Polycrystalline diamond compact, drill bit incorporating same, and methods of manufacture
View Patent ↗Methods of making superabrasive elements may include forming a first superabrasive body, forming discrete components from the first superabrasive body, and then forming a second abrasive element from the discrete components. For example, microstructures (e.g., micro-cylinders or other geometries) may be formed from the first superabrasive element, catalyst materials may be removed from the microstructures, with the microstructures being recombined and bonded during a subsequent high-pressure, high-temperature (HPHT) process. In other embodiments, superabrasive elements may be formed to include microfeatures formed in a surface of a superabrasive body or table. For example, blind holes or slots may be formed in a surface of the element for use in attaching the superabrasive table to a substrate. The holes may be coated to provide an impermeable surface, or they may be filled with a metallic material to enhance the attachment to a substrate.
1. A method of forming a superabrasive element, the method comprising:
forming a first superabrasive body comprising a polycrystalline table in a high-pressure, high-temperature (HPHT) process, wherein forming the first superabrasive body includes sweeping a catalyst material into a plurality of diamond grains during the HPHT process, removing the catalyst material from interstitial spaces between bonded diamond grains subsequent to the HPHT process;
forming a plurality of discrete micro-structures from the superabrasive body;
forming a second superabrasive body from at least some of the plurality of discrete structures in an HPHT process;
forming a material coating on the at least some of the plurality of micro-structures subsequent to removing catalyst material and prior to forming the second superabrasive body.
2. The method according to claim 1 , wherein forming a plurality of micro-structures includes forming at least one of a cylinder, a sphere, a polyhedron, a disc and a platelet.
3. The method according to claim 1 , further comprising forming the plurality of micro-structures by an electric discharge machining (EDM) process.
4. The method according to claim 1 , further comprising maintaining the at least some of the plurality of micro-structures free of catalyst material during the HPHT process associated with forming the second superabrasive body.
5. The method according to claim 4 , further comprising attaching the second superabrasive body to a substrate.
6. The method according to claim 5 , further comprising forming a plurality of micro-features in a surface of the second superabrasive body that is to be bonded to the substrate.
7. The method according to claim 6 , wherein forming a plurality of micro-features includes forming a plurality of blind holes.
8. The method according to claim 7 , further comprising disposing a material in the plurality of blind holes prior to attaching the superabrasive body to the substrate.
9. A superabrasive element comprising:
a superabrasive body comprising a plurality of pre-formed, superabrasive microstructures, the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;
wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within each of the microstructures are substantially devoid of any catalyst material;
wherein each of the plurality of microstructures has a material coating at least partially thereon.
10. A superabrasive element comprising:
a superabrasive body comprising a plurality of pre-formed, micro-cut, superabrasive microstructures, the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;
wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within each of the microstructures are substantially devoid of any catalyst material;
wherein the superabrasive element further comprises a plurality of diamond grains intermixed with and bonded to the plurality of plurality of microstructures.
11. The superabrasive element of claim 10 , wherein the plurality of pre-formed, micro-cut, superabrasive microstructures, includes a plurality of pre-formed, laser-cut superabrasive microstructures are leached subsequent to being laser-cut.
12. The superabrasive element of claim 11 , wherein the plurality of pre-formed, laser-cut, superabrasive microstructures.
13. The superabrasive element of claim 10 , wherein the superabrasive body exhibits a coercivity of about 115 Oersteds or more.
14. The superabrasive element of claim 10 , wherein the superabrasive body exhibits a specific magnetic saturation of about 15 Gauss·cm 3 /grams or less.
15. A superabrasive element comprising:
a superabrasive body bonded to a preformed, superabrasive ring, wherein the superabrasive body includes a plurality of interstitial spaces having a catalyst material disposed therein, and wherein the superabrasive ring includes a plurality of interstitial spaces being substantially devoid of any catalyst material.
16. The superabrasive element of claim 15 , wherein the superabrasive body comprises polycrystalline diamond, and wherein the preformed superabrasive ring comprises polycrystalline diamond.
17. The superabrasive element of claim 16 , further comprising a material coating on the superabrasive ring.
18. A rotary drill bit for drilling a subterranean formation, the drill bit comprising:
a shank;
a bit body attached to the shank;
at least one superabrasive element coupled with the bit body, the at least one superabrasive element comprising:
a superabrasive body comprising a plurality of pre-formed, superabrasive microstructures, the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;
wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within each of the microstructures are substantially devoid of any catalyst material;
wherein each of the plurality of microstructures has a material coating at least partially thereon.
19. A rotary drill bit for drilling a subterranean formation, the drill bit comprising:
a shank;
a bit body attached to the shank;
at least one cutting element coupled with the bit body, the at least one cutting element comprising:
a superabrasive body bonded to a preformed, superabrasive ring, wherein the superabrasive body includes a plurality of interstitial spaces having a catalyst material disposed therein, and wherein the superabrasive ring includes a plurality of interstitial spaces being substantially devoid of any catalyst material.
20. A rotary drill bit for drilling a subterranean formation, the drill bit comprising:
a shank;
a bit body attached to the shank;
at least one superabrasive element coupled with the bit body, the at least one superabrasive element comprising a superabrasive body, the superabrasive body comprising a plurality of pre-formed, superabrasive microstructures, the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;
wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within each of the microstructures are substantially devoid of any catalyst material;
wherein the superabrasive element further comprises a plurality of diamond grains intermixed with and bonded to the plurality of plurality of microstructures.