Polycrystalline compacts and methods of formation

摘要

Methods for forming cutting elements, methods for forming polycrystalline compacts, and related polycrystalline compacts are disclosed. Grains of a hard material are subjected to a high-pressure, high-temperature process to form a polycrystalline compact. Inclusion of at least one relatively quick spike in system pressure or temperature during an otherwise plateaued temperature or pressure stage accommodates formation of inter-granular bonds between the grains. The brevity of the peak stage may avoid undesirable grain growth. Embodiments of the methods may also include at least one of oscillating at least one system condition (e.g., pressure, temperature) and subjecting the grains to ultrasonic or mechanical vibrations. A resulting polycrystalline compact may include a high density of inter-granularly bonded hard material with a minimized amount of catalyst material, and may provide improved thermal stability, wear resistance, toughness, and behavior during use of a cutting element incorporating the polycrystalline compact.

主权项

1. A method of forming a polycrystalline compact, comprising:
subjecting a feed comprising grains of a hard material to a high-pressure, high-temperature process to form inter-granular bonds between at least some of the grains, the high-pressure, high-temperature process comprising:
subjecting the feed to a condition at an initial level, the condition being a pressure or a temperature;elevating the condition from the initial level to a plateau level;after the elevating to the plateau level, maintaining the condition at the plateau level for a duration;after the maintaining at the plateau level, elevating the condition from the plateau level to a peak level at a rate greater than a rate of the elevating to the plateau level;after the elevating to the peak level, lowering the condition from the peak level to the plateau level;after the lowering to the plateau level, maintaining the condition at the plateau level for another duration; andafter the maintaining for the another duration, lowering the condition from the plateau level to a final level.