ALLOYS WITH LOW COEFFICIENT OF THERMAL EXPANSION AS PDC CATALYSTS AND BINDERS
A cutting table includes a lattice structure and a catalyst material deposited within voids formed within the lattice structure. The catalyst material is deposited in the voids during a sintering process that forms the lattice structure. The catalyst material facilitates the growth of the lattice structure. The catalyst material has a coefficient of thermal expansion that is less than that of cobalt.
1 . A cutting table, comprising:
a lattice structure forming interstitial spaces therein; and
a catalyst material deposited within the interstitial spaces during a sintering process that forms the lattice structure, the catalyst material facilitating the growth of the lattice structure, the catalyst material having a coefficient of thermal expansion that is less than the coefficient of thermal expansion of cobalt.
2 . The cutting table of claim 1 , wherein the catalyst material is selected from a group consisting of chromium, tantalum, and ruthenium.
3 . The cutting table of claim 1 , wherein the catalyst material is selected from a group consisting of alloys of cobalt, alloys of a Group VIII metal and at least one non-catalyst metal, and alloys of two or more Group VIII metals.
4 . The cutting table of claim 1 , wherein the catalyst material comprises a eutectic alloy, the eutectic alloy comprising a eutectic composition.
5 . The cutting table of claim 1 , wherein the catalyst material comprises a near eutectic alloy.
6 . The cutting table of claim 1 , wherein the catalyst material has a thermal conductivity that is greater than the thermal conductivity of cobalt.
7 . The cutting table of claim 1 , wherein the lattice structure comprises a polycrystalline diamond.
8 . A cutter, comprising:
a substrate comprising a top surface;
a cutting table, comprising:
a cutting surface;
an opposing surface coupled to the top surface;
a cutting table outer wall extending from the circumference of the opposing surface to the circumference of the cutting surface;
a lattice structure forming interstitial spaces therein; and
a catalyst material deposited within the interstitial spaces during a sintering process that forms the lattice structure, the catalyst material facilitating the growth of the lattice structure, the catalyst material having a coefficient of thermal expansion that is less than the coefficient of thermal expansion of cobalt.
9 . The cutter of claim 8 , wherein the catalyst material is selected from a group consisting of chromium, tantalum, and ruthenium.
10 . The cutter of claim 8 , wherein the catalyst material is selected from a group consisting of alloys of cobalt, alloys of a Group VIII metal and at least one non-catalyst metal, and alloys of two or more Group VIII metals.
11 . The cutter of claim 8 , wherein the catalyst material comprises a eutectic alloy, the eutectic alloy comprising a eutectic composition.
12 . The cutter of claim 8 , wherein the catalyst material comprises a near eutectic alloy.
13 . The cutter of claim 8 , wherein the catalyst material has a thermal conductivity that is greater than the thermal conductivity of cobalt.
14 . The cutter of claim 8 , wherein the lattice structure comprises a polycrystalline diamond.
15 . The cutter of claim 8 , wherein the substrate is formed from a substrate powder and a binder material, the binder material cementing the substrate powder to form the substrate, the binder material being the same as the catalyst material.
16 . The cutter of claim 15 , wherein the catalyst material originates in the substrate and infiltrates into the cutting table.
17 . The cutter of claim 8 , wherein the substrate is formed from a substrate powder and a binder material, the binder material cementing the substrate powder to form the substrate, the binder material being different than the catalyst material.
18 . The cutter of claim 17 , wherein the melting point of the catalyst material is lower than the melting point of the binder material.