of metal

Abstract

Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

Claims

1. A thermally stable diamond construction comprising:

a substrate; and

a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,

the diamond body including a top surface and a side surface extending away from the top surface, and

the diamond body comprising;

a first region of the diamond body being substantially free of a Group VIII metal, and the first region extending into the diamond body from the top surface a partial depth between about 0.02 mm and 0.09 mm and a partial depth along a partial length of the side surface, wherein the partial length extends substantially uniformly around a circumference of the diamond body along at least 50% of the side surface; and

a second region adjacent the first region, the second region comprising the Group VIII metal.

2. The thermally stable diamond construction of claim 1, wherein the partial depth from top surface ranges from about 0.04 to 0.08 mm.

3. The thermally stable diamond construction of claim 1, wherein the second region is interposed between the first region and the substrate.

4. The thermally stable diamond construction of claim 1, wherein diamond body comprises a beveled surface disposed along a circumferential edge of the top surface.

5. The thermally stable diamond construction of claim 1, wherein the partial depth from the side surface is between about 0.02 mm and 1 mm.

6. The thermally stable diamond construction of claim 5, wherein the partial depth from the side surface is between about 0.1 mm and 0.5 mm.

7. The thermally stable diamond construction of claim 6, wherein the partial depth from the side surface is between about 0.15 mm and 0.3 mm.

8. The thermally stable diamond construction of claim 1, wherein the interstitial regions in the first region are substantially empty.

9. The thermally stable diamond construction of claim 1, wherein the Group VIII material was used to initially sinter the diamond body.

10. The thermally stable diamond construction of claim 1, wherein the source of the Group VIII material is the substrate.

11. A thermally stable diamond construction comprising:

a substrate; and

a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,

the diamond body including a top surface and a side surface extending away from the top surface, and

the diamond body comprising;

a first region of the diamond body being substantially free of a Group VIII metal, and the first region extending a partial depth into the diamond body along a partial length of the side surface, wherein the partial depth ranges between about 0.1 mm to 0.5 mm; and

a second region adjacent the first region, the second region comprising the Group VIII metal.

12. The thermally stable diamond construction of claim 11, wherein the partial depth from the side surface ranges from about 0.15 mm to 0.3 mm.

13. The thermally stable diamond construction of claim 11, wherein the partial length ranges from 25 percent to less than 100 percent of the side surface length.

14. The thermally stable diamond construction of claim 13, wherein the partial length is greater than about 40 percent of the side surface length.

15. The thermally stable diamond construction of claim 14, wherein the partial length is greater than about 50 percent of the side surface length.

16. The thermally stable diamond construction of claim 11, wherein the interstitial regions in the first region are substantially empty.

17. The thermally stable diamond construction of claim 11, wherein the Group VIII material was used to initially sinter the diamond body.

18. The thermally stable diamond construction of claim 11, wherein the source of the Group VIII material is the substrate.

19. The thermally stable diamond construction of claim 11, wherein the first region also extends a partial depth into the diamond body from the top surface.

20. The thermally stable diamond construction of claim 11, wherein the partial depth from the top surface ranges from about 0.008 to 0.10 mm.

21. The thermally stable diamond construction of claim 20, wherein the partial depth from the top surface ranges from about 0.04 mm to 0.08 mm.

22. A fixed cutter drill bit, comprising:

a bit body;

a plurality of blades extending radially from a center of the bit body;

a plurality of cutter pockets formed in the plurality of blades; and

a plurality of cutting elements attached to the plurality of cutter pockets, at least one cutting element comprising;

a substrate; and

a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,

the diamond body including an upper surface and a side surface substantially perpendicular to upper surface, and a beveled surface disposed between a circumferential edge of the upper surface and the side surface, and

the diamond body comprising;

a first region of the diamond body being substantially free of a Group VIII metal, and the first region extending from the top surface and beveled surface a partial depth into the diamond body between about 0.02 and 0.09 mm and a partial depth along a partial length of the side surface, wherein the partial length extends substantially uniformly around a circumference of the diamond body along at least 50% of the side surface; and

a second region adjacent the first region, the second region comprising the Group VIII metal.

23. The bit of claim 22, wherein the partial depth from the top surface ranges from about 0.04 to 0.08 mm.

24. The bit of claim 22, wherein the partial depth from the side surface ranges from 0.02 to 1 mm.

25. The bit of claim 22, wherein the partial depth from the side surface ranges from 0.1 to 0.5 mm.

26. The bit of claim 25, wherein the partial depth from the side surface ranges from 0.15 to 0.3 mm.

27. The bit of claim 22, wherein the first region extends from the side surface a depth within the diamond body that changes along the length of the diamond body side surface.

28. The bit of claim 27, wherein the first region extends from the side surface a depth within the diamond body that decreases along the length of the diamond body side surface away from the top surface.

29. The bit of claim 22, wherein the second region is interposed between the first region and the substrate.

30. A fixed cutter drill bit, comprising:

a bit body;

a plurality of blades extending radially from a center of the bit body;

a plurality of cutter pockets formed in the plurality of blades; and

a plurality of cutting elements attached to the plurality of cutter pockets, at least one cutting element comprising;

a substrate; and

a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,

the diamond body including a top surface and a side surface extending away from the top surface, and

the diamond body comprising;

a first region of the diamond body being substantially free of a Group VIII metal, and the first region extending a partial depth into the diamond body along a partial length of the side surface, wherein the partial depth ranges between about 0.1 mm to 0.5 mm; and

a second region adjacent the first region, the second region comprising the Group VIII metal.

31. The bit of claim 30, wherein the partial depth from the side surface ranges from about 0.15 mm to 0.3 mm.

32. The bit of claim 30, wherein the partial length ranges from 25 percent to less than 100 percent of the side surface length.

33. The bit of claim 32, wherein the partial length is greater than about 40 percent of the side surface length.

34. The bit of claim 33, wherein the partial length is greater than about 50 percent of the side surface length.

35. The bit of claim 30, wherein the interstitial regions in the first region as substantially empty.

36. The bit of claim 30, wherein the Group VIII material was used to initially sinter the diamond body.

37. The bit of claim 30, wherein the source of the Group VIII material is the substrate.

38. The bit of claim 30, wherein the first region also extends a partial depth into the diamond body from the top surface.

39. The bit of claim 30, wherein the partial depth from the top surface ranges from about 0.008 to 0.10 mm.

40. The bit of claim 30, wherein the partial depth from the top surface ranges from about 0.02 to 0.09 mm.

41. The bit of claim 30, wherein the partial depth from the top surface ranges from about 0.04 mm to 0.08 mm.