Polycrystalline diamond cutting elements with engineered porosity and method for manufacturing such cutting elements
First Claim
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1. A cutting element comprising:
- a substrate; and
a preformed thermally stable polycrystalline diamond body bonded to the substrate with at least an infiltrant,wherein the thermally stable polycrystalline diamond body comprises;
a working surface opposite the substrate;
a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material;
a first portion of the material microstructure proximate the substrate and having a porosity; and
a second portion of the material microstructure adjacent said first portion along an interface and extending to at least proximate the working surface and having a porosity,wherein the first portion occupies at least 25% of a volume of the polycrystalline diamond body,wherein the first portion comprises said infiltrant material in one or more of the pores between the diamond crystals previously occupied by a catalyst and a filler, said filler being different from said catalyst, andwherein the material microstructure has a differential porosity of at least 1.6% between the first and second portions when said porosities are measured without said infiltrant.
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Abstract
A method for facilitating infiltration of an infiltrant material into a TSP material during re-bonding of the TSP material to a substrate, by enhancing the porosity of the TSP material near the interface with the substrate is provided. Cutting elements formed by such method and downhole tools including such cutting elements are also provided.
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Citations
34 Claims
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1. A cutting element comprising:
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a substrate; and a preformed thermally stable polycrystalline diamond body bonded to the substrate with at least an infiltrant, wherein the thermally stable polycrystalline diamond body comprises; a working surface opposite the substrate; a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material; a first portion of the material microstructure proximate the substrate and having a porosity; and a second portion of the material microstructure adjacent said first portion along an interface and extending to at least proximate the working surface and having a porosity, wherein the first portion occupies at least 25% of a volume of the polycrystalline diamond body, wherein the first portion comprises said infiltrant material in one or more of the pores between the diamond crystals previously occupied by a catalyst and a filler, said filler being different from said catalyst, and wherein the material microstructure has a differential porosity of at least 1.6% between the first and second portions when said porosities are measured without said infiltrant. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A cutting element comprising:
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a substrate; and a preformed thermally stable polycrystalline diamond body bonded to the substrate with at least an infiltrant, wherein the thermally stable polycrystalline diamond body comprises; a working surface opposite the substrate; a peripheral surface extending from the substrate to the working surface, wherein an edge is defined at an intersection of the peripheral surface and the working surface; a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material; a first portion of the material microstructure proximate the substrate having a porosity and comprising a projection; and a second portion of the material microstructure extending to at least proximate the working surface having a porosity and comprising a depression receiving said projection, wherein the first portion comprises said infiltrant material in one or more of the pores between the diamond crystals previously occupied by a catalyst and a filler, said filler being different from said catalyst, and wherein the material microstructure has a differential porosity between the first and second portions when said porosities are measured without said infiltrant. - View Dependent Claims (25, 26, 27, 28, 29)
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30. A cutting element comprising:
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a substrate; and a preformed thermally stable polycrystalline diamond body bonded to the substrate with at least an infiltrant, wherein the thermally stable polycrystalline diamond body comprises; a working surface opposite the substrate; a material microstructure comprising a plurality of bonded-together diamond crystals, and pores between the diamond crystals, the pores being substantially free of a catalyst material; a first portion of the material microstructure proximate the substrate and having a porosity; and a second portion of the material microstructure adjacent said first portion along an interface and extending to at least proximate the working surface and having a porosity, wherein the first portion occupies at least 25% of a volume of the polycrystalline diamond body, wherein the first portion comprises said infiltrant material in one or more of the pores between the diamond crystals previously occupied by a catalyst and a filler, said filler being different from said catalyst, wherein the diamond crystals of said first portion have a first average grain size and the diamond crystals of the second portion have a second average grain size that is the same as the first average grain size, and wherein the material microstructure has a differential porosity of at least 1.6% between the first and second portions when said porosities are measured without said infiltrant. - View Dependent Claims (31, 32, 33, 34)
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Specification