METHODS OF FORMING POLYCRYSTALLINE COMPACTS AND EARTH-BORING TOOLS INCLUDING POLYCRYSTALLINE COMPACTS

摘要

Methods of forming polycrystalline compacts include subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The methods further comprise substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact; and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact. The polycrystalline cutting elements may be secured to a bit body of an earth-boring tool.

主权项

1. A method of forming a polycrystalline compact, comprising:
subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material, wherein the catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material; substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact; and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.