Granted Patent B2

US 12,297,153 · App. 16/880,131 · Granted May 13, 2025

Inventors: Kenneth E. Bertagnolli (Riverton, UT); Jiang Qian (Cedar Hills, UT); Jason Wiggins (Draper, UT); Michael Vail (Genola, UT); Debkumar Mukhopadhyay (Sandy, UT)

Assignee: US SYNTHETIC CORPORATION

C04B37/001B21C3/025B24D18/0009C22C26/00E21B10/567F16C33/043F16C33/26G01N27/72G01N27/80C04B2237/36C04B2237/363F16C17/02F16C17/04F16C2206/04F16C2206/82F16C2220/20F16C2240/40F16C2240/48F16C2352/00Y10T428/24058Y10T428/24997Y10T428/25Y10T428/252Y10T428/30

Abstract

Claims (36)

1. A polycrystalline diamond compact, comprising:

a polycrystalline diamond table including a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, wherein the plurality of diamond grains exhibit an average grain size of about 5 μm to about 50 μm;

wherein the polycrystalline diamond table includes an unleached portion including:

a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions, the metal-solvent catalyst present in the unleached portion in an amount of about 3 weight % to about 7.5 weight %;

a portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a coercivity of about 115 Oersteds (“Oe”) to about 250 Oe; and

the portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a specific magnetic saturation of about 5 Gauss·cm 3 /grams (“G·cm 3 /g”) to about 15 G·cm 3 /g;

wherein the polycrystalline diamond table exhibits a G ratio of at least about 4.0×106, and

a substrate bonded to the polycrystalline diamond table.

2. The polycrystalline diamond compact of claim 1 , wherein the plurality of diamond grains exhibit an average grain size of about 10 μm to about 18 μm.

3. The polycrystalline diamond compact of claim 1 , wherein the coercivity of the portion of the plurality of diamond grains and the metal-solvent catalyst collectively is about 115 Oe to about 175 Oe.

4. The polycrystalline diamond compact of claim 1 , wherein the coercivity of the portion of the plurality of diamond grains and the metal-solvent catalyst collectively is about 155 Oe to about 175 Oe.

5. The polycrystalline diamond compact of claim 1 , wherein the magnetic saturation of the portion of the plurality of diamond grains and the metal-solvent catalyst collectively is about 10 G·cm 3 /g to about 15 G·cm 3 /g.

6. The polycrystalline diamond compact of claim 1 , wherein the portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a specific permeability of about 0.10 G·cm 3 /g·Oe or less.

7. The polycrystalline diamond compact of claim 1 , wherein the specific permeability of the portion of the plurality of diamond grains and the metal-solvent catalyst collectively is about 0.06 G·cm 3 /g·Oe to about 0.09 G·cm 3 /g·Oe.

8. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table includes an unleached volume exhibiting a G ratio of at least about 15.0×10 6 .

9. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table is formed in a high-pressure/high-temperature process at a cell pressure of at least 7.5 GPa.

10. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table, when unleached, exhibits a thermal stability, as determined by a distance cut, prior to failure, in a vertical lathe test of at least about 1300 m.

11. The polycrystalline diamond compact of claim 1 , wherein the polycrystalline diamond table is formed from only a single layer of polycrystalline diamond extending from the upper exterior surface to the substrate.

12. A polycrystalline diamond compact, comprising:

a polycrystalline diamond table including a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, wherein the plurality of diamond grains exhibit an average grain size of about 5 μm to about 30 μm;

wherein the polycrystalline diamond table is formed in a high-pressure/high-temperature process at a cell pressure of at least 7.5 Gpa

wherein the polycrystalline diamond table includes an unleached volume exhibiting a G ratio of at least about 4.0×10 6 ;

wherein the polycrystalline diamond table includes an unleached portion including:

a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions, the metal-solvent catalyst present in the unleached portion in an amount of about 3 weight % to about 7.5 weight %;

a portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a coercivity of about 115 Oersteds (“Oe”) to 250 Oe;

the portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a specific magnetic saturation of about 5 Gauss·cm 3 /grams (“G·cm 3 /g”) to 15 G·cm 3 /g; and

a substrate bonded to the polycrystalline diamond table.

13. A polycrystalline diamond compact, comprising:

a polycrystalline diamond table including a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, wherein the plurality of diamond grains exhibit an average grain size of about 5 μm to about 20 μm; and

a substrate bonded to the polycrystalline diamond table

wherein the polycrystalline diamond table includes an unleached volume, the unleached volume exhibiting a G ratio of at least about 8.0×10 6 ;

wherein the polycrystalline diamond table includes an unleached portion includes:

a metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions, the metal-solvent catalyst present in the unleached portion in an amount of about 3 weight % to about 7.5 weight %;

a portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a coercivity of about 115 Oersteds (“Oe”) to 250 Oe;

the portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a specific magnetic saturation of about 10 Gauss·cm 3 /grams (“G·cm 3 /g”) to 15 G·cm 3 /g; and

the portion of the plurality of diamond grains and the metal-solvent catalyst collectively exhibiting a specific permeability of about 0.060 G·cm 3 /g·Oe to about 0.090 G·cm 3 /g·Oe.

Assignments (3)

Continuity (5)

References Cited (400)