Polycrystalline composites reinforced with elongated nanostructures
A sintered polycrystalline composite for cutting tools that includes a plurality of diamond or cubic boron nitride particles; a plurality of nanotube materials; and a refractory or binder material is disclosed. Methods of forming such polycrystalline composites that include integrating or mixing a plurality of nanotube materials with diamond or cubic boron nitride particle and/or refractory or binder particles are also disclosed.
1. A polycrystalline composite comprising:
a plurality of interconnected diamond particles forming a polycrystalline diamond lattice structure;
a refractory or binder material; and
a plurality of elongated nanostructures integrated into the polycrystalline composite.
2. The polycrystalline composite of claim 1 , further comprising a carbide substrate attached to the polycrystalline composite.
3. The polycrystalline composite of claim 1 , wherein the polycrystalline composite is thermally stable.
4. The polycrystalline composite of claim 1 , wherein the refractory or binder material is a metal catalyst.
5. The polycrystalline composite of claim 1 , wherein the plurality of elongated nanostructures comprise carbon nanotubes.
6. The polycrystalline composite of claim 5 , wherein the nanotubes comprise single-walled carbon nanotubes, multi-walled carbon nanotubes, or combinations thereof.
7. The polycrystalline composite of claim 1 , wherein the plurality of plurality of elongated nanostructures comprise inorganic nanotubes.
8. The polycrystalline composite of claim 7 , wherein the inorganic nanotube is formed by depositing an inorganic coating by atomic layer deposition on a carbon nanotube and removing the carbon nanotube.
9. The polycrystalline composite of claim 1 , wherein the plurality of plurality of elongated nanostructures comprises a coating deposited by atomic layer deposition disposed thereon.
10. The polycrystalline composite of claim 9 , wherein the coating has a thickness of less than 100 nm.
11. The polycrystalline composite of claim 9 , wherein the coating comprises at least one of a metal, ceramic materials, alloys thereof, or combinations thereof.
12. The polycrystalline composite of claim 9 , wherein the coating comprises multiple layers of coating.
13. The polycrystalline composite of claim 1 , wherein at least one of an end cap or sidewall of the plurality of elongated nanostructures is functionalized.
14. The polycrystalline composite of claim 1 , wherein the plurality of elongated nanostructures have a non-uniform orientation.
15. The polycrystalline composite of claim 1 , wherein the plurality of elongated nanostructures integrated into the polycrystalline composite is present in an amount up to 10 percent by volume.
16. The polycrystalline composite of claim 1 , wherein the polycrystalline composite is thermally stable at temperatures greater than 750° C.
17. A method of forming a polycrystalline composite body for cutting tools, comprising:
integrating a plurality of plurality of elongated nanostructures in one of a plurality of diamond particles or a binder material;
mixing in the other of the plurality of diamond particles or binder material; and
sintering the mixture to form a polycrystalline diamond lattice structure.
18. The method of claim 17 , wherein the integrating comprises dispersing the plurality of plurality of elongated nanostructures in the plurality of diamond particles.
19. The method of claim 17 , wherein the integrating comprises dispersing the plurality of plurality of elongated nanostructures into a plurality of refractory particles.
20. A method of incorporating functionalized nanotubes in a polycrystalline material, comprising:
applying a coating to nanotubes by atomic layer deposition;
mixing a plurality of diamond particles, a refractory or binder material, and a plurality of the coated nanotubes; and
sintering the mixture to form a polycrystalline diamond lattice structure.
21. The method of claim 20 , wherein the coating comprises at least one of a metal, ceramic materials, alloys thereof, or combinations thereof.