Polycrystalline diamond compact and method of fabricating same

摘要

Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads or more and a specific magnetic saturation of about 15 Gauss·cm3/grams or less. Other embodiments are directed to polycrystalline diamond compacts (“PDCs”) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

主权项

1. A method of fabricating a polycrystalline diamond compact, comprising:
fabricating a polycrystalline diamond element in a high-pressure/high-temperature process including subjecting a cell assembly including a pressure transmitting medium at least partially enclosing diamond particles and a metal-solvent catalyst to a temperature of at least about 1000° C. and a pressure in the pressure transmitting medium of at least about 7.5 GPa, the polycrystalline diamond element including:
a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions, the plurality of diamond grains exhibits an average grain size of about 30 μm or less; anda metal-solvent catalyst occupying at least a portion of the plurality of interstitial regions, the metal-solvent catalyst present in the at least a portion of the polycrystalline diamond element in an amount of about 1 weight % to about 6 weight %;wherein the plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oe or more;wherein the plurality of diamond grains and the metal-solvent catalyst collectively exhibit a specific magnetic saturation of about 15 G·cm3/g or less;wherein the plurality of diamond grains and the metal-solvent catalyst of the polycrystalline diamond element collectively exhibit a specific permeability of about 0.060 G·cm3/g·Oe to about 0.090 G·cm3/g·Oe; wherein the polycrystalline diamond element exhibits a Gratio of at least about 4.0×106; removing at least a portion of the metal-solvent catalyst from the polycrystalline diamond element; and brazing the polycrystalline diamond element to a substrate to form the polycrystalline diamond compact.