Polycrystalline diamond compact (PDC) cutting element having multiple catalytic elements
View Patent ↗A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.
1. A polycrystalline diamond compact, comprising:
a volume of polycrystalline diamond material having a plurality of interstitial spaces, wherein a material comprising cobalt is disposed in at least some interstitial spaces and wherein a material comprising phosphorous is disposed in at least some other interstitial spaces.
2. The polycrystalline diamond compact of claim 1 , wherein the volume of polycrystalline diamond material includes a top surface and a side surface, and wherein the material comprising phosphorous is disposed in at least some interstitial spaces adjacent the top surface.
3. The polycrystalline diamond compact of claim 2 , further comprising a substrate, wherein the volume of polycrystalline diamond material is attached to the substrate.
4. The polycrystalline diamond compact of claim 3 , wherein the substrate comprises tungsten carbide.
5. The polycrystalline diamond compact of claim 4 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.
6. The polycrystalline diamond compact of claim 5 ,
wherein the volume of polycrystalline diamond material is beveled.
7. The polycrystalline diamond compact of claim 2 , wherein the material comprising phosphorous is disposed in substantially all of the interstices adjacent the top surface.
8. The polycrystalline diamond compact of claim 2 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.
9. A drill bit, comprising:
a shank; and
a bit body attached to the shank;
at least one polycrystalline diamond compact attached to the body, wherein the at least one polycrystalline body comprises:
a substrate; and
a volume of polycrystalline diamond material having a plurality of interstitial spaces, wherein a material comprising cobalt is disposed in at least some interstitial spaces and wherein a material comprising phosphorous is disposed in at least some other interstitial spaces.
10. The drill bit of claim 9 , wherein the volume of polycrystalline diamond material includes a top surface and a side surface, and wherein the material comprising phosphorous is disposed in at least some interstitial spaces adjacent the top surface.
11. The drill bit of claim 10 , further comprising a substrate,
wherein the volume of polycrystalline diamond material is attached to the substrate.
12. The drill bit of claim 11 , wherein the substrate comprises tungsten carbide.
13. The drill bit of claim 10 , wherein the material comprising phosphorous is disposed in substantially all of the interstices adjacent the top surface.
14. The drill bit of claim 10 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.
15. The drill bit of claim 14 , wherein the volume of polycrystalline diamond material is beveled.