Methods of forming polycrystalline elements from brown polycrystalline tables

摘要

Methods of forming a polycrystalline table may involve disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles may be partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate may be removed from the brown polycrystalline table and catalyst material may be removed from the brown polycrystalline table. The brown polycrystalline table may then be fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate may include a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table may include a plurality of interbonded grains of a superabrasive material.

主权项

1. A method of forming a cutting element for an earth-boring tool, comprising:
partially sintering particles of a superabrasive material in the presence of a catalyst material to form a brown polycrystalline table; at least substantially fully removing the catalyst material from the brown polycrystalline table; positioning the brown polycrystalline table proximate a substrate after at least substantially fully removing the catalyst material from the brown polycrystalline table; and fully sintering the brown polycrystalline table in the presence of another catalyst material and the substrate to form a fully sintered polycrystalline table attached to the substrate.