Polycrystalline diamond element

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or ail of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

POLYCRYSTALLINE DIAMOND ELEMENT

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmospheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD element includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond. 1. A polycrystalline diamond (PCD) element having internal diamond surfaces , the internal diamond surfaces defining interstices between them , the PCD element comprising a working surface , a low melting point region adjacent the working surface and in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1 ,300 degrees centigrade at atmospheric pressure , and an intermediate region extending a distance of between about 5 microns and about 600 microns from a boundary defined by the low melting point region , the interstices of the intermediate region being at least partially filled with a catalyst material for diamond.2. A polycrystalline diamond element according to claim 1 , in which the intermediate region extends a distance from the boundary of at most about 400 microns.3. A polycrystalline diamond element according to claim 1 , in which the intermediate region extends a distance from the boundary of at least about 5 microns.4. A polycrystalline diamond element according to claim 1 , in which the interstices of the intermediate region are at least 50% filled with a sintering aid or catalyst material for diamond.5. A polycrystalline diamond element ...

POLYCRYSTALLINE DIAMOND

A polycrystalline diamond (PCD) material comprising at least 88 volume percent and at most 99 volume percent diamond grains , the mean diamond grain contiguity being greater than 60.5 percent. The PCD material is particularly but not exclusively for use in boring into the earth. 115-. (canceled)16. A method of making PCD material , the method including subjecting an aggregated mass of diamond grains to a pressure treatment at a pressure of greater than 6.0 GPa in the presence of a metallic catalyst material for diamond at a temperature sufficiently high for the catalyst material to melt , and sintering the diamond grains to form PCD material; the diamond grains having the size distribution characteristic that at least 50 percent of the grains have average equivalent circle diameter (ECD) size greater than 5 microns , and at least 20 percent of the grains have average ECD size in the range from 10 to 15 microns.17. A method as claimed in claim 16 , including subjecting the PCD material to a further pressure treatment at a pressure of at least about 2 GPa.18. A method as claimed in claim 16 , including removing metallic catalyst material for diamond from interstices between the diamond grains of the PCD material.19. A method as claimed in claim 16 , including subjecting the PCD material to a heat treatment at a temperature of at least about 500 degrees centigrade for at least about 5 minutes.20. A method as claimed in claim 16 , including introducing an additive material into the aggregated mass claim 16 , the additive material containing at least one element selected from V claim 16 , Ti claim 16 , Mo claim 16 , Zr claim 16 , W claim 16 , Ta claim 16 , Hf claim 16 , Si claim 16 , Sn or Al.2127-. (canceled) This application claims the benefit of U.S. Provisional Application Ser. No. 61/183,208, filed on Jun. 2, 2009, which is hereby incorporated by reference in its entirety, including any figures, tables, and drawings.Embodiments of the invention relate to ...

METHOD OF MAKING POLYCRYSTALLINE DIAMOND MATERIAL

A method for making polycrystalline diamond material comprises providing a plurality of diamond particles or grains, coating the diamond particles or grains with a binder material comprising a non-metallic catalyst material for diamond, consolidating the coated diamond particles or grains to form a green body, and subjecting the green body to a temperature and pressure at which diamond is thermodynamically stable, sintering and forming polycrystalline diamond material. 1. A method for making polycrystalline diamond material , the method comprising providing a plurality of diamond particles or grains , coating the diamond particles or grains with a binder material comprising a non-metallic catalyst material for diamond , consolidating the coated diamond particles or grains to form a green body , and subjecting the green body to a temperature and pressure at which diamond is thermodynamically stable , sintering and forming polycrystalline diamond material.2. A method according to claim 1 , wherein the diamond particles or grains are suspended in a liquid medium claim 1 , the non-metallic catalyst material for diamond precipitating in situ onto the surfaces of respective diamond particles or grains in the liquid medium in order to coat the diamond particles or grains.3. A method according to claim 1 , wherein the non-metallic catalyst material for diamond is a precipitated salt comprising the reaction product of a solution of a first salt of an alkali or alkali earth metal and the solution of a second salt of an anion capable of forming an insoluble salt with the alkali earth or alkali earth metal of the first salt.4. A method according to claim 3 , wherein the first and second salt containing solutions are introduced simultaneously into the diamond suspension claim 3 , thereby coating the diamond particles or grains upon precipitation of the non-metallic catalyst material for diamond.5. A method according to claim 1 , wherein the diamond particles or grains prior to ...

POLYCRYSTALLINE DIAMOND MATERIAL

A polycrystalline diamond material comprising a mass of diamond particles or grains exhibiting inter-granular bonding and a binder material comprises a non-metallic catalyst material for diamond, the non-metallic catalyst material for diamond comprising at least one nitrogen compound derived from an ammonium compound and/or at least one halide compound. 1. A polycrystalline diamond material comprising a mass of diamond particles or grains exhibiting inter-granular bonding and a binder material comprising a non-metallic catalyst material for diamond , the non-metallic catalyst material for diamond comprising at least one nitrogen compound derived from an ammonium compound and/or at least one halide compound.2. A polycrystalline diamond material according to claim 1 , wherein the ammonium compound comprises an anion selected from the group comprising the carbonates claim 1 , phosphates claim 1 , hydroxides claim 1 , oxides claim 1 , sulphates claim 1 , borates claim 1 , titanates claim 1 , silicates claim 1 , halides claim 1 , and combinations thereof.3. A polycrystalline diamond material according to claim 1 , wherein the halide compound comprises a cation selected from the group comprising the alkali metals claim 1 , alkali earth metals claim 1 , transition metals claim 1 , ammonium claim 1 , and combinations thereof.4. A polycrystalline diamond material according to claim 3 , wherein the non-metallic catalyst material for diamond comprises one or more of lithium chloride claim 3 , sodium chloride claim 3 , potassium chloride claim 3 , rubidium chloride claim 3 , caesium chloride claim 3 , magnesium chloride claim 3 , calcium chloride claim 3 , strontium chloride claim 3 , barium chloride claim 3 , yttrium chloride claim 3 , zirconium chloride claim 3 , zinc chloride claim 3 , niobium chloride claim 3 , oxidation states thereof claim 3 , and/or mixtures thereof.5. A polycrystalline diamond material according to claim 1 , wherein the diamond particles or grains have ...

POLYCRYSTALLINE DIAMOND MATERIAL

A polycrystalline diamond material comprises a mass of diamond particles or grains exhibiting inter-granular bonding and a binder material comprising a non-metallic catalyst material for diamond, the non-metallic catalyst material for diamond being a metal oxoanion, the oxoanion being selected from the group comprising molybdates, tungstates, vanadates, phosphates and mixtures thereof. 1. A polycrystalline diamond material comprising a mass of diamond particles or grains exhibiting inter-granular bonding and a binder material comprising a non-metallic catalyst material for diamond , the non-metallic catalyst material for diamond being a metal oxoanion , the oxoanion being selected from the group comprising molybdates , tungstates , vanadates , phosphates and mixtures thereof.2. A polycrystalline diamond material according to claim 1 , wherein the metal oxoanion is selected from the group of compounds of the general formula A(MO)or AB(MO) claim 1 , where A and B are alkali metals claim 1 , alkali earth metals claim 1 , transition metals claim 1 , lanthanides claim 1 , actinides claim 1 , or monovalent claim 1 , divalent or trivalent metals claim 1 , M is tungsten claim 1 , molybdenum claim 1 , vanadium or phosphorous claim 1 , and 0.67≦x≦4 claim 1 , 3≦y≦12 claim 1 , and 1≦z≦3.3. A polycrystalline diamond material according to claim 1 , wherein the metal oxoanion is selected from the group comprising sodium molybdate claim 1 , cobalt molybdate claim 1 , zirconium tungstate claim 1 , potassium vanadate claim 1 , KBi(WO) claim 1 , LaCuMoO claim 1 , ZrMoO claim 1 , HfWO claim 1 , LaMoO claim 1 , EuMoO claim 1 , ScWO claim 1 , EuMoO claim 1 , Zr(WO)(PO)and LnAg(WO)(MoO).4. A polycrystalline diamond material according to claim 1 , wherein the metal oxoanion is sodium molybdate.5. A polycrystalline diamond material according to claim 1 , wherein the diamond particles have an average particle or grain size of from about 10 nanometres to about 50 microns.6. A polycrystalline ...

METHOD FOR ATTACHING A PRE-SINTERED BODY OF POLYCRYSTALLINE DIAMOND MATERIAL TO A SUBSTRATE

A method of attaching a pre-sintered body of polycrystalline diamond material to a substrate along an interface therebetween, the substrate being formed of cemented carbide and a metal binder phase dispersed therein, comprises placing a layer comprising one or more elements or alloys thereof on the interface on one or other of the body of polycrystalline diamond material or substrate; the one or more elements being selected to form a eutectic mixture with the metal in the binder phase, the eutectic mixture having a lower melting point than the melting point of the metal in the binder phase of the substrate. The other of the body of polycrystalline diamond material or the substrate is then placed on the layer and the body of polycrystalline material, the layer and the substrate are then subjected to a predetermined temperature at least equal to or greater than the melting point of the eutectic mixture at substantially ambient pressure or a vacuum to melt the metal in the binder phase at the interface with the substrate so that the metal from the binder phase infiltrates into the adjacent body of polycrystalline diamond material to form a bond between the body of polycrystalline diamond material and the substrate. 1. A method for attaching a pre-sintered body of polycrystalline diamond material to a substrate along an interface therebetween , the substrate being formed of cemented carbide and a metal binder phase dispersed therein , the method comprising:placing a layer comprising one or more elements or alloys thereof on the interface on one or other of the body of polycrystalline diamond material or substrate;the one or more elements or alloys being selected to form a eutectic mixture with the metal in the binder phase, the eutectic mixture having a lower melting point than the melting point of the metal in the binder phase of the substrate;placing the other of the body of polycrystalline diamond material or the substrate on the layer;subjecting the body of ...

POLYCRYSTALLINE SUPERHARD MATERIAL AND METHOD OF FORMING

A body of polycrystalline diamond (PCD) material having a diamond content of at most 95 percent of the volume of the PCD material, a binder content of at least 5 percent of the volume of the PCD material, and comprising diamond grains having a mean diamond grain contiguity of greater than 60 percent and a standard deviation of less than 2.2 percent is disclosed. Also disclosed is a method of making such a body of polycrystalline diamond material.

METHODS OF FORMING EARTH-BORING TOOLS

A method of forming a cutting element for an earth-boring tool. The method includes providing diamond particles on a supporting substrate, the volume of diamond particles comprising a plurality of diamond nanoparticles. A catalyst-containing layer is provided on exposed surfaces of the volume of diamond nanoparticles and the supporting substrate. The diamond particles are processed under high temperature and high pressure conditions to form a sintered nanoparticle-enhanced polycrystalline compact. A cutting element and an earth-boring tool including a cutting element are also disclosed. 1. A method of forming an earth-boring tool , comprising:forming a catalyst-containing material on each of a top and sides of a diamond material discrete from the catalyst-containing material, the diamond material comprising diamond nanoparticles;processing the diamond material under high temperature and high pressure conditions to form a sintered nanoparticle-enhanced polycrystalline compact; andattaching the sintered nanoparticle-enhanced polycrystalline compact to a bit body.2. The method of claim 1 , further comprising selecting the catalyst-containing material to comprise particles comprising at least one catalyst material.3. The method of claim 1 , further comprising selecting the catalyst-containing material to comprise a solid structure comprising at least one catalyst material.4. The method of claim 1 , further comprising selecting the catalyst-containing material to comprise one or more of cobalt claim 1 , iron claim 1 , and nickel.5. The method of claim 1 , further comprising selecting the catalyst-containing material to comprise cemented tungsten carbide.6. The method of claim 1 , further comprising selecting the catalyst-containing material to comprise at least one catalyst material and at least one non-diamond carbon material.7. The method of claim 1 , further comprising depositing the diamond material on a supporting substrate prior to forming the catalyst-containing ...

MULTI-LAYERED POLYCRYSTALLINE DIAMOND STRUCTURE

A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers (), (), each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a poly crystalline diamond structure. 1. A polycrystalline diamond structure comprising a first region and a second region adjacent the first region , the second region being bonded to the first region by intergrowth of diamond grains , the first region comprising a plurality of alternating strata or layers , each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns; wherein the polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material , a binder content of at least about 5 percent of the volume of the PCD material , and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent.2. A PCD structure according to claim 1 , wherein each stratum or layer in the first region has a thickness in the range of around 30 to 300 microns.3. A PCD structure according to claim 1 , wherein one or more ...

POLYCRYSTALLINE DIAMOND

A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material. 1. A PCD body comprising a skeletal mass of inter-bonded diamond grains defining interstices between them , at least some of the interstices containing a filler material comprising a metal catalyst material for diamond , the filler material containing Ti , W and an additional metal M selected from the group consisting of V , Y , Nb , Hf , Mo , Ta , Cr , Zr and the rare earth elements; the content of Ti within the filler material being at least about 0.1 weight % and at most about 20 weight %; the content of M within the filler material being at least about 0.1 weight % and at most about 20 weight %; and the content of W within the filler material being at least about 5 weight % and at most about 50 weight % of the filler material.2. A PCD body as claimed in claim 1 , wherein the additional metal M is V and the combined content of Ti and V is at least about 0.5 weight % and at most about 10 weight % of the filler material.3. A PCD body as claimed in claim 1 , wherein the filler material comprises at least about 50 weight % Co and at most about 99 weight % Co.4. A PCD body as claimed in claim 1 , wherein the filler material comprises a particulate phase dispersed therein claim 1 , the particulate phase comprising a mixed carbide phase containing Ti claim 1 , M and W.5. A PCD body as claimed in ...

POLYCRYSTALLINE DIAMOND

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material. 1. A method for manufacturing a PCD element; the method including providing a PCD body having internal diamond surfaces , the internal diamond surfaces defining interstices , the PCD body containing a thermally stable region and a porous region , in which at least some of the interstices contain at least partly unfilled pores; introducing a mask or passivation medium proximate or into the thermally stable region; and introducing at least one infiltrant material into the porous region , the mask or passivation medium at least partly isolating diamond of the thermally stable region from chemical interaction with the at least one infiltrant material , wherein a controlled temperature cycle is employed in such a manner as to allow sufficient or a certain amount of the mask or passivation medium or its precursor to be introduced proximate or into the thermally stable region prior to the at least one infiltrant material melting and infiltrating into the porous PCD body.2. A method as claimed in claim 1 , in which the thermally stable region is at least partly porous.3. A method as claimed in claim 1 , the method including coating some or all of the internal diamond surfaces of the thermally stable region claim 1 , at least partially claim 1 , with a mask or passivation medium.4. ...

POLYCRYSTALLINE DIAMOND

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material. 1. A method for manufacturing a PCD element; the method including providing a PCD body having internal diamond surfaces , the internal diamond surfaces defining interstices , the PCD body containing a thermally stable region and a porous region , in which at least some of the interstices contain at least partly unfilled pores; introducing a mask or passivation medium proximate or into the thermally stable region; and introducing at least one infiltrant material into the porous region , the mask or passivation medium at least partly isolating diamond of the thermally stable region from chemical interaction with the at least one infiltrant material , wherein a controlled temperature cycle is employed in such a manner as to allow sufficient or a certain amount of the mask or passivation medium or its precursor to be introduced proximate or into the thermally stable region prior to the at least one infiltrant material melting and infiltrating into the porous PCD body.2. A method as claimed in claim 1 , in which the thermally stable region is at least partly porous.3. A method as claimed in claim 1 , the method including coating some or all of the internal diamond surfaces of the thermally stable region claim 1 , at least partially claim 1 , with a mask or passivation medium.4. ...

POLYCRYSTALLINE DIAMOND ELEMENT

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmospheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD clement includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond. 1. A polycrystalline diamond (PCD) element having internal diamond surfaces , the internal diamond surfaces defining interstices between them , the PCD element comprising a working surface , a low melting point region adjacent the working surface and in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1 ,300 degrees centigrade at atmospheric pressure , and an intermediate region extending a distance of between about 5 microns and about 600 microns from a boundary defined by the low melting point region , the interstices of the intermediate region being at least partially filled with a catalyst material for diamond.2. A polycrystalline diamond element according to claim 1 , in which the intermediate region extends a distance from the boundary of at most about 400 microns.35. A polycrystalline diamond element according to claim 1 , in which the intermediate region extends a distance from the boundary of at least about microns.4. A polycrystalline diamond element according to claim 1 , in which the interstices of the intermediate region are at least 50% filled with a sintering aid or catalyst material for diamond.5. A polycrystalline diamond element ...

Polycrystalline diamond structure

A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.

METHOD OF MAKING POLYCRYSTALLINE DIAMOND MATERIAL

A method of making polycrystalline diamond material includes providing a fraction of diamond particles or grains and a sintering additive, the sintering additive comprising a carbon source of nano-sized particles or grains, forming the diamond particles and sintering additive into an aggregated mass, consolidating the aggregated mass and a binder material to form a green body, and subjecting the green body to conditions of pressure and temperature at which diamond is more thermodynamically stable than graphite and for a time sufficient to consume the sintering additive, sintering it and forming polycrystalline diamond material that is thermodynamically and crystallographically stable and is substantially devoid of any nano-structures. 1. A method of making polycrystalline diamond material , the method including providing a fraction of diamond particles or grains and a sintering additive , the sintering additive comprising a carbon source of nano-sized particles or grains , forming the diamond particles and sintering additive into an aggregated mass , consolidating the aggregated mass and a binder material to form a green body , and subjecting the green body to conditions of pressure and temperature at which diamond is more thermodynamically stable than graphite and for a time sufficient to consume the sintering additive , sintering it and forming polycrystalline diamond material that is thermodynamically and crystallographically stable and is substantially devoid of any nano-structures.2. A method according to claim 1 , wherein the binder material comprises a catalyst material for diamond.3. A method according to claim 1 , wherein the sintering additive is nanodiamond.4. A method according to claim 3 , wherein nanodiamond is UDD (ultra-dispersed nanodiamond) claim 3 , PDD (polycrystalline detonated diamond powder) claim 3 , or a crushed source of nanodiamond.5. A method according to claim 1 , wherein the sintering additive is a nano-sized carbon source selected from ...

Polycrystalline diamond

A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material.

METHOD OF MAKING POLYCRYSTALLINE DIAMOND MATERIAL

A method of making polycrystalline diamond material includes providing a fraction of diamond particles or grains and a sintering additive, the sintering additive comprising a carbon source of nano-sized particles or grains, forming the diamond particles and sintering additive into an aggregated mass, consolidating the aggregated mass and a binder material to form a green body, and subjecting the green body to conditions of pressure and temperature at which diamond is more thermodynamically stable than graphite and for a time sufficient to consume the sintering additive, sintering it and forming polycrystalline diamond material that is thermodynamically and crystallographically stable and is substantially devoid of any nano-structures. 1. A method of making polycrystalline diamond material , the method including providing a fraction of diamond particles or grains and a sintering additive , the sintering additive comprising a carbon source of nano-sized particles or grains , forming the diamond particles and sintering additive into an aggregated mass , consolidating the aggregated mass and a binder material to form a green body , and subjecting the green body to conditions of pressure and temperature at which diamond is more thermodynamically stable than graphite and for a time sufficient to consume the sintering additive , sintering it and forming polycrystalline diamond material that is thermodynamically and crystallographically stable and is substantially devoid of any nano-structures.2. A method according to claim 1 , wherein the binder material comprises a catalyst material for diamond.3. A method according to claim 1 , wherein the sintering additive is nanodiamond.4. A method according to claim 3 , wherein nanodiamond is UDD (ultra-dispersed nanodiamond) claim 3 , PDD (polycrystalline detonated diamond powder) claim 3 , or a crushed source of nanodiamond.5. A method according to claim 1 , wherein the sintering additive is a nano-sized carbon source selected from ...

Polycrystalline diamond.

Una modalidad de un inserto de PCD comprende una modalidad de un elemento de PCD unido a un sustrato de carburo cementado en una interfaz. El elemento de PCD tiene superficies de diamante internas que definen intersticios entre ellas. El elemento de PCD comprende una región enmascarada o pasivada y una región no enmascarada o no pasivada, la región no enmascarada o nó pasivada que define un límite con el sustrato, el límite siendo la interfaz. Por lo menos algunas de las superficies internas de la región enmascarada o pasivada se pone en contacto con un medio de enmascaramiento o pasivación y algunos o todos los intersticios de la región enmascarada o pasivada y de la región por lo menos se llenan parcialmente con in material de infiltración.

POLYCRYSTALLINE DIAMOND

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Polycrystalline diamond (pcd) materials

The invention is for a polycrystalline diamond material comprising a first phase of bonded diamond particles and a second phase interspersed through the first phase. The second phase contains vanadium in the form of the metal or vanadium carbide or vanadium tungsten carbide or two or more of these forms and may be present in the polycrystalline diamond material in the range 1 to 8 percent by mass of the material.

Polycrystalline diamond element

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide sub-strate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least par-tially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmo-spheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD element includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond.

Polycrystalline diamond

A polycrystalline diamond (PCD) material 10 comprising at least 88 volume percent and at most 99 volume percent diamond grains 12, the mean diamond grain contiguity being greater than 60.5 percent. The PCD material 10 is particularly but not exclusively for use in boring into the earth.

Methods of forming a cutting element for an earth-boring tool, a related cutting element, and an earth-boring tool including such a cutting element

A method of forming a cutting element for an earth-boring tool. The method includes providing diamond particles on a supporting substrate, the volume of diamond particles comprising a plurality of diamond nanoparticles. A catalyst-containing layer is provided on exposed surfaces of the volume of diamond nanoparticles and the supporting substrate. The diamond particles are processed under high temperature and high pressure conditions to form a sintered nanoparticle-enhanced polycrystalline compact. A cutting element and an earth-boring tool including a cutting element are also disclosed.

Polycrystalline diamond (pcd) materials

The invention is for a polycrystalline diamond material comprising a first phase of bonded diamond particles and a second phase interspersed through the first phase. The second phase contains vanadium in the form of the metal or vanadium carbide or vanadium tungsten carbide or two or more of these forms and may be present in the polycrystalline diamond material in the range 1 to 8 percent by mass of the material.

Boron carbide composite materials

The invention relates to a boron carbide composite material comprising diamond particles and boron carbide, the composite material having a porosity of less than 2 percent by volume. The invention further relates to a method for manufacturing such materials, the method including coating a plurality of diamond particles with boron carbide, combining the plurality of diamond particles to form a green body and subjecting the green body to a temperature in the range from about 1,200 degrees centigrade to about 2,000 degrees centigrade and pressure or vacuum not exceeding about 2,000 Mpa.

Boron carbide composite materials

Polycrystalline diamond

A polycrystalline diamond (PCD) material 10 comprising at least 88 volume percent and at most 99 volume percent diamond grains 12 , the mean diamond grain contiguity being greater than 60.5 percent. The PCD material 10 is particularly but not exclusively for use in boring into the earth.

Polycrystalline diamond

A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material.

Polycrystalline diamond

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide sub-strate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element com-prises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or ail of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Polycrystalline diamond

A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material.

Polycrystalline diamond element

A PCD insert comprises a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Electrode

A diamond electrode comprises a polycrystalline mass of diamond particles bonded together and has a porous surface, or an at least partly porous surface. The porous surface of the electrode is typically created by leaching non-diamond material, such as a second phase of a metallic material, at least in part, from the bonded polycrystalline mass of diamond particles, either before or after shaping it into an electrode. Alternatively, or additionally, the porous surface of the electrode may be created by subjecting a mass of diamond particles to conditions of elevated temperature and pressure to self-bond the particles together in the absence of a second phase.

Polycrystalline diamond material comprising a metal oxoanion, the oxoanion being selected from the group comprising molybdates, tungstates, vanadates, phosphates and mixtures thereof

A polycrystalline diamond material comprises a mass of diamond particles or grains exhibiting inter-granular bonding and a binder material comprising a non-metallic catalyst material for diamond, the non-metallic catalyst material for diamond being a metal oxoanion, the oxoanion being selected from the group comprising molybdates, tungstates, vanadates, phosphates and mixtures thereof.

Polycrystalline diamond

An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Multi-layered polycrystalline diamond structure

A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers (21), (22), each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.

Diamond electrode

A diamond electrode comprises a polycrystalline mass of diamond particles bonded together and has a porous surface, or an at least partly porous surface. The porous surface of the electrode is typically created by leaching non-diamond material, such as a second phase of a metallic material, at least in part, from the bonded polycrystalline mass of diamond particles, either before or after shaping it into an electrode. Alternatively, or additionally, the porous surface of the electrode may be created by subjecting a mass of diamond particles to conditions of elevated temperature and pressure to self-bond the particles together in the absence of a second phase.

Methods of forming earth-boring tools

A method of forming a cutting element for an earth-boring tool. The method includes providing diamond particles on a supporting substrate, the volume of diamond particles comprising a plurality of diamond nanoparticles. A catalyst-containing layer is provided on exposed surfaces of the volume of diamond nanoparticles and the supporting substrate. The diamond particles are processed under high temperature and high pressure conditions to form a sintered nanoparticle-enhanced polycrystalline compact. A cutting element and an earth-boring tool including a cutting element are also disclosed.