Methods of fabricating polycrystalline diamond, and cutting elements and earth-boring tools comprising polycrystalline diamond
View Patent ↗Methods of fabricating polycrystalline diamond include encapsulating diamond particles and a hydrocarbon substance in a canister, and subjecting the encapsulated diamond particles and hydrocarbon substance to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. Cutting elements for use in an earth-boring tool includes a polycrystalline diamond material formed by such processes. Earth-boring tools include such cutting elements.
1. A method of fabricating polycrystalline diamond, comprising:
encapsulating diamond particles and a hydrocarbon substance in a canister at a temperature below room temperature; and
subjecting the encapsulated diamond particles and the hydrocarbon substance to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles.
2. The method of claim 1 , wherein encapsulating the diamond particles and the hydrocarbon substance in the canister comprises:
placing the diamond particles in the canister;
positioning the canister with the diamond particles therein in an environment comprising a gaseous hydrocarbon substance; and
sealing the canister in the environment comprising the gaseous hydrocarbon substance.
3. The method of claim 2 , further comprising:
positioning the canister with the diamond particles therein in a chamber; and
introducing the gaseous hydrocarbon substance into the chamber.
4. The method of claim 3 , further comprising increasing a pressure within the chamber.
5. The method of claim 4 , further comprising selecting the pressure within the chamber to selectively control an amount of the hydrocarbon substance to be encapsulated within the canister.
6. The method of claim 1 , wherein encapsulating the diamond particles and the hydrocarbon substance in the canister at a temperature below room temperature comprises:
placing the diamond particles in the canister;
placing a liquid or solid hydrocarbon substance in the canister with the diamond particles; and
sealing the canister with the diamond particles and the liquid or solid hydrocarbon substance therein.
7. The method of claim 6 , wherein sealing the canister with the diamond particles and the liquid or solid hydrocarbon substance therein comprises sealing the canister at a temperature of about −150° C. or less.
8. The method of claim 7 , wherein sealing the canister at a temperature of about −150° C. or less comprises sealing the canister at a temperature of about −161° C. or less.
9. The method of claim 8 , wherein sealing the canister at a temperature of about −161° C. or less comprises sealing the canister at a temperature of about −182° C. or less.
10. A method of fabricating polycrystalline diamond, comprising:
placing diamond particles in a canister;
placing a liquid or solid hydrated hydrocarbon in the canister with the diamond particles;
sealing the canister with the diamond particles and the hydrated hydrocarbon therein; and
subjecting the encapsulated diamond particles and the hydrated hydrocarbon to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles.
11. The method of claim 1 , wherein encapsulating diamond particles and a hydrocarbon substance in the canister at a temperature below room temperature comprises encapsulating diamond nanoparticles and a hydrocarbon substance in the canister.
12. A method of fabricating polycrystalline diamond, comprising:
encapsulating diamond particles and a hydrocarbon substance in a canister, the hydrocarbon substance consisting of materials selected from the group consisting of methane, ethane, propane, butane, pentane, hexane, heptane, octane, and hydrates thereof; and
subjecting the encapsulated diamond particles and the hydrocarbon substance to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles.
13. The method of claim 12 , further comprising selecting the hydrocarbon substance to comprise methane.
14. A method of fabricating polycrystalline diamond, comprising:
encapsulating diamond particles and a hydrocarbon substance in a canister, the hydrocarbon substance comprising methane hydrate; and
subjecting the encapsulated diamond particles and the hydrocarbon substance to a pressure of at least 5.0 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles.