Cutting elements and methods for fabricating diamond compacts and cutting elements with functionalized nanoparticles
A method of fabricating a diamond compact includes functionalizing surfaces of diamond nanoparticles with fluorine; combining the functionalized diamond nanoparticles with a non-group-VIII metal to form a particle mixture; and subjecting the particle mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles. A cutting element for an earth-boring tool includes a plurality of grains of diamond material; a plurality of diamond nanoparticles bonded to the plurality of grains of diamond material; and a non-group-VIII metal fluoride disposed within interstitial spaces between the grains of diamond material and the plurality of diamond nanoparticles. The cutting element is substantially free of a metal-solvent catalyst.
1. A cutting element for an earth-boring tool, comprising:
a substrate; and
a polycrystalline diamond material directly attached to the substrate, the polycrystalline diamond material comprising:
grains of diamond material;
diamond nanoparticles bonded to the grains of diamond material; and
a material disposed within and approximately filling all interstitial spaces between the grains of diamond material and the diamond nanoparticles, the material consisting of aluminum fluoride;
wherein the polycrystalline diamond material is substantially free of a metal-solvent catalyst.
2. The cutting element of claim 1 , wherein the diamond nanoparticles comprise crushed diamond nanoparticles.
3. The cutting element of claim 1 , wherein the diamond nanoparticles have a mean diameter of about 90 nm.
4. The cutting element of claim 1 , wherein a volume percentage of the grains of diamond material of the polycrystalline diamond material is at least 96%.
5. The cutting element of claim 1 , wherein a modulus of elasticity of the polycrystalline diamond material is from 800 GPa to 850 GPa.
6. The cutting element of claim 1 , wherein the substrate comprises metal-solvent catalyst.
7. The cutting element of claim 1 , wherein the substrate comprises cobalt-cemented tungsten carbide.
8. An earth-boring tool, comprising:
a body; and
a cutting element secured to the body, the cutting element comprising a polycrystalline diamond material comprising:
grains of diamond material;
diamond nanoparticles bonded to the grains of diamond material; and
a material disposed within and approximately filling all interstitial spaces between the grains of diamond material and the diamond nanoparticles, the material consisting of aluminum fluoride;
wherein the polycrystalline diamond material is substantially free of a metal-solvent catalyst.
9. The earth-boring tool of claim 8 , wherein the body comprises a bit body.
10. The earth-boring tool of claim 8 , wherein the cutting element is secured within a pocket defined by the body.
11. The earth-boring tool of claim 8 , wherein the cutting element is brazed to the body.
12. The earth-boring tool of claim 8 , wherein a volume percentage of the grains of diamond material of the polycrystalline diamond material is at least 96%.
13. The earth-boring tool of claim 8 , wherein a modulus of elasticity of the polycrystalline diamond material is from 800 GPa to 850 GPa.
14. A cutting element for an earth-boring tool, comprising:
a substrate; and
a polycrystalline diamond material directly attached to the substrate, the polycrystalline diamond material comprising:
grains of diamond material;
diamond nanoparticles bonded to the grains of diamond material;
a material disposed within and approximately filling all interstitial spaces between the grains of diamond material and the diamond nanoparticles, the material consisting of a non-group-VIII metal fluoride; and
an oxide of the non-group-VIII metal;
wherein the polycrystalline diamond material is substantially free of a metal-solvent catalyst.
15. The cutting element of claim 14 , wherein the non-group-VIII metal fluoride comprises aluminum fluoride.
16. The cutting element of claim 14 , wherein the polycrystalline diamond material further comprises a carbide of the non-group-VIII metal.