POLYCRYSTALLINE COMPACTS INCLUDING DIFFERING REGIONS, AND RELATED EARTH-BORING TOOLS AND METHODS OF FORMING CUTTING ELEMENTS

摘要

Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming such polycrystalline compacts include removing catalyst material from interstitial spaces within a second region of a polycrystalline compact without entirely removing catalyst material from interstitial spaces within a first region of the compact.

主权项

1. A polycrystalline compact, comprising:
a hard polycrystalline material comprising:
a first region adjacent a substrate and comprising:
inter-bonded grains of hard material; andinterstitial spaces between the inter-bonded grains of hard material, the interstitial spaces at least partially filled with catalyst material; and a second region directly adjacent to the first region and comprising:
additional inter-bonded grains of the hard material, the second region having a smaller volume percentage of the hard material than a volume percentage of the hard material of the first region; andadditional interstitial spaces between the additional inter-bonded grains of the hard material, the additional interstitial spaces at least substantially free of the catalyst material.