Methods of forming cutting elements having different interstitial materials in multi-layer diamond tables

摘要

Methods of forming cutting elements for earth-boring tools include providing a barrier material between a first powder and a second powder each comprising diamond grains, and subjecting the powders and barrier material to high temperature and high pressure conditions to form polycrystalline diamond material. The formation of the polycrystalline diamond material is catalyzed, and catalytic material may be hindered from migrating across the layer of barrier material. Cutting elements for use in earth-boring tools include a barrier material disposed between a first layer of polycrystalline diamond material and a second layer of polycrystalline diamond material. Earth-boring tools include one or more such cutting elements for cutting an earth formation.

主权项

1. A method of forming a cutting element for an earth-boring tool using catalyst material to catalyze formation of polycrystalline diamond material, comprising:
providing a first powder comprising diamond crystals adjacent a surface of a cutting element substrate; providing a generally planar barrier structure adjacent the first powder on a side thereof opposite the cutting element substrate, the barrier structure comprising at least one of a disc, a film, and a foil of barrier material; providing a second powder comprising diamond crystals adjacent the barrier structure on a side thereof opposite the first powder; subjecting the cutting element substrate, the first powder, the barrier structure, and the second powder to high temperature and high pressure conditions and forming a continuous multi-layer diamond table including a first layer including polycrystalline diamond material adjacent the cutting element substrate, a barrier layer including polycrystalline diamond material adjacent the first layer on a side thereof opposite the cutting element substrate, and a second layer including polycrystalline diamond material adjacent the barrier layer on a side thereof opposite the first layer, the barrier material disposed in interstitial spaces between grains of polycrystalline diamond material within the barrier layer; and hindering migration of catalyst material across a plane of the generally planar barrier structure while subjecting the cutting element substrate, the first powder, the barrier structure, and the second powder to the high temperature and high pressure conditions.