POLYCRYSTALLINE DIAMOND COMPACTS HAVING INTERSTITIAL DIAMOND GRAINS AND METHODS OF MAKING THE SAME

Polycrystalline diamond compacts having interstitial diamonds and methods of forming polycrystalline diamond compact shaving interstitial diamonds with a quench cycle are described herein. In one embodiment, a polycrystalline diamond compact includes a substrate and a polycrystalline diamond body attached to the substrate. The polycrystalline diamond body includes a plurality of inter-bonded diamond grains that are attached to one another in an interconnected network of diamond grains and interstitial pockets between the inter-bonded diamond grains, and a plurality of interstitial diamond grains that are positioned in the interstitial pockets. Each of the plurality of interstitial diamond grains are attached to a single diamond grain of the interconnected network of diamond grains or other interstitial diamond grains. 1. A polycrystalline diamond compact comprising: a plurality of inter-bonded diamond grains that are attached to one another in an interconnected network of diamond grains and interstitial pockets between the inter-bonded diamond grains; and', 'a plurality of interstitial diamond grains that are positioned in the interstitial pockets, each of the plurality of interstitial diamond grains are attached to a single diamond grain of the interconnected network of diamond grains or other interstitial diamond grains., 'a polycrystalline diamond body comprising2. The polycrystalline diamond compact of claim 1 , wherein:a. least a portion of the interstitial pockets comprise a catalyst material positioned between the diamond grains; andthe plurality of interstitial diamond grains reduce an exposed surface area of the inter-bonded diamond grains to the catalyst material.3. The polycrystalline diamond compact of claim 1 , wherein:at least a portion of the interstitial pockets comprise a catalyst material positioned between the diamond grains; andthe polycrystalline diamond body further comprises an interstitial diamond grain that is positioned within the catalyst ...

METHODS OF FORMING SUPPORTING SUBSTRATES FOR CUTTING ELEMENTS, AND RELATED METHODS OF FORMING CUTTING ELEMENTS

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described. 1. A method of forming a supporting substrate for a cutting element , comprising:forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W; andsubjecting the precursor composition to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C.2. The method of claim 1 , wherein forming a precursor composition comprises forming the precursor composition to comprise the discrete WC particles claim 1 , the binding agent claim 1 , and one or more of discrete Co—Al—C alloy particles and discrete Co—Al—W alloy particles.3. The method of claim 1 , wherein forming the precursor composition comprises forming the precursor composition to comprise from about 5 wt % discrete Co—Al—C particles to about 15 wt % discrete Co—Al—C particles claim 1 , and from about 85 wt % discrete WC particles to about 95 wt % discrete WC particles.4. The method of claim 1 , wherein forming the precursor composition comprises forming the precursor composition to comprise about 12 wt % discrete Co—Al—C particles and about 88 wt % discrete WC particles.5. The method of claim 1 , wherein forming a precursor composition further comprises forming the precursor composition to comprise at least one additive comprising one or more of B claim 1 , Al claim 1 , C claim 1 , Ti claim 1 , Zr claim 1 , Hf claim 1 , ...

BRAZE MATERIALS AND EARTH-BORING TOOLS COMPRISING BRAZE MATERIALS

A method includes disposing a braze material adjacent a first body and a second body; heating the braze material and forming a transient liquid phase; and transforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body. The braze material includes copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth. 1. A braze material comprising:copper;from about 50% to about 70% silver by weight;at least one element selected from the group consisting of nickel and titanium; andat least one element selected from the group consisting of indium, tin, zinc zinc, and magnesium.2. The braze material of claim 1 , wherein the braze material comprises at least two elements selected from the group consisting of indium claim 1 , tin claim 1 , zinc and magnesium.3. The braze material of claim 1 , wherein the braze material comprises zinc.4. The braze material of claim 1 , wherein the braze material comprises metallic particles having an average particle size in a range from about 1 μm to about 15 μm.5. The braze material of claim 1 , further comprising an organic binder.6. The braze material of claim 1 , wherein the braze material comprises a first plurality of metallic particles and a second plurality of metallic particles interspersed with the first plurality of metallic particles.7. The braze material of claim 6 , wherein the particles of the first plurality comprise a first material having a first composition and the particles of the second plurality comprise a second material having a second composition different from the first composition.8. The braze material of claim 1 , wherein the braze material comprises at least one intermetallic compound.9. The braze material of claim 1 , further comprising nanoparticles comprising at least one material selected from the group consisting of carbides claim 1 , ...

Polycrystalline diamond, methods of forming same, cutting elements, and earth-boring tools

A method of forming polycrystalline diamond includes providing an alloy over at least portions of a plurality of diamond particles, and subjecting the plurality of diamond particles to a high-temperature, high-pressure process to form a polycrystalline diamond material having inter-granular bonds between adjacent diamond particles. The alloy includes iridium and nickel, and a volume of the diamond particles is at least about 92% of a total volume of the alloy and the diamond particles. The polycrystalline diamond material includes at least about 92% diamond by volume. A polycrystalline diamond compact includes grains of diamond bonded to one another by inter-granular bonds and an alloy disposed within interstitial spaces between the grains of diamond. The grains of diamond occupy at least 94% by volume of the polycrystalline diamond compact. An earth-boring tool may include a bit body and such a polycrystalline diamond compact.

METHODS OF FORMING POLYCRYSTALLINE DIAMOND

A method of forming polycrystalline diamond includes providing an alloy over at least portions of a plurality of diamond particles, and subjecting the plurality of diamond particles to a high-temperature, high-pressure process to form a polycrystalline diamond material having inter-granular bonds between adjacent diamond particles. The alloy includes iridium and nickel, and a volume of the diamond particles is at least about 92% of a total volume of the alloy and the diamond particles. The polycrystalline diamond material includes at least about 92% diamond by volume. A polycrystalline diamond compact includes grains of diamond bonded to one another by inter-granular bonds and an alloy disposed within interstitial spaces between the grains of diamond. The grains of diamond occupy at least 94% by volume of the polycrystalline diamond compact. An earth-boring tool may include a bit body and such a polycrystalline diamond compact. 1. A method of forming polycrystalline diamond , comprising:providing an alloy over at least portions of a plurality of diamond particles, wherein the alloy comprises iridium and nickel, and wherein a volume of the diamond particles is at least about 92% of a total volume of the alloy and the diamond particles; andsubjecting the plurality of diamond particles to a high-temperature, high-pressure process to form a polycrystalline diamond material having inter-granular bonds between adjacent diamond particles, wherein the polycrystalline diamond material comprises at least about 92% diamond by volume.2. The method of claim 1 , wherein providing the alloy over at least portions of the plurality of diamond particles comprises covering at least 30% of a surface area of the plurality of diamond particles with the alloy.3. The method of claim 1 , wherein providing the alloy over at least portions of the plurality of diamond particles comprises forming a layer of the alloy having a thickness from about 1 nm to about 50 nm over the diamond particles.4 ...

METHODS OF REDUCING STRESS IN CUTTING ELEMENTS FOR EARTH-BORING TOOLS AND RESULTING CUTTING ELEMENTS

Cutting elements for earth-boring tools may include a superhard, polycrystalline material and a substrate adjacent to and secured to the superhard, polycrystalline material at an interface. The substrate may include a first region exhibiting a first coefficient of thermal expansion and a second region exhibiting a second, different coefficient of thermal expansion. The first region may be spaced from the superhard, polycrystalline material. The second region may extend from laterally adjacent to at least a portion of the first region to longitudinally between the first region and the superhard, polycrystalline material. 1. A cutting element for an earth-boring tool , comprising:a superhard, polycrystalline material; and a first region exhibiting a first coefficient of thermal expansion, the first region spaced from the superhard, polycrystalline material; and', 'a second region exhibiting a second, different coefficient of thermal expansion, the second region extending from laterally adjacent to at least a portion of the first region to longitudinally between the first region and the superhard, polycrystalline material., 'a substrate adjacent to and secured to the superhard, polycrystalline material at an interface, the substrate comprising2. The cutting element of claim 1 , wherein the second region laterally surrounds the first region.3. The cutting element of claim 1 , wherein the first region is located within a channel extending laterally through the second region.4. The cutting element of claim 1 , wherein a cross-sectional shape of the first region is at least substantially circular and a cross-sectional shape of the substrate is at least substantially circular and wherein a diameter of the first region is between about 50% and about 80% of a diameter of the substrate.5. The cutting element of claim 1 , wherein a first material of the first region is a metal or metal alloy and a second material of the second region is a ceramic-metallic composite material.6. ...

POLYCRYSTALLINE DIAMOND BODIES INCORPORATING FRACTIONATED DISTRIBUTION OF DIAMOND PARTICLES OF DIFFERENT MORPHOLOGIES

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 μm) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 μm). During high pressure—high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations. 1. A polycrystalline diamond body , comprising a plurality of diamond grains that are bonded to one another through diamond particle-to-diamond particle bonds , the diamond grains comprise a first fraction and a second fraction;', 'the first fraction has a first median particle distribution D50;', 'the second fraction has a second median particle distribution D50, the second fraction of diamond grains comprising at least about 60 vol. % of the diamond grains in the diamond body; and', 'the second median particle distribution D50 is at least about 7 times the first median particle distribution D50., 'wherein2. The polycrystalline diamond body of claim 1 , wherein the first fraction of diamond grains are positioned to separate each of the diamond grains of the second fraction from one another.3. A polycrystalline diamond body claim 1 , comprising a plurality of diamond grains that are bonded to one another through diamond particle-to-diamond particle bonds claim 1 , the diamond grains comprise a first fraction and a second fraction;', 'the first fraction has a first ...

METHODS OF FORMING CUTTING ELEMENTS AND SUPPORTING SUBSTRATES FOR CUTTING ELEMENTS

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described. 1. A method of forming a supporting substrate for a cutting element , comprising:forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W; andsubjecting the precursor composition to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Sn, and Si.2. The method of claim 1 , wherein forming the precursor composition comprises selecting the discrete particles to comprise Co claim 1 , two or more of Al claim 1 , Be claim 1 , Ga claim 1 , Ge claim 1 , Si claim 1 , and Sn claim 1 , and one or more of C and W.3. The method of claim 1 , wherein forming a precursor composition comprises forming the precursor composition to comprise the discrete WC particles claim 1 , the binding agent claim 1 , and discrete alloy particles individually comprising Co claim 1 , one or more of Al claim 1 , Be claim 1 , Ga claim 1 , Ge claim 1 , Si claim 1 , and Sn claim 1 , and one or more of C and W.4. The method of claim 3 , further comprising selecting the discrete alloy particles to individually comprise Co claim 3 , two or more of Al claim 3 , Be claim 3 , Ga claim 3 , Ge claim 3 , Si claim 3 , and Sn claim 3 , and one or more of C and W.5. ...

METHODS AND COMPOSITIONS FOR BRAZING

A method includes disposing a braze material adjacent a first body and a second body; heating the braze material and forming a transient liquid phase; and transforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body. The braze material includes copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth. 1. A method , comprising:disposing a braze material adjacent a first body and a second body, wherein the braze material comprises copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth;heating the braze material and forming a transient liquid phase; andtransforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body.2. The method of claim 1 , wherein disposing a braze material adjacent a first body and a second body comprises disposing a braze material comprising at least one intermetallic compound adjacent the first body and the second body.3. The method of claim 1 , wherein disposing a braze material adjacent a first body and a second body comprises disposing a braze material comprising a plurality of particles adjacent the first body and the second body.4. The method of claim 3 , wherein disposing a braze material comprising a plurality of particles adjacent the first body and the second body comprises disposing a braze material comprising a plurality of particles having an average particle size in a range from about 1 μm to about 15 μm adjacent the first body and the second body.5. The method of claim 1 , wherein disposing a braze material adjacent the first body and the second body comprises disposing a paste comprising at least a composition of the braze material adjacent the first body and the second body ...

MAGNETIC SAMPLE HOLDER FOR ABRASIVE OPERATIONS AND RELATED METHODS

Magnetic sample holders for abrasive operations include an array of magnets embedded in a matrix material. Each magnet of the array is positioned between about 0 mm and about 4 mm from at least one adjacent magnet of the array. Exposed surfaces of the magnets of the array are coplanar with a planar working surface of the matrix material. Methods of forming a polycrystalline diamond compact element include magnetically securing an alloy sample to an array of magnets embedded in a matrix. Each of the magnets of the array is within about 4 mm of at least one adjacent magnet of the array. A portion of the alloy sample is abraded away, and the alloy sample is positioned proximate to diamond grains and a substrate. The alloy sample, diamond grains, and substrate are subjected to a high pressure/high temperature process to sinter the diamond grains. 1. A magnetic sample holder for an abrasive operation , the magnetic sample holder comprising:an array of magnets, each magnet of the array of magnets being positioned between about 0 mm and about 4 mm from at least one adjacent magnet of the array of magnets; anda matrix material, the array of magnets embedded in the matrix material,wherein exposed surfaces of the magnets of the array of magnets are coplanar with a planar working surface of the matrix material.2. The magnetic sample holder of claim 1 , wherein the array of magnets comprises cylindrical magnets having magnetic flux lines that are positioned parallel to each other.3. The magnetic sample holder of claim 2 , wherein the exposed surface of each magnet of the array of magnets comprises a longitudinal end surface of each magnet.4. The magnetic sample holder of claim 1 , wherein the magnets of the array of magnets are arranged in a hexagonal close-packed configuration.5. The magnetic sample holder of claim 1 , wherein the magnets of the array of magnets are arranged in a square-packed configuration.6. The magnetic sample holder of claim 1 , wherein each magnet of the ...

DIAMOND PARTICLES HAVING TEXTURED SURFACES, AND RELATED EARTH-BORING TOOLS

A method of modifying surfaces of diamond particles comprises forming spinodal alloy coatings over discrete diamond particles, thermally treating the spinodal alloy coatings to form modified coatings each independently exhibiting a reactive metal phase and a substantially non-reactive metal phase, and etching surfaces of the discrete diamond particles with at least one reactive metal of the reactive metal phase of the modified coatings. Diamond particles and earth-boring tools are also described. 1. A diamond particle comprising a textured surface exhibiting elevated regions and recessed regions between the elevated regions , lateral dimensions and spacing of the recessed regions respectively corresponding to lateral dimensions and spacing of regions of at least one phase of a spinodally decomposed alloy substantially reactive with diamond at a temperature greater than or equal to about 650° C.2. The diamond particle of claim 1 , wherein the recessed regions exhibit substantially the same lateral dimensions and substantially the same spacing as regions of a Ni phase of a spinodally decomposed Cu—Ni alloy.3. The diamond particle of claim 1 , wherein the recessed regions exhibit substantially the same lateral dimensions and substantially the same spacing as regions of a Ni—Sn phase of a spinodally decomposed Cu—Ni—Sn alloy.4. The diamond particle of claim 1 , wherein the recessed regions are substantially uniformly spaced apart from one another.5. An earth-boring tool comprising at least one structure comprising diamond particles claim 1 , at least one of the diamond particles having a textured surface exhibiting elevated regions and recessed regions between the elevated regions claim 1 , lateral dimensions and spacing of the recessed regions respectively corresponding to lateral dimensions and spacing of regions of at least one phase of a spinodally decomposed alloy substantially reactive with diamond at a temperature greater than or equal to about 650° C.6. The ...

METHODS OF FORMING CUTTING ELEMENTS, AND RELATED EARTH-BORING TOOLS

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, AXZ, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described. 1. An earth-boring tool , comprising: inter-bonded diamond particles; and', [{'br': None, 'sub': 3', '1-n, 'AXZ,'}, 'where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U;', 'X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P;', 'Z comprises C; and', 'n is greater than or equal to 0 and less than or equal to 0.75., 'a thermally stable material within interstitial spaces between the inter-bonded diamond particles, the thermally stable material comprising a carbide precipitate having the general chemical formula], 'a cutting table comprising, 'a cutting element comprising2. A method of forming a cutting element , comprising:providing a diamond-containing material comprising discrete diamond particles over a substrate;sintering the diamond-containing material in the presence of a liquid phase of a homogenized alloy comprising at least one first element selected ...

Cutting elements, and related earth-boring tools, supporting substrates, and methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A3XZn-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

POLYCRYSTALLINE DIAMOND BODIES INCORPORATING FRACTIONATED DISTRIBUTION OF DIAMOND PARTICLES OF DIFFERENT MORPHOLOGIES

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 μm) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 μm). During high pressure-high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations. 14.-. (canceled)5. A feedstock for manufacturing a polycrystalline diamond body , the feedstock comprising:a plurality of diamond particles including at least one fraction of modified diamond particles having a first median particle distribution D50 and at least one fraction of monocrystalline diamond particles having a second median particle distribution D50;wherein the first median particle distribution D50 is less than the second median particle distribution D50, andwherein at least about 40% of the first fraction of modified diamond grains have a sphericity of less than about 0.7 and at least about 75% of the second fraction of monocrystalline diamond grains have a sphericity of greater than about 0.8.6. The feedstock of claim 5 , wherein the second median particle distribution D50 is at least about 7 times the first median particle distribution D50 claim 5 ,7. The feedstock of claim 5 , wherein the first fraction of modified diamond grains comprises from about 20 vol. % to 40 vol % of the diamond particles in the feedstock claim 5 , and wherein the second ...

POLYCRYSTALLINE DIAMOND COMPACTS AND EARTH-BORING TOOLS INCLUDING SUCH COMPACTS

A polycrystalline diamond compact includes a polycrystalline diamond material having a plurality of grains of diamond bonded to one another by inter-granular bonds and an intermetallic gamma prime (γ′) or κ-carbide phase disposed within interstitial spaces between the inter-bonded diamond grains. The ordered intermetallic gamma prime (γ′) or κ-carbide phase includes a Group VIII metal, aluminum, and a stabilizer. An earth-boring tool includes a bit body and a polycrystalline diamond compact secured to the bit body. A method of forming polycrystalline diamond includes subjecting diamond particles in the presence of a metal material comprising a Group VIII metal and aluminum to a pressure of at least 4.5 GPa and a temperature of at least 1,000° C. to form inter-granular bonds between adjacent diamond particles, cooling the diamond particles and the metal material to a temperature below 500° C., and forming an intermetallic gamma prime (γ′) or κ-carbide phase adjacent the diamond particles. 1. A polycrystalline diamond compact , comprising:a polycrystalline diamond material comprising a plurality of grains of diamond bonded to one another by inter-granular bonds; andan intermetallic gamma prime (γ′) or κ-carbide phase disposed within interstitial spaces between the inter-bonded diamond grains, the intermetallic gamma prime (γ′) or κ-carbide phase comprising a Group VIII metal, aluminum, and a stabilizer.2. The polycrystalline diamond compact of claim 1 , wherein the stabilizer comprises a material selected from the group consisting of titanium claim 1 , nickel claim 1 , tungsten claim 1 , and carbon.3. The polycrystalline diamond compact of claim 1 , wherein the intermetallic gamma prime (γ′) or κ-carbide phase comprises a metastable CoAl phase stabilized by the stabilizer.4. The polycrystalline diamond compact of claim 1 , wherein the intermetallic gamma prime (γ′) or κ-carbide phase comprises a metastable (CoNi)Al phase stabilized by the stabilizer.5. The ...

TECHNIQUES FOR FORMING POLYCRYSTALLINE, SUPERABRASIVE MATERIALS, AND RELATED METHODS AND CUTTING ELEMENTS FOR EARTH-BORING TOOLS

Methods of making cutting elements for earth-boring tools may involve intermixing discrete particles of superabrasive material with a binder material in a solvent to form a slurry. The slurry may be vacuum dried or spray dried to disaggregate individual precursor agglomerates including a group of discrete particles suspended in a discrete quantity of the binder material from one another. The precursor agglomerates may be sintered while exposing the precursor agglomerates to a quantity of catalyst material to form agglomerates including discrete quantities of polycrystalline, superabrasive material while inhibiting formation of inter-granular bonds among the agglomerates themselves. The agglomerates may subsequently be sintered while exposing the agglomerates to another quantity of catalyst material to form a table for the cutting element including inter-granular bonds among adjacent grains of the agglomerates. 1. A method of making a cutting element for an earth-boring tool , comprising:intermixing discrete particles of superabrasive material with a binder material in a solvent to form a slurry;vacuum drying or spray drying the slurry to disaggregate individual agglomerates comprising a group of discrete particles suspended in a discrete quantity of the binder material from one another; andsintering the agglomerates comprising the binder material while exposing the agglomerates to a quantity of catalyst material to form discrete quantities of polycrystalline, superabrasive material comprising inter-granular bonds among the discrete particles of each of the individual agglomerates while inhibiting formation of inter-granular bonds among the agglomerates themselves.2. The method of claim 1 , further comprising subsequently sintering the agglomerates comprising the polycrystalline claim 1 , superabrasive material while exposing the agglomerates to another quantity of catalyst material to form a table for the cutting element comprising inter-granular bonds among ...

CUTTING ELEMENTS AND EARTH-BORING TOOLS COMPRISING POLYCRYSTALLINE DIAMOND

A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1,400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cmand a modulus of at least about 1,000 GPa. An earth-boring tool may include such a cutting element secured to a body. 1. A cutting element comprising polycrystalline diamond material comprising inter-bonded grains of diamond , wherein the polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds , and wherein the polycrystalline diamond material exhibits a density of at least about 3.49 g/cmand a modulus of at least about 1 ,000 GPa.2. The cutting element of claim 1 , further comprising a substrate secured to the polycrystalline diamond material.3. The cutting element of claim 2 , wherein the substrate comprises a material having a chemical composition different from a chemical composition of the polycrystalline diamond material.4. An earth-boring tool claim 2 , comprising:a body; and{'sup': '3', 'a cutting element secured to the body, the cutting element comprising polycrystalline diamond material comprising inter-bonded grains of diamond, wherein the polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds, and wherein the polycrystalline diamond material exhibits a density of at least about 3.49 g/cmand a modulus of at least about 1,000 GPa.'}5. The earth-boring tool of claim 4 , wherein the body comprises an earth-boring rotary drill bit.6. The ...

POLYCRYSTALLINE DIAMOND COMPACTS HAVING INTERSTITIAL DIAMOND GRAINS AND METHODS OF MAKING THE SAME

Polycrystalline diamond compacts having interstitial diamonds and methods of forming polycrystalline diamond compact shaving interstitial diamonds with a quench cycle are described herein. In one embodiment, a polycrystalline diamond compact includes a substrate and a polycrystalline diamond body attached to the substrate. The polycrystalline diamond body includes a plurality of inter-bonded diamond grains that are attached to one another in an interconnected network of diamond grains and interstitial pockets between the inter-bonded diamond grains, and a plurality of interstitial diamond grains that are positioned in the interstitial pockets. Each of the plurality of interstitial diamond grains are attached to a single diamond grain of the interconnected network of diamond grains or other interstitial diamond grains. 1. A polycrystalline diamond compact comprising: a plurality of inter-bonded diamond grains that are attached to one another in an interconnected network of diamond grains and interstitial pockets between the inter-bonded diamond grains; and', 'a plurality of interstitial diamond grains that are positioned in the interstitial pockets, each of the plurality of interstitial diamond grains are attached to a single diamond grain of the interconnected network of diamond grains or other interstitial diamond grains., 'a polycrystalline diamond body comprising2. The polycrystalline diamond compact of claim 1 , wherein:at least a portion of the interstitial pockets comprise a catalyst material positioned between the diamond grains; andthe plurality of interstitial diamond grains reduce an exposed surface area of the inter-bonded diamond grains to the catalyst material.3. The polycrystalline diamond compact of claim 1 , wherein:at least a portion of the interstitial pockets comprise a catalyst material positioned between the diamond grains; andthe polycrystalline diamond body further comprises an interstitial diamond grain that is positioned within the catalyst ...

POLYCRYSTALLINE DIAMOND COMPACTS, METHODS OF FORMING POLYCRYSTALLINE DIAMOND, AND EARTH-BORING TOOLS

A polycrystalline diamond compact includes a polycrystalline diamond material having a plurality of grains of diamond bonded to one another by inter-granular bonds and an intermetallic gamma prime (γ′) or κ-carbide phase disposed within interstitial spaces between the inter-bonded diamond grains. The ordered intermetallic gamma prime (γ′) or κ-carbide phase includes a Group VIII metal, aluminum, and a stabilizer. An earth-boring tool includes a bit body and a polycrystalline diamond compact secured to the bit body. A method of forming polycrystalline diamond includes subjecting diamond particles in the presence of a metal material comprising a Group VIII metal and aluminum to a pressure of at least 4.5 GPa and a temperature of at least 1,000° C. to form inter-granular bonds between adjacent diamond particles, cooling the diamond particles and the metal material to a temperature below 500° C., and forming an intermetallic gamma prime (γ′) or κ-carbide phase adjacent the diamond particles. 1. A polycrystalline diamond compact , comprising:a polycrystalline diamond material comprising a plurality of grains of diamond bonded to one another by inter-granular bonds; andan intermetallic gamma prime (γ′) or κ-carbide phase disposed within interstitial spaces between the inter-bonded diamond grains, the gamma prime (γ′) or κ-carbide phase comprising a Group VIII metal, aluminum, and a stabilizer.2. The polycrystalline diamond compact of claim 1 , wherein the stabilizer comprises a material selected from the group consisting of titanium claim 1 , nickel claim 1 , tungsten claim 1 , and carbon.3. The polycrystalline diamond compact of claim 1 , wherein the gamma prime (γ′) or κ-carbide phase comprises a metastable CoAl phase stabilized by the stabilizer.4. The polycrystalline diamond compact of claim 1 , wherein the gamma prime (γ′) or κ-carbide phase comprises a metastable (CoNi)Al phase stabilized by the stabilizer.5. The polycrystalline diamond compact of claim 1 , wherein ...

Polycrystalline diamond compacts having a microstructure including nanodiamond agglomerates, cutting elements and earth-boring tools including such compacts, and related methods

A polycrystalline diamond compact (PDC) has a diamond matrix including inter-bonded diamond grains and nanodiamond agglomerates within interstitial spaces in the diamond matrix. A volume percentage of the nanodiamond agglomerates in the PDC may be greater than or equal to a percolation threshold volume of the nanodiamond agglomerates in the PDC, and a remainder of the volume of the PDC may be at least substantially comprised by the diamond matrix. The PDC may be at least substantially free of metal solvent catalyst material. Earth-boring tools include one or more such PDCs. A method of manufacturing a PDC includes mixing diamond grains with nanodiamond agglomerates to form a mixture, and subjecting the mixture to a high temperature/high pressure (HTHP) sintering process to form the PDC without any substantial assistance from a metal solvent catalyst material.

Polycrystalline diamond, methods of forming same, cutting elements, and earth-boring tools

A method of forming polycrystalline diamond includes providing an alloy over diamond particles and subjecting the diamond particles to a pressure of at least 4.5 GPa and a temperature of at least 1,000° C. to form inter-granular bonds. The alloy includes iridium and at least one of copper, silver, and gold. A polycrystalline diamond compact includes diamond grains bonded by inter-granular bonds and an alloy disposed within interstitial spaces. The alloy includes iridium, carbon, and at least one of copper, silver, and gold. An earth-boring tool includes a bit body and a polycrystalline diamond compact secured to the bit body. Some methods include selecting an alloy that is catalytic to formation of diamond-to-diamond bonds when the alloy is in a liquid phase, but non-catalytic to the back-conversion of diamond to graphite at temperatures of less than about 1,000° C.

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 μm) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 μm). During high pressure—high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

BRAZE MATERIALS AND EARTH-BORING TOOLS COMPRISING BRAZE MATERIALS

A method includes disposing a braze material adjacent a first body and a second body; heating the braze material and forming a transient liquid phase; and transforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body. The braze material includes copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth. 1. A braze material comprising:copper;silver;from about 25% to about 35% zinc by weight;magnesium; andat least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth.2. The braze material of claim 1 , wherein the braze material comprises metallic particles having an average particle size in a range from about 1 μm to about 15 μm.3. The braze material of claim 1 , further comprising an organic binder.4. The braze material of claim 1 , wherein the braze material comprises a first plurality of metallic particles and a second plurality of metallic particles interspersed with the first plurality of metallic particles.5. The braze material of claim 4 , wherein the first plurality of metallic particles comprises a first material having a first composition and the second plurality of metallic particles comprises a second material having a second composition different from the first composition.6. The braze material of claim 1 , wherein the braze material comprises at least one intermetallic compound.7. The braze material of claim 1 , further comprising nanoparticles comprising at least one material selected from the group consisting of carbides claim 1 , oxides claim 1 , and borides.8. The braze material of claim 7 , wherein the nanoparticles comprise tungsten carbide.9. The braze material of claim 7 , wherein the nanoparticles comprise aluminum oxide.10. The braze material of claim 6 , wherein the braze material ...

METHODS OF FORMING POLYCRYSTALLINE DIAMOND AND CUTTING ELEMENTS AND TOOLS COMPRISING POLYCRYSTALLINE DIAMOND

A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cmand a modulus of at least about 1000 GPa. An earth-boring tool may include such a cutting element secured to a body. 1. A method of forming polycrystalline diamond , comprising:encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container; andsubjecting the encapsulated diamond particles, carbon monoxide, and carbon dioxide to a pressure of at least 4.5 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles.2. The method of claim 1 , wherein encapsulating diamond particles claim 1 , carbon monoxide claim 1 , and carbon dioxide in a container comprises encapsulating diamond particles claim 1 , carbon monoxide claim 1 , carbon dioxide claim 1 , and an inert gas in a container.3. The method of claim 1 , wherein encapsulating diamond particles claim 1 , carbon monoxide claim 1 , and carbon dioxide in a container further comprises removing at least one of oxygen and water from the container.4. The method of claim 1 , wherein encapsulating diamond particles claim 1 , carbon monoxide claim 1 , and carbon dioxide in a container comprises encapsulating diamond particles claim 1 , carbon monoxide claim 1 , carbon dioxide claim 1 , and a substrate in a container.5. The method of claim 1 , wherein subjecting the encapsulated diamond particles claim 1 , carbon monoxide claim 1 ...

Methods of forming supporting substrates for cutting elements, and related cutting elements, methods of forming cutting elements, and earth-boring tools

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

METHODS OF FORMING SUPPORTING SUBSTRATES FOR CUTTING ELEMENTS, AND RELATED CUTTING ELEMENTS, METHODS OF FORMING CUTTING ELEMENTS, AND EARTH-BORING TOOLS

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described. 1. A method of forming a supporting substrate for a cutting element , comprising:forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W; andsubjecting the precursor composition to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C.2. The method of claim 1 , wherein forming a precursor composition comprises forming the precursor composition to comprise the discrete WC particles claim 1 , the binding agent claim 1 , and one or more of discrete Co—Al—C alloy particles and discrete Co—Al—W alloy particles.3. The method of claim 1 , wherein forming the precursor composition comprises forming the precursor composition to comprise from about 5 wt % discrete Co—Al—C particles to about 15 wt % discrete Co—Al—C particles claim 1 , and from about 85 wt % discrete WC particles to about 95 wt % discrete WC particles.4. The method of claim 1 , wherein forming the precursor composition comprises forming the precursor composition to comprise about 12 wt % discrete Co—Al—C particles and about 88 wt % discrete WC particles.5. The method of claim 1 , wherein forming a precursor composition further comprises forming the precursor composition to comprise at least one additive comprising one or more of B claim 1 , Al claim 1 , C claim 1 , Ti claim 1 , Zr claim 1 , Hf claim 1 , ...

Methods of modifying surfaces of diamond particles, and releated diamond particles and earth-boring tools

A method of modifying surfaces of diamond particles comprises forming spinodal alloy coatings over discrete diamond particles, thermally treating the spinodal alloy coatings to form modified coatings each independently exhibiting a reactive metal phase and a substantially non-reactive metal phase, and etching surfaces of the discrete diamond particles with at least one reactive metal of the reactive metal phase of the modified coatings. Diamond particles and earth-boring tools are also described.

Cutting elements, and related earth-boring tools, supporting substrates, and methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A 3 XZ n-1 , where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Casting furnace method and apparatus

A system for casting comprising a mold for forming molten metal; a support for supporting the mold and transferring heat to and from the mold; and a furnace operable to substantially surround the mold through a preheat cycle, a heat cycle, and a cooling cycle. The furnace preferably moves vertically down to surround the mold for the preheat, heat, and cooling cycles and moves up and away from the mold after the cooling cycle is complete. In an alternative embodiment, the furnace may be replaced with a cooling can just before initiation of the cooling cycle. The support is preferably stationary and provides directional cooling for the mold during the cooling cycle.

Polycrystalline diamond compacts, methods of forming polycrystalline diamond, and earth-boring tools

A polycrystalline diamond compact includes a polycrystalline diamond material having a plurality of grains of diamond bonded to one another by inter-granular bonds and an intermetallic gamma prime (?') or ?-carbide phase disposed within interstitial spaces between the inter-bonded diamond grains. The ordered intermetallic gamma prime (?') or ?-carbide phase includes a Group VIII metal, aluminum, and a stabilizer. An earth-boring tool includes a bit body and a polycrystalline diamond compact secured to the bit body. A method of forming polycrystalline diamond includes subjecting diamond particles in the presence of a metal material comprising a Group VIII metal and aluminum to a pressure of at least 4.5 GPa and a temperature of at least 1,000°C to form inter-granular bonds between adjacent diamond particles, cooling the diamond particles and the metal material to a temperature below 500°C, and forming an intermetallic gamma prime (?') or ?-carbide phase adjacent the diamond particles.

Polycrystalline diamond compacts having interstitial diamond grains and methods of making the same

Polycrystalline diamond compacts having interstitial diamonds and methods of forming polycrystalline diamond compact shaving interstitial diamonds with a quench cycle are described herein. In one embodiment, a polycrystalline diamond compact includes a substrate and a polycrystalline diamond body attached to the substrate. The polycrystalline diamond body includes a plurality of inter-bonded diamond grains that are attached to one another in an interconnected network of diamond grains and interstitial pockets between the inter-bonded diamond grains, and a plurality of interstitial diamond grains that are positioned in the interstitial pockets. Each of the plurality of interstitial diamond grains are attached to a single diamond grain of the interconnected network of diamond grains or other interstitial diamond grains.

Cutter pocket having reduced stress concentration

A method for forming a drag bit using displacements having a rounded end that creates a cutter pocket having a rounded rear portion. The displacement may comprise an insert on the rounded end that remains in the drag bit during and after formation. A cutter element may then be attached to the upper portion of the insert. The rounded shape of the insert provides a more even force distribution.

Polycrystalline diamond, methods of forming same, cutting elements, and earth-boring tools

A method of forming polycrystalline diamond includes providing an alloy over at least portions of a plurality of diamond particles, and subjecting the plurality of diamond particles to a high-temperature, high-pressure process to form a polycrystalline diamond material having inter-granular bonds between adjacent diamond particles. The alloy includes iridium and nickel, and a volume of the diamond particles is at least about 92% of a total volume of the alloy and the diamond particles. The polycrystalline diamond material includes at least about 92% diamond by volume. A polycrystalline diamond compact includes grains of diamond bonded to one another by inter-granular bonds and an alloy disposed within interstitial spaces between the grains of diamond. The grains of diamond occupy at least 94% by volume of the polycrystalline diamond compact. An earth-boring tool may include a bit body and such a polycrystalline diamond compact.

Earth-boring tools attachable to a casing string and methods for their manufacture

Casing bits include a crown having a substantially hollow interior. The bit crown has blades over a face portion thereof, the blades including a plurality of cutting elements attached thereto. The bit crown further includes a composite inlay (85) positioned at least within the substantially hollow interior. Casing bits also include case hardened outer surfaces radially outside the drill-out region. Casing bits further include short- substrate cutting elements. Methods of forming a casing bit are also disclosed.

Casting furnace method and apparatus

A system for casting comprising a mold for forming molten metal; a support for supporting the mold and transferring heat to and from the mold; and a furnace operable to substantially surround the mold through a preheat cycle, a heat cycle, and a cooling cycle. The furnace preferably moves vertically down to surround the mold for the preheat, heat, and cooling cycles and moves up and away from the mold after the cooling cycle is complete. In an alternative embodiment, the furnace may be replaced with a cooling can just before initiation of the cooling cycle. The support is preferably stationary and provides directional cooling for the mold during the cooling cycle.

Methods of forming polycrystalline diamond and cutting elements and tools comprising polycrystalline diamond

A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1400°C to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm 3 and a modulus of at least about 1000 GPa. An earth-boring tool may include such a cutting element secured to a body.

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies.

Se describen cuerpos de diamante y métodos para fabricación. Los cuerpos de diamante se forman de al menos una materia prima bi-modal, alternativamente tri-modal o superior, que tiene al menos una fracción de partículas de diamante modificado con un tamaño de partícula fina (0.5-3.0 µm) y al menos una fracción de partículas de diamante con tamaño de partícula grueso (15.0 a 30 µm). Durante el procesamiento a alta presión alta temperatura, las partículas de diamante modificado de tamaño de partícula fina, en la primera fracción, de preferencia se fracturan en tamaños menores mientras se preserva la morfología de partículas de diamante de tamaño de partícula gruesa en la segunda fracción. Los cuerpos de diamante que incorporan las dos fracciones tienen una microestructura que incluye las partículas de diamante de la segunda fracción dispersas en una matriz continua de la primera fracción de partículas de diamante modificado y muestran características de desgaste mejoradas, particularmente para el desgaste asociado con la perforación de yacimientos geológicos.

Infiltration methods for forming drill bits

An infiltration method of forming an article including providing a working mold including a solid binder member extending through an interior of the working mold, wherein the solid binder member is made of a binder material, and providing a layer of powder matrix material within a molding void of the working mold. The method further includes heating the working mold to form a molten binder pathway from the solid binder member to infiltrate the layer of powder matrix material.

Estimation of properties of a subterranean region using a synthetic physical model

A method of estimating a property associated with a subterranean region includes acquiring a synthetic physical model of the subterranean region, the physical model made from at least a mineral material and constructed using an additive manufacturing process, the physical model having a microstructure, the microstructure having a parameter that varies along at least a first axis of the physical model. The method also includes performing a measurement of the physical model under an applied condition, and estimating the property of the subterranean region based on the measurement.

Methods of modifying surfaces of diamond particles, and related diamond particles and earth-boring tools

A method of modifying surfaces of diamond particles comprises forming spinodal alloy coatings over discrete diamond particles, thermally treating the spinodal alloy coatings to form modified coatings each independently exhibiting a reactive metal phase and a substantially non-reactive metal phase, and etching surfaces of the discrete diamond particles with at least one reactive metal of the reactive metal phase of the modified coatings. Diamond particles and earth-boring tools are also described.

Cutting elements for earth-boring tools and related earth-boring tools and methods

Cutting elements for earth-boring tools may include a cutting edge located proximate to a periphery of the cutting element. The cutting edge may be positioned and configured to contact an earth formation during an earth-boring operation. The cutting edge may include a first portion having a first radius of curvature and a second portion having a second, larger radius of curvature. The second portion may be circumferentially offset from the first portion.

Techniques for forming polycrystalline, superabrasive materials, and related methods, materials, cutting elements. and earth-boring tools

Methods of making cutting elements for earth-boring tools may involve intermixing discrete particles of superabrasive material with a binder material in a solvent to form a slurry. The slurry may be vacuum dried or spray dried to disaggregate individual precursor agglomerates including a group of discrete particles suspended in a discrete quantity of the binder material from one another. The precursor agglomerates may be sintered while exposing the precursor agglomerates to a quantity of catalyst material to form agglomerates including discrete quantities of poly crystalline, superabrasive material while inhibiting formation of inter-granular bonds among the agglomerates themselves. The agglomerates may subsequently be sintered while exposing the agglomerates to another quantity of catalyst material to form a table for the cutting element including inter-granular bonds among adjacent grains of the agglomerates.

Methods of forming cutting elements and supporting substrates for cutting elements

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Methods of forming cutting elements

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A3XZn-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Techniques for forming polycrystalline, superabrasive materials, and related methods, materials, cutting elements. and earth-boring tools

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Polycrystalline diamond bodies incorporating fractionated distribution of diamond particles of different morphologies

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 µm) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 µm). During high pressure - high temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

Cemented carbide containing muli-component high entropy carbide and/or multi-component high entropy alloy

A sintered cemented carbide includes a high entropy carbide or a spinodal decomposed product thereof; and a metallic binder containing at least one of Co, Co—Ru, Ni, Co—Ni, Co—Cr, Co—Ni—Cr, Co—Re, Co—Ni—Re, Co—Ni—Ru, or a high entropy alloy, wherein the high entropy carbide is a single-phase solid solution carbide comprising four to ten metallic elements, and the spinodal decomposed product thereof includes two chemically distinct phases having a same crystal structure. A sintered cemented carbide also includes a carbide including at least one of WC, TiC, ZrC, HfC, NbC, TaC, or Cr3C2; and a metallic binder including a high entropy alloy. The high entropy alloy is an alloy of four to ten alloy elements selected from Al, Be, Fe, Co, Cr, Ni, Cu, W, V, Zr, Ti, Mn, Hf, Nb, Mo, Ru, Re, Ge, Sn, C, B, or Si.

Methods of making of polycrystalline diamond compacts having interstitial diamond grains

Selectively leached thermally stable cutting element in earth-boring tools, earth-boring tools having selectively leached cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Abgerundete schneidvorrichtungstasche mit verminderter spannungskonzentration

Selectively leached thermally stable cutting element in earth-boring tools, earth-boring tools having selectively leached cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Precipitate-strengthened hard metal-diamond composite

A cutting table for a cutting element, including: a diamond phase; a tungsten carbide phase; a cobalt-tungsten metallic phase; and an intermetallic phase comprising Co3WCx, where 0≤x≤1. Also disclosed is a method of manufacturing a cutting element, the method including: sintering diamond and tungsten carbide particles in the presence of Co and W to about 1520 °C or greater under pressure of about 57 kbar or greater to form a hard metal-diamond composite compact and solubilize carbon and tungsten within the compact; cooling the cutting element at about 1 °C/sec or greater; and subsequent to cooling the cutting element, heat-treating the cutting element to precipitate carbon and tungsten in the compact as an intermetallic phase.

Cemented carbide containing muli-component high entropy carbide and/or multi-component high entropy alloy

A sintered cemented carbide includes a high entropy carbide or a spinodal decomposed product thereof; and a metallic binder containing at least one of Co, Co-Ru, Ni, Co-Ni, Co-Cr, Co-Ni-Cr, Co-Re, Co-Ni-Re, Co-Ni-Ru, or a high entropy alloy, wherein the high entropy carbide is a single-phase solid solution carbide comprising four to ten metallic elements, and the spinodal decomposed product thereof includes two chemically distinct phases having a same crystal structure. A sintered cemented carbide also includes a carbide including at least one of WC, TiC, ZrC, HfC, NbC, TaC, or Cr3C2; and a metallic binder including a high entropy alloy. The high entropy alloy is an alloy of four to ten alloy elements selected from Al, Be, Fe, Co, Cr, Ni, Cu, W, V, Zr, Ti, Mn, Hf, Nb, Mo, Ru, Re, Ge, Sn, C, B, or Si.

Methods of forming supporting substrates for cutting elements, and related cutting elements, methods of forming cutting elements, and earth-boring tools

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Supporting substrates for cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A3XZn-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Selectively leached thermally stable cutting element in earth-boring tools, earth-boring tools having selectively leached cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the interbonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Selectively leached thermally stable cutting element in earth-boring tools, earth-boring tools having selectively leached cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the interbonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Methods of forming supporting substrates for cutting elements, and related cutting elements, methods of forming cutting elements, and earth-boring tools

A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, Al, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, Al, W, and C. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Supporting substrates for cutting elements, and related methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A 3 XZ n-1 , where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Cutting elements, and related earth-boring tools, supporting substrates, and methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A3XZn-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Elemento de corte térmicamente estable lixiviado selectivamente en herramientas de perforación de tierra, herramientas de perforación de tierra que tienen elementos de corte lixiviados selectivamente, y métodos relacionados.

Un elemento de corte comprende un sustrato de soporte, y una mesa de corte unida a un extremo del sustrato de soporte. La mesa de corte comprende una primera región y una segunda región. La primera región comprende partículas de diamante intercohesionadas y está sustancialmente libre de compuestos metálicos al menos altamente catalíticos, uno o más compuestos no catalíticos dentro de los espacios intersticiales entre las partículas de diamante intercohesionadas, y vacíos dentro de los espacios intersticiales entre las partículas de diamante intercohesionadas. La segunda región comprende partículas de diamante intercohesionadas, uno o más compuestos no catalíticos dentro de los espacios intersticiales entre las partículas de diamante intercohesionadas, y una o más fases metálicas dentro de los espacios intersticiales entre las partículas de diamante intercohesionadas. La primera región de la mesa de corte tiene un contenido de metales elementales de al menos aproximadamente 2.6 % en peso. También se describe un método para formar un elemento de corte, y una herramienta de perforación de tierra.

Precipitate-strengthened hard metal-diamond composite

A cutting table for a cutting element, including: a diamond phase; a tungsten carbide phase; a cobalt-tungsten metallic phase; and an intermetallic phase comprising Co3WCx, where 0≤x≤1. Also disclosed is a method of manufacturing a cutting element, the method including: sintering diamond and tungsten carbide particles in the presence of Co and W to about 1520° C. or greater under pressure of about 57 kbar or greater to form a hard metal-diamond composite compact and solubilize carbon and tungsten within the compact; cooling the cutting element at about 1° C./sec or greater; and subsequent to cooling the cutting element, heat-treating the cutting element to precipitate carbon and tungsten in the compact as an intermetallic phase.

Methods of forming polycrystalline diamond

A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1400° C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm 3 and a modulus of at least about 1000 GPa. An earth-boring tool may include such a cutting element secured to a body.

Polycrystalline diamond, methods of forming same, cutting elements, and earth-boring tools

A method of forming polycrystalline diamond includes providing an alloy over diamond particles and subjecting the diamond particles to a pressure of at least 4.5 GPa and a temperature of at least 1,000° C. to form inter-granular bonds. The alloy includes iridium and at least one of copper, silver, and gold. A polycrystalline diamond compact includes diamond grains bonded by inter-granular bonds and an alloy disposed within interstitial spaces. The alloy includes iridium, carbon, and at least one of copper, silver, and gold. An earth-boring tool includes a bit body and a polycrystalline diamond compact secured to the bit body. Some methods include selecting an alloy that is catalytic to formation of diamond-to-diamond bonds when the alloy is in a liquid phase, but non-catalytic to the back-conversion of diamond to graphite at temperatures of less than about 1,000° C.

Polycrystalline diamond compacts having a microstructure including nanodiamond agglomerates, cutting elements and earth-boring tools including such compacts, and related methods

A polycrystalline diamond compact (PDC) has a diamond matrix including inter-bonded diamond grains and nanodiamond agglomerates within interstitial spaces in the diamond matrix. A volume percentage of the nanodiamond agglomerates in the PDC may be greater than or equal to a percolation threshold volume of the nanodiamond agglomerates in the PDC, and a remainder of the volume of the PDC may be at least substantially comprised by the diamond matrix. The PDC may be at least substantially free of metal solvent catalyst material. Earth-boring tools include one or more such PDCs. A method of manufacturing a PDC includes mixing diamond grains with nanodiamond agglomerates to form a mixture, and subjecting the mixture to a high-temperature/high-pressure (HTHP) sintering process to form the PDC without any substantial assistance from a metal solvent catalyst material.

Methods and compositions for brazing

A method includes disposing a braze material adjacent a first body and a second body; heating the braze material and forming a transient liquid phase; and transforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body. The braze material includes copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth.