Methods of fabricating polycrystalline diamond elements and compacts using SP2-carbon-containing particles
View Patent ↗Methods of fabricating polycrystalline diamond elements and compacts using sp 2 -carbon-containing particles are disclosed. In an embodiment, a method of fabricating a polycrystalline diamond element includes mixing a plurality of sp 2 -carbon-containing particles and a plurality of diamond particles to form a mixture. An amount of the plurality of sp 2 -carbon-containing particles present in the mixture is effective to increase a thermal stability of the polycrystalline diamond element formed at least partially from the mixture. The method further includes sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element.
1. A method of fabricating a polycrystalline diamond element, the method comprising:
mixing a plurality of sp 2 -carbon-containing particles and a plurality of diamond particles to form a mixture; and
sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element;
wherein the plurality of sp 2 -carbon-containing particles is present in the mixture in an effective amount such that the polycrystalline diamond element is capable of cutting a distance of at least 1868 linear feet in a granite workpiece during a vertical turret lathe thermal stability test without removal of the catalyst material from the polycrystalline diamond element.
2. The method of claim 1 wherein at least a portion of the plurality of sp 2 -carbon-containing particles comprise a plurality of nanocrystalline diamond particles.
3. The method of claim 1 wherein at least a portion of the plurality of sp 2 -carbon-containing particles comprise a plurality of ultra-dispersed diamond particles.
4. The method of claim 1 wherein at least a portion of the plurality of sp 2 -carbon-containing particles comprise carbon onion.
5. The method of claim 1 wherein at least a portion of the plurality of sp 2 -carbon-containing particles comprise amorphous carbon.
6. The method of claim 1 , further comprising:
disposing the mixture adjacent a substrate including the catalyst material therein; and
wherein sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element comprises infiltrating the mixture with the catalyst material from the substrate.
7. The method of claim 1 , further comprising:
disposing the mixture adjacent a substrate including the catalyst material therein; and
wherein sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element comprises forming the polycrystalline diamond element as a tablet on the substrate.
8. The method of claim 7 wherein the substrate comprises cemented tungsten carbide.
9. The method of claim 1 wherein the effective amount of the plurality of sp 2 -carbon-containing particles is greater than zero to about 5 weight percent of the mixture.
10. The method of claim 1 wherein the effective amount of the plurality of sp 2 -carbon-containing particles is about 0.1 weight percent to about 0.5 weight percent of the mixture.
11. The method of claim 1 wherein the effective amount of the sp 2 -carbon-containing particles is greater than zero weight percent to about 1 weight percent of the mixture.
12. The method of claim 1 wherein the effective amount of the plurality of sp 2 -carbon-containing particles is greater than zero weight percent to about 2 weight percent of the mixture.
13. The method of claim 1 , further comprising removing a portion of the catalyst material from the polycrystalline diamond element.
14. The method of claim 13 wherein removing a portion of the catalyst material from the polycrystalline diamond element comprises leaching the catalyst material from the polycrystalline diamond element.
15. The method of claim 1 , further comprising bonding the polycrystalline diamond element to a substrate.
16. The method of claim 1 wherein the catalyst material comprises cobalt, iron, nickel, or alloys thereof.
17. A method of fabricating a polycrystalline diamond element, the method comprising:
mixing a plurality of nanocrystalline diamond particles and a plurality of diamond particles to form a mixture; and
sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element;
wherein the plurality of nanocrystalline diamond particles is present in the mixture in an effective amount such that the polycrystalline diamond element is capable of cutting a distance of at least 1868 linear feet in a granite workpiece during a vertical turret lathe thermal stability test without removal of the catalyst material from the polycrystalline diamond element.
18. The method of claim 17 wherein the effective amount of the plurality of nanocrystalline diamond particles is greater than zero to about 5 weight percent of the mixture.
19. The method of claim 17 wherein the effective amount of the plurality of nanocrystalline diamond particles is about 0.1 weight percent to about 0.5 weight percent of the mixture.
20. The method of claim 17 wherein the effective amount of the plurality of nanocrystalline diamond particles is greater than zero weight percent to about 1 weight percent of the mixture.
21. The method of claim 17 wherein the effective amount of the plurality of nanocrystalline diamond particles is greater than zero weight percent to about 2 weight percent of the mixture.
22. The method of claim 17 wherein at least a portion of the plurality of nanocrystalline diamond particles comprise a plurality of ultra-dispersed diamond particles.
23. The method of claim 17 wherein at least a portion of the plurality of nanocrystalline diamond particles comprise a plurality of sp 2 -carbon-containing particles.
24. The method of claim 17 , further comprising removing a portion of the catalyst material from the polycrystalline diamond element.
25. The method of claim 24 wherein removing a portion of the catalyst material from the polycrystalline diamond element comprises leaching the catalyst material from the polycrystalline diamond element.
26. The method of claim 17 , further comprising bonding the polycrystalline diamond element to a substrate.
27. A method of fabricating a polycrystalline diamond element, the method comprising:
mixing a plurality of sp 2 -carbon-containing particles and a plurality of diamond particles to form a mixture; and
sintering the mixture in the presence of a catalyst material to form the polycrystalline diamond element, wherein the plurality of sp 2 -carbon-containing particles is present in the mixture in an effective amount so that the polycrystalline diamond element is capable of cutting a distance of at least 2135 linear feet in a granite workpiece during a vertical turret lathe thermal stability test without leaching of the catalyst material from the polycrystalline diamond element.
28. A method of fabricating a polycrystalline diamond compact, the method comprising:
mixing a plurality of sp 2 -carbon-containing particles and a plurality of diamond particles to form a mixture;
disposing the mixture adjacent to a cemented carbide substrate; and
subjecting the mixture and the cemented carbide substrate to a high-pressure/high-temperature process to sinter the mixture in the presence of a catalyst material infiltrated from the cemented carbide substrate and form a polycrystalline diamond table that bonds to the cemented carbide substrate;
wherein the plurality of sp 2 -carbon-containing particles is present in the mixture in an effective amount such that the polycrystalline diamond table is capable of cutting a distance of at least 1868 linear feet in a granite workpiece during a vertical turret lathe thermal stability test without removal of the catalyst material from the polycrystalline diamond table.
29. The method of claim 1 wherein the distance is at least 2135 linear feet.
30. The method of claim 17 wherein the distance is at least 2135 linear feet.
31. The method of claim 28 wherein the distance is at least 2135 linear feet.