Polycrystalline diamond tables and compacts and related methods
In an embodiment, a polycrystalline diamond table includes a plurality of bonded diamond grains and a plurality of interstitial regions defined by the plurality of bonded diamond grains. The polycrystalline diamond table may be at least partially leached such that at least a portion of at least one interstitial constituent has been removed from at least a portion of the plurality of interstitial regions by exposure to a leaching agent. The leaching agent may include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, and water in a concentration of about 50 weight % to about 85 weight %. Various other materials, articles, and methods are also disclosed.
1. A polycrystalline diamond body produced by a process comprising:
providing a polycrystalline diamond body including bonded diamond grains defining interstitial regions comprising at least one interstitial constituent disposed in the interstitial regions;
at least partially leaching the polycrystalline diamond body with a leaching agent comprising a mixture having:
a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4; and
water in a concentration of about 50 weight % to about 85 weight %;
producing an at least partially leached polycrystalline diamond body by removing at least a portion of the at least one interstitial constituent from the polycrystalline diamond body; and
producing the at least partially leached polycrystalline diamond body such that a portion of the leaching agent and/or a byproduct of the leaching agent remains within the at least partially leached polycrystalline diamond body.
2. The polycrystalline diamond body of claim 1 , the process further comprising removing substantially all of the at least one interstitial constituent from the polycrystalline diamond body.
3. The polycrystalline diamond body of claim 1 , wherein providing a polycrystalline diamond body including bonded diamond grains comprises providing a polycrystalline diamond compact including a polycrystalline diamond table bonded to a substrate.
4. The polycrystalline diamond body of claim 1 , the process further comprising selecting the mixture of the leaching agent to result in the portion of the leaching agent and/or the byproduct of leaching agent comprising a residual salt of nitric acid or hydrochloric acid or a residual oxide comprising a metal oxide.
5. The polycrystalline diamond body of claim 1 , the process further comprising selecting the mixture to comprise the hydrofluoric acid in a concentration of greater than about 15 weight % and the nitric acid in a concentration of less than about 20 weight %.
6. The polycrystalline diamond body of claim 1 , the process further comprising selecting the mixture to comprise the hydrofluoric acid in a concentration of about 15 weight % to about 25 weight % and the nitric acid in a concentration of about 10 weight % to about 20 weight %.
7. The polycrystalline diamond body of claim 1 , the process further comprising selecting the mixture to exhibit a viscosity of less than about 0.55 centipoise.
8. A polycrystalline diamond compact produced by a process comprising:
at least partially leaching, with a leaching agent, a polycrystalline diamond table comprising bonded diamond grains and interstitial regions to remove at least a portion of at least one interstitial constituent from at least some of the interstitial regions;
wherein, during the at least partially leaching, at least a portion of the diamond table is sealed from the leaching agent; and
selecting the leaching agent to include a mixture comprising a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4 and water in a concentration of about 50 weight % to about 85 weight %, wherein a portion of the leaching agent remains within the at least partially leached polycrystalline diamond table.
9. The polycrystalline diamond compact of claim 8 , the process further comprising selecting the mixture to comprise the hydrofluoric acid in a concentration of about 25 weight % to about 30 weight %, the nitric acid in a concentration of about 10 weight % to about 15 weight %, and the water in a concentration of about 55 weight % to about 65 weight %.
10. The polycrystalline diamond compact of claim 8 , the process further comprising selecting the mixture to comprise the hydrofluoric acid in a concentration of greater than about 15 weight % and the nitric acid in a concentration of less than about 20 weight %.
11. The polycrystalline diamond compact of claim 10 , the process further comprising selecting the mixture to exhibit a viscosity of less than about 0.5 centipoise.
12. The polycrystalline diamond compact of claim 8 , the process further comprising selecting the mixture to comprise the hydrofluoric acid in a concentration of about 15 weight % to about 25 weight % and the nitric acid in a concentration of about 10 weight % to about 20 weight %.
13. The polycrystalline diamond compact of claim 12 , the process further comprising selecting the mixture to exhibit a viscosity of less than about 0.4 centipoise.
14. The polycrystalline diamond compact of claim 8 , the process further comprising reducing a viscosity of the mixture prior to the leaching.
15. The polycrystalline diamond compact of claim 8 , the process further comprising heating the leaching agent during the at least partially leaching.
16. The polycrystalline diamond compact of claim 15 , the process further comprising selecting the mixture to exhibit a viscosity of less than about 0.5 centipoise.
17. A polycrystalline diamond compact produced by a process comprising:
leaching a polycrystalline diamond table bonded to a substrate with a leaching agent to remove at least a portion of at least one interstitial constituent disposed in interstitial regions defined in bonded diamond grains of the polycrystalline diamond table; and
selecting the leaching agent to include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, the mixture exhibiting a viscosity of less than about 0.55 centipoise, wherein the leaching agent from the leaching of the polycrystalline diamond table leaves at least one of a residual salt or a residual oxide in the polycrystalline diamond table.
18. The polycrystalline diamond compact of claim 17 , the process further comprising supplying the leaching agent to the polycrystalline diamond table at a temperature greater than about 25° C.
19. The polycrystalline diamond compact of claim 18 , the process further comprising supplying the leaching agent to the polycrystalline diamond table leached for more than about 100 hours.
20. The polycrystalline diamond compact of claim 17 , the process further comprising selecting the mixture of the leaching agent to result in the residual salt comprising a salt of nitric acid or hydrochloric acid or the residual oxide comprising a metal oxide.