CN103890308B

CN103890308B - Make the method for polycrystalline diamond and include cutting element and the earth-boring tools of polycrystalline diamond

Info

Publication number: CN103890308B
Application number: CN201280052009.6A
Authority: CN
Inventors: A·A·迪乔瓦尼; S·查克拉伯蒂
Original assignee: Baker Hughes Inc
Current assignee: Baker Hughes Holdings LLC
Priority date: 2011-09-16
Filing date: 2012-09-14
Publication date: 2016-11-30
Anticipated expiration: 2032-09-14

Abstract

The method making polycrystalline diamond; it surface including carrying out functionalization carbon-free nanoscale granule with one or more functional groups; merge with diamond nano-particles and diamond grit to form granulate mixture by functionalized nano-particle, and make this granulate mixture experience high pressure and high temperature (HPHT) condition to form inter-granular bond between diamond nano-particles and diamond grit.Cutting element for earth-boring tools comprises the polycrystalline diamond abrasive compact formed by this method.Earth-boring tools includes this cutting element.

Description

Make the method for polycrystalline diamond and include cutting element and the earth-boring tools of polycrystalline diamond

Priority right

This application claims the U.S. Provisional Patent Application Serial No. of JIUYUE in 2011 submission on the 16th The submission day rights and interests of 61/535,475, the artificial DiGiovanni of application of this application and Chakraborty, entitled " METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND, AND CUTTING ELEMENTS AND EARTH-BORING TOOLS COMPRISING POLYCRYSTALLINE DIAMOND”。

The theme of the application relates to the application artificial Anthony A. submitted to its same date U.S. Patent Application Serial Number 13/___ of DiGiovanni, _ _ _ (act on behalf of Reference Number 1684-P10759.1US theme (NAN4-52001-US)).The theme of the application further relates to The U.S. Patent Application Serial Number of the artificial Mazyar of application of December in 2011 submission on the 9th et al. The theme of 13/316,094 (acting on behalf of Reference Number NAN4-52588-US/BAO0893US).

Technical field

Embodiment of the present invention relate generally to the method forming polycrystalline diamond abrasive compact, comprise The cutting element of polycrystalline diamond abrasive compact, and include this cutting element for drilling subterranean formations Earth-boring tools.

Background of invention

Can include multiple being arranged on machine for forming the earth-boring tools of well container in subsurface formations Cutting element with it.Such as, the brill ground rotary rig drill bit (also referred to as " scraper of fixed cutting tool Drill bit ") include multiple cutting element, it is fixedly attached to the bit body of drill bit.Similarly, tooth Wheel bores ground rotary drilling-head and includes gear wheel, and it is installed to the bearing pin extended from the support of bit body, So that each gear wheel can rotate around the bearing pin that it is mounted thereto.Multiple cutting elements Each gear wheel of drill bit can be installed to.

Cutting element for this earth-boring tools often includes that polycrystalline diamond cutters (often claims Make " PDC "), it is the cutting element including polycrystalline diamond (PCD) material.This polycrystalline gold Hard rock cutting element such as gets off formation: under elevated temperature and pressure conditions, catalyst (such as cobalt, Ferrum, nickel or its alloys and mixts) in the presence of, relatively small diamond crystals or crystal are burnt Tie and combine, to form polycrystalline diamond abrasive compact layer in cutting element substrate.These Process often referred to as high pressure-temperature (or " HPHT ") to process.Cutting element substrate can comprise metal Ceramic material (i.e. ceramic-metal composite material), such as cobalt cemented tungsten carbide.In this case, Cobalt (or other catalyst materials) in cutting element substrate can enter Buddha's warrior attendant in sintering process In stone crystal grain or crystal, and serve as catalyst material for being carried out shape by diamond crystals or crystal Become diamond table.In additive method, at diamond crystals or crystal in HPHT method Together before sintering, the catalyst material of powdered can mix with this crystal grain or crystal.

By using HPHT process to form diamond table, catalyst material may remain in institute's shape In the gap between diamond crystals or crystal in the polycrystalline diamond table become.Diamond table Present in catalyst material can cause the diamond table when cutting element is in use heated In hot injury, this is owing to the friction at the contact point between cutting element and stratum.Many Diamond cutting element (during catalyst material is maintained at this diamond table wherein) is generally at height It is heat-staple to the temperature of about 750 DEG C, but the internal stress in polycrystalline diamond table is exceeding The temperature of about 350 DEG C can initially form.This internal stress be at least partly due to diamond table and The difference of the coefficient of thermal expansion between the cutting element substrate that it is attached to.This thermal expansion rate variance Different meeting interface between diamond table and substrate produces relatively large compressive stress and answers Power, and diamond table delamination from substrate can be caused.About 750 DEG C and higher temperature, Stress in diamond table can substantially increase, and this is owing to diamond in diamond table self And the difference of thermal coefficient of expansion between catalyst material.Such as, cobalt thermal expansion is significantly faster than that Buddha's warrior attendant Stone, this can cause crackle in the diamond table comprise cobalt formed and spread, ultimately result in Buddha's warrior attendant Shitai County's deterioration and cutting element lost efficacy.

In order to reduce relevant problem different from thermal expansion rates in polycrystalline diamond cutting element, Have been developed for so-called " heat-staple " polycrystalline diamond (TSD) cutting element.This heat is steady Fixed polycrystalline diamond cutting element can be by using such as acid by catalyst material (such as cobalt) The gap between diamond crystals from diamond table is leached out and is formed.Can be from gold Hard rock platform removes whole catalyst materials, or can only remove a part.It has been reported that (the most substantially all of catalyst material is for heat-staple polycrystalline diamond cutting element Through extracting away from diamond table) it is heat-staple in the temperature of height to about 1200 DEG C.But, Also reporting compared with non-leaching diamond table, this diamond table extracted completely is the most more Crisp and be easily subject to shear stress, compressive stress and tensile stress damage.Have relative to non-leaching in offer The diamond table carried is more thermally-stabilised, but also the most crisp compared with the diamond table extracted completely With the cutting element being less susceptible to the diamond table damaged by shear stress, compressive stress and tensile stress Effort in, there has been provided include only partially catalyzed agent material from diamond table extract The cutting element of diamond table.

Summary of the invention

In some embodiments of the disclosure, a kind of method making polycrystalline diamond includes using One or more functional groups come the surface of functionalization carbon-free nanoscale granule, by functionalized nanometer Granule merges to form granulate mixture with diamond nano-particles and diamond grit, and makes This granulate mixture experience high pressure and high temperature (HPHT) condition are with at diamond nano-particles and gold Inter-granular bond is formed between hard rock abrasive grain.

In some embodiments, a kind of cutting element for earth-boring tools comprises by including The polycrystalline diamond abrasive compact that following method is formed: with one or more functional groups come functionalization without The surface of carbon nano-particle, by functionalized nano-particle and diamond nano-particles and Buddha's warrior attendant Stone abrasive grain merges to form granulate mixture, and makes this granulate mixture experience HPHT condition To form inter-granular bond between diamond nano-particles and diamond grit.

In some embodiments, a kind of earth-boring tools includes cutting element.This cutting element bag Containing by including the polycrystalline diamond abrasive compact that following methods is formed: come with one or more functional groups The surface of functionalization carbon-free nanoscale granule, by functionalized nano-particle and diamond nano Grain and diamond grit merge to form granulate mixture, and make this granulate mixture experience HPHT condition is to form inter-granular bond between diamond nano-particles and diamond grit.

Accompanying drawing explanation

Fig. 1 is included in a kind of embodiment party of the cutting element of suprabasil a large amount of polycrystalline diamond The partial cutaway view of case；

Fig. 2 is the microcosmic knot representing the polycrystalline diamond of the cutting element of Fig. 1 under zoomed-in view The simplification figure how structure presents；

Fig. 3 A-3D show by by functionalized nano-particle and diamond nano-particles and Diamond grit merges to form granulate mixture, many for forming the cutting element of Fig. 1 Diamond；

Fig. 4 is a cross-sectional view simplified, it is shown that for forming cutting of Fig. 1 in a reservoir Cutting the material of element, it comprises granulate mixture that is described in reference diagram 3 and that formed, and this container is accurate Standby experience HPHT sintering process；

Fig. 5 A and 5B shows in closing chamber, at the gas containing hydrocarbon materials (such as methane) In state environment, the material of Fig. 3 is encapsulated in the container of Fig. 4；With

Fig. 6 shows that is bored a ground rotary drilling-head, and it includes that polycrystalline diamond described herein is cut Cut element.

Detailed description of the invention

Diagram presented herein is not offered as any concrete material, equipment, system or method Actual view, and be only Utopian expression, it is for describing some embodiment party of the present invention Case.In order to understand explanation, different feature total in the present embodiment and element can To represent by same or similar reference.

Fig. 1 shows cutting element 100, and it can be according to the embodiment party of method disclosed herein Case is formed.Cutting element 100 includes polycrystalline diamond 102.Optionally, cutting element 100 Can also include that substrate 104, polycrystalline diamond 102 can be incorporated into this substrate.Such as, base The end 104, can include the cylinder of usual cobalt cemented tungsten carbide material, but can also use not With geometry and the substrate of composition.Polycrystalline diamond 102 can be the polycrystalline in substrate 104 The form of the platform (i.e. layer) of diamond 102, as shown in Figure 1.Polycrystalline diamond 102 can carry For on the surface of (be such as formed at or be fixed to) substrate 104.In other embodiments In, cutting element 100 can include that the polycrystalline diamond 102 of certain volume (has and appoints simply The shape what is required), and any substrate 104 can not be included.

As in figure 2 it is shown, Buddha's warrior attendant that is that polycrystalline diamond 102 can comprise distribution and that be mutually bonded Stone crystal grain, which form the three-dimensional network of diamond.In some embodiments, polycrystalline The diamond crystals of diamond 102 optionally can have multimodal grain size distribution.Such as, Polycrystalline diamond 102 can include bigger diamond crystals 106 and less diamond crystals 108.Bigger diamond crystals 106 and/or the average grain of less diamond crystals 108 Size (such as average diameter) can be less than 1mm, less than 0.1mm, less than 0.01mm, little In 1 μm, less than 0.1 μm or even less than 0.01 μm.That is, bigger diamond crystals 106 and less diamond crystals 108 can all include micron diamond crystal grain (about 1 μm-about The diamond crystals of 500 μm (0.5mm)), submicron diamond crystals (about 500nm (0.5 μm)- The diamond crystals of about 1 μm) and/or diamond nano-particles (average particulate diameter is about The granule of 500nm or lower).In some embodiments, bigger diamond crystals 106 Can be micron diamond crystal grain, less diamond crystals 108 can be submicron diamond Crystal grain or diamond nano-particles.In some embodiments, bigger diamond crystals 106 Can be submicron diamond crystals, less diamond crystals 108 can be diamond nano Granule.In other embodiments, the diamond crystals of polycrystalline diamond 102 can have list Peak grain size distribution.In fig. 2, direct diamond between diamond crystals 106,108 Between-diamond crystals, key dotted line 110 represents.Gap 112 (black shade in Fig. 2) is deposited It is between the diamond crystals 106,108 being mutually bonded of polycrystalline diamond 102.These Gap 112 can be at least partially filled with solid matter, such as metal-solvent catalyst (such as Ferrum, cobalt, nickel or its alloy or mixture) and/or carbon-free material.In other embodiments, Gap 112 can include the space in polycrystalline diamond 102, the most there is not solid or liquid Body material (but gas such as air may reside in this space).This space can be passed through From gap 112, after forming polycrystalline diamond 102, remove (such as extraction) solid material come Formed.In still other embodiments, in one or more districts of polycrystalline diamond 102 In territory, gap 112 can be at least partially filled with solid matter, and at polycrystalline diamond 102 Other regions one or more in, gap 112 includes space.

The embodiment of method disclosed herein may be used for being formed polycrystalline diamond 102, and The crystal grain of improvement can be produced between diamond crystals 106,108 in polycrystalline diamond 102 Between diamond-diamond bonding.

Can use without carbon granule (such as nano-particle, submicron particles and/or micrometer-sized particles) Diamond precursor functional group carrys out functionalization, and carrys out shape in diamond crystals experience HPHT processing Become before polycrystalline diamond 102 with diamond particles (such as nano-particle, submicron particles and/ Or micrometer-sized particles) mixing.Fig. 3 A-3D show may be used for formed granulate mixture with Experience HPHT condition forms the example embodiment of the method for polycrystalline diamond 102.

Fig. 3 A shows the simplification figure of diamond nano-particles 130.Diamond nano-particles 130 Can be unimodal or (the including bimodal) of multimodal.In some embodiments, diamond is received Rice grain 130 can include exterior carbon shell, and it can be referred to as carbon " Bulbus Allii Cepae " in the art. In other embodiments, diamond nano-particles 130 can not include any such outside Carbon shell.

As shown in Figure 3 B, diamond nano-particles 130 can with have carbon-free core through official's energy The nano-particle 131 changed merges and mixes, to form the first granulate mixture 132.Through official's energy The nano-particle 131 changed can have core, and it includes such as metal or metal alloy.This metal Or metal alloy can be alloy or the mixture of such as ferrum, cobalt, nickel or these metals. These metals can serve as solvent metal catalyst, is used for forming direct diamond-diamond brilliant Intergranular key, as known in the art.In further embodiment, functionalized Nano-particle 131 can have core, and it includes ceramic material such as oxide (such as aluminium oxide (Al₂O₃), magnesium oxide (MgO) etc.) or nitride.

As the example of indefiniteness, this core can be with functional group such as methyl functional group or acetylene Functional group carrys out functionalization.The functional group comprising carbon and hydrogen can strengthen in polycrystalline diamond 102 The formation (Fig. 2) of the intercrystalline diamond-diamond key between diamond crystals 106,108.No Being limited to concrete theory, the hydrogen in chemical functional group can be under hpht conditions at diamond Granule is provided about reducing atmosphere.Such as, under hpht conditions, this functional group can be down to Partially dissociate or decompose.The product of this decomposition can include simple substance carbon and hydrogen.

In some embodiments, carbon-free core (such as carbon-free nanoscale granule, such as ceramic nanoparticles) Functionalization can be carried out by this carbon-free core is exposed to the functional group comprising carbon and hydrogen.Such as, should Functional group can be methyl, and it provides by this carbon-free core is exposed to methane gas environment.First Alkane gas can form carbon back functional group by chemical gaseous phase deposition (CVD) on this carbon-free core.? In some embodiment, nano-particle can use acid treatment, then uses polymeric encapsulate.This Method is described in " the Nanocomposite particles with of A.R.Mahdavian et al. Core-shell morphology III:preparation and characterization of nano Al₂O₃-poly(styrene-methyl methacrylate)particles via miniemulsion Polymerization ", in 63Polymer Bulletin329-340 (2009).Implement at other In scheme, it is public that this carbon-free core can use technology to be such as disclosed on October 20th, 1 U.S. Patent Application Publication 2011/0252711 (entitled " the Method of Preparing of cloth Polycrystalline Diamond from Derivatized Nanodiamond ") in those Technology carrys out functionalization.

In some embodiments, there is the functionalized nano-particle of different functional groups 131 can be before functionalized nano-particle 131 mixes with diamond nano-particles 130 Blend.Such as, the functionalized nano-particle 131 with the first functional group can be with Any ratio and the functionalized nano-particle 131 with the second functional group blend.Therefore, Can select or regulate at the mixture of functionalized nano-particle 131 with formed The amount of one granulate mixture 132 Zhong Meizhong functional group.Concrete functional group or sense can be selected The combination of group has carbon atom and the ratio selected by hydrogen atom.Such as, functional group or sense The carbon atom of combination of group can be about 1:1-about 1:3 with the ratio of hydrogen atom, and e.g., from about 1:2-is about 1:3。

As shown in Figure 3 B, the first granulate mixture 132 can be such as by by functionalized Nano-particle 131 and diamond nano-particles 130 are suspended in liquid formation suspended substance and are formed. This suspended substance can be dried, and leaves the first granulate mixture 132, and it can be powdered product (example Such as muffin) form.Drying means can include such as following one or more: spray drying side Method, freeze-drying method, flash drying method or known in the art any other are dried side Method.

Optionally, the first granulate mixture 132 can crush, grinds or otherwise stir Mix, to form relatively small bunch or aggregation 133 of the first granulate mixture 132, such as figure Shown in 3C.The aggregation 133 of the first granulate mixture 132 can be with relatively large diamond Granule 134 (that is, diamond " abrasive grain ") merges and mixes to form the second granulate mixture 135, as shown in Figure 3 D.As a not limiting example, relatively large diamond particles 134 can be micron diamond particles and/or submicron diamond particles, and average particle size particle size is About 500 nanometers (500nm) are to about ten microns (10 μm).Relatively large diamond particles 134 As diamond nano-particles 130, can include or exterior carbon shell can not be included.

In further embodiment, the second granulate mixture 135 can be such as formation of getting off: will Relatively large diamond particles 134 and diamond nano-particles 130 and functionalized nanometer Granule 131 is suspended in liquid suspension together, uses the most disclosed above that of technology subsequently It is dried this liquid suspension.In this approach, different first and second will not be produced Granulate mixture, because diamond nano-particles 130, functionalized nano-particle 131 and Relatively large diamond particles 134 can be incorporated in single liquid suspension together, and it can To be dried directly to form the second granulate mixture 135.

Therefore second granulate mixture 135 includes diamond nano-particles 130, functionalized Nano-particle 131 and bigger diamond particles 134.Then second granulate mixture 135 may be used Process with experience HPHT to form polycrystalline diamond 102.Optionally, the second granulate mixture 135 can experience attrition process, then make the second granulate mixture 135 experience HPHT process.

In some embodiments, HPHT condition can include the temperature of at least about 1400 DEG C The pressure of at least about 5.0GPa.

Seeing Fig. 4, granulate mixture 135 may be located in container 118 (such as canister). Granulate mixture 135 includes diamond nano-particles 130 and relatively large diamond particles 134, it finally forms the diamond crystals in polycrystalline diamond 102 in sintering process respectively 108,106 (Fig. 2).Granulate mixture 135 also includes functionalized nano-particle 131.

As shown in Figure 4, container 118 can include interior cup 120, and granulate mixture 135 is permissible It is arranged therein.If cutting element 100 includes substrate 104, then substrate 104 optionally may be used To provide on or below granulate mixture 135 in interior cup 120, and can finally wrap It is enclosed in container 118.Container 118 may further include top sheet 122 and bottom sheet 124, It can be around interior cup 120 together with granulate mixture 135 and the most optional substrate 104 Assemble and combine (such as swaged forging combination).Then the container 118 of this sealing can experience HPHT Process is to form polycrystalline diamond 102.

In some embodiments, hydrocarbon materials such as methane gas, another kind of hydrocarbon or the mixing of hydrocarbon Thing can also be encapsulated in container 118, is in granulate mixture 135 between variable grain In space.Methane be for formed in CVD method the primary carbon source of epitaxial diamond films it One.If used, hydrocarbon materials can penetrate into container 118 (the interior cup 120 of such as container 118), its In there is granulate mixture 135.Container 118 then can with granulate mixture 135 and its In hydrocarbon materials seal.Vacuum purification process can have been carried out (such as on granulate mixture 135 Diamond particles 116 and/or container 118 are being exposed to the decompression (vacuum) being in selected temperature Environment is with evaporating volatile compound) after reducing the impurity in container 118, introduce hydrocarbon materials. Hydrocarbon materials can also introduce in container 118 under stress, in order to is sealing container 118 and should The container 118 sealed experiences selectivity before HPHT condition and controls the concentration of hydrocarbon materials.Change sentence Talk about, controlled the pressure (such as dividing potential drop) of hydrocarbon materials by selectivity, it is also possible to selectivity controls The concentration of the hydrocarbon materials in sealing container 118.Container 118 it is incorporated under stress at hydrocarbon materials In some embodiments in, the dividing potential drop of hydrocarbon materials can be at least about 10kPa, at least about 100kPa, at least about 1000kPa (1.0MPa), at least about 10MPa, at least about 100MPa Or the most about 500MPa.

Before sealing container 118 and the container 118 of this sealing experienced HPHT condition, can Granulate mixture 135, optional hydrocarbon materials and the temperature of container 118 is controlled with selectivity.Example As, can be at e.g., less than-150 DEG C, the temperature less than-161 DEG C or less than-182 DEG C introduces Hydrocarbon materials and sealing container 118.In some embodiments, hydrocarbon materials can be liquid respectively The temperature of the pact of nitrogen and liquid helium temperature-196 DEG C (77K) or the most about-269 DEG C (4.2K) introduces. In such temperature, hydrocarbon materials can be liquid or solid, and seals the appearance with hydrocarbon materials Device 118 can be simpler than the gaseous hydrocarbon material sealed in container 118.Specifically, as Really hydrocarbon materials is methane, then this methane can be in the liquid form of the temperature less than-161 DEG C With the solid form of the temperature less than-182 DEG C, it is boiling point and the fusing point of methane respectively.Ability Proper temperature when field technique personnel can be in liquid or solid form to select other hydrocarbon materials, No longer enumerate at this.

Fig. 5 A shows in the interior cup 120 being placed in the container 118 (Fig. 4) closed in chamber 128 Granulate mixture 135.Hydrocarbon materials can be incorporated in closing chamber 128 by entrance 139, As shown in the direction arrow in Fig. 5 A.Chamber 128 can be closed with selectivity control (such as improving) The pressure of interior hydrocarbon materials, the amount controlling the hydrocarbon materials in container 118 to be encapsulated into selectivity (is schemed 4).Such as, in closing chamber 128, the pressure of hydrocarbon materials can be at least about 10kPa, at least About 100kPa, at least about 1000kPa (1.0MPa), at least about 10MPa, at least about 100MPa Or the most about 500MPa.

Seeing Fig. 5 B, container 118 can be assembled in closing chamber 128, will close chamber Present in gaseous environment in 128, granulate mixture 135 and hydrocarbon materials are encapsulated in container 118 In.Then the container 118 of this sealing can experience HPHT processing.

In some embodiments, after granulate mixture 135 is inserted container 118, hydrocarbon thing Matter can be incorporated in container 118 with experience HPHT processing.In other embodiments, exist Being inserted by granulate mixture 135 in container 118 before experience HPHT processing, hydrocarbon materials can To be incorporated in the granulate mixture 135 in container respectively.In this embodiment, Grain mixture 135 may remain in hydrocarbon ring border, until it is sealed in container 118 with experience HPHT processes.

In disclosure other embodiments, hydrocarbon materials can mix with granulate mixture 135, And be sealed in container 118 with experience HPHT processing, simultaneously this hydrocarbon materials be in solid-state or Liquid.Such as, hydrocarbon materials can be the liquid of compression or solid-state or hydrocarbon and the joining of other materials Compound.In some embodiments, hydrocarbon materials can include the hydrocarbon of hydration, such as methane hydration Thing (namely for methane clathrate), ethane hydrates etc..Methane hydrate, other hydrocarbon hydrates or The hydrocarbon mixture (it can be to be liquid or solid form) of other forms can be with granulate mixture 135 are concomitantly introduced into.Introducing hydrocarbon materials can be optionally in the temperature (such as low temperature) less than room temperature Carry out.Such as, hydrocarbon materials can together with granulate mixture 135 hydrocarbon materials formed liquid or The temperature of solid e.g., less than-150 DEG C, the temperature less than-161 DEG C or less than-182 DEG C is drawn Enter.

It is not only restricted to any concrete theory, it is believed that the functionalized official on nano-particle 131 Can roll into a ball and optional hydrocarbon materials promotes the diamond-Buddha's warrior attendant between diamond crystals 106,108 The formation of stone inter-granular bond 110, as shown in Figure 2.Such as, functional group and hydrocarbon materials can be HPHT condition dissociates.Each carbon atom can be with one or more diamond after dissociation Grain (such as diamond nano-particles 130 or relatively large diamond particles 134 (Fig. 3 D)) Bonding.Hydrogen atom can form hydrogen (H after dissociation₂), it can be reducing agent.Some hydrogen Gas can react with the impurity in polycrystalline diamond 102 or catalyst material (if present).One A little hydrogen can diffuse out this polycrystalline diamond 102, and can react with the material of container 118. Some hydrogen can be bonded to the exposed surface of polycrystalline diamond 102 to form the polycrystalline gold of hydrogen end-blocking Hard rock.

Including the enforcement of the cutting element 100 of the polycrystalline diamond 102 made as described here Scheme (Fig. 1) can be installed on earth-boring tools and for according to disclosure other embodiments Remove subsurface formations material.Fig. 6 shows that fixed cutting tool bores ground rotary drilling-head 160.Drill bit 160 include bit body 162.Multiple cutting elements 100 described here can be installed to drill bit On the bit body 162 of 160.Cutting element 100 can be with soldering or be otherwise fixedly secured to In the recess formed in the outer surface of bit body 162.Other kinds of earth-boring tools such as gear wheel Drill bit, drill hammer, hybrid bit, reamer are first-class can also include described herein cutting Cut element 100.

The polycrystalline diamond 102 (Fig. 1 and 2) using method described here to make can show and change The wearability entered and heat stability.

The indefiniteness example embodiment that the present invention is other is described below.

Embodiment 1: a kind of method making polycrystalline diamond, comprising: with a kind of or many Plant functional group and come the surface of functionalization carbon-free nanoscale granule, by functionalized nano-particle and gold Hard rock nano-particle and diamond grit merge to form granulate mixture, and make this granule mix Compound experience HPHT condition is to form crystalline substance between diamond nano-particles and diamond grit Intergranular key.

Embodiment 2: the method for embodiment 1, wherein carrys out official with one or more functional groups The surface that can change carbon-free nanoscale granule includes carrying out functionalization carbon-free nanoscale granule with methyl functional group Surface.

Embodiment 3: embodiment 1 or the method for embodiment 2, wherein with a kind of or many Kind of functional group come the surface of functionalization carbon-free nanoscale granule include with acetylene functional groups come functionalization without The surface of carbon nano-particle.

Embodiment 4: the method for any one of embodiment 1-3, it farther includes to select nothing Carbon nano-particle is to comprise metal or metal alloy.

Embodiment 5: the method for embodiment 4, it farther includes to select carbon-free nanoscale Grain is to comprise one or more in ferrum, cobalt and nickel.

Embodiment 6: the method for any one of embodiment 1-3, it farther includes to select nothing Carbon nano-particle is to comprise ceramic material.

Embodiment 7: the method for embodiment 6, it farther includes to select carbon-free nanoscale Grain is to comprise one or more in oxide and nitride.

Embodiment 8: embodiment 6 or the method for embodiment 7, it farther includes choosing Select carbon-free nanoscale granule to comprise aluminium oxide or magnesium oxide.

Embodiment 9: the method for any one of embodiment 1-8, wherein receives functionalized Rice grain merges with diamond nano-particles and diamond grit and includes with formation granulate mixture Float on a liquid to form suspension by functionalized nano-particle and diamond nano-particles Body, and it is dried this suspended substance.

Embodiment 10: the method for embodiment 9, is wherein dried this suspended substance and includes spray dried One or more in dry, lyophilization and this suspended substance of flash drying.

Embodiment 11: embodiment 9 or the method for embodiment 10, it farther includes Diamond grit is floated on a liquid.

Embodiment 12: the method for any one of embodiment 9-11, is wherein dried this suspended substance Including this suspended substance dry to form powdered product.

Embodiment 13: the method for embodiment 12, it farther includes this powdered product Mix with diamond grit to form this granulate mixture.

Embodiment 14: the method for embodiment 13, it further includes at the mixing of this granule Before thing experience HPHT condition, grind this granulate mixture.

Embodiment 15: the method for embodiment 12, it farther includes to grind this powder and produces Thing.

Embodiment 16: the method for any one of embodiment 1-15, wherein makes this granule mix Thing experience HPHT condition include by this granulate mixture experience at least about 1400 DEG C temperature and The pressure of at least about 5.0GPa.

Embodiment 17: a kind of cutting element for earth-boring tools, this cutting element comprises logical Cross the polycrystalline diamond abrasive compact including that following method is formed: carry out official with one or more functional groups The surface of carbon-free nanoscale granule can be changed, by functionalized nano-particle and diamond nano-particles Merge to form granulate mixture with diamond grit, and make this granulate mixture experience HPHT condition is to form inter-granular bond between diamond nano-particles and diamond grit.

Embodiment 18: the cutting element of embodiment 17, wherein uses one or more senses Group comes the surface of functionalization carbon-free nanoscale granule and includes carrying out functionalization with methyl or acetylene functional groups The surface of carbon-free nanoscale granule.

Embodiment 19: a kind of earth-boring tools including cutting element, this cutting element comprises logical Cross the polycrystalline diamond abrasive compact including that following method is formed: carry out official with one or more functional groups The surface of carbon-free nanoscale granule can be changed, by functionalized nano-particle and diamond nano-particles Merge to form granulate mixture with diamond grit, and make this granulate mixture experience HPHT condition is to form inter-granular bond between diamond nano-particles and diamond grit.

Embodiment 20: the earth-boring tools of embodiment 19, it farther includes to select carbon-free Nano-particle is to comprise pottery, metal or metal alloy.

Embodiment 21: embodiment 19 or the earth-boring tools of embodiment 20, wherein this brill Ground instrument includes boring ground rotary drilling-head.

Although describe the present invention at this with reference to some embodiment, but art technology Personnel will recognize that and understand that it is not limited to this.But can be to shown and described embodiment Carry out the increase of many, delete and change, without deviating from the model of the present invention as hereafter claimed Enclose, and legal equivalents.It addition, the feature from a kind of embodiment can be real with another The feature executing scheme is combined, is still included in the model of the present invention desired by the present inventor simultaneously In enclosing.Additionally, the present invention can be used for having different bit profile and different tool types Drill bit.

Claims

1. the method making polycrystalline diamond, comprising:

The table of the carbon-free nanoscale granule that functionalization comprises ceramic material is carried out with one or more functional groups Face；

Functionalized nano-particle is merged with diamond nano-particles and diamond grit with Form granulate mixture；With

Make this granulate mixture experience high pressure and high temperature (HPHT) condition with at diamond nano-particles And between diamond grit, form inter-granular bond.

Method the most according to claim 1, wherein carrys out functionalization with one or more functional groups The surface of carbon-free nanoscale granule includes the surface carrying out functionalization carbon-free nanoscale granule with methyl functional group.

Method the most according to claim 1, wherein carrys out functionalization with one or more functional groups The surface of carbon-free nanoscale granule includes the surface carrying out functionalization carbon-free nanoscale granule with acetylene functional groups.

Method the most according to claim 1, its farther include select carbon-free nanoscale granule with Comprise one or more in oxide and nitride.

Method the most according to claim 1, its farther include select carbon-free nanoscale granule with Comprise aluminium oxide or magnesium oxide.

6. the method making polycrystalline diamond, comprising:

The surface of functionalization carbon-free nanoscale granule is come with one or more functional groups；

Functionalized nano-particle is merged with diamond nano-particles and diamond grit；

Functionalized nano-particle and diamond nano-particles are floated on a liquid outstanding to be formed Buoyancy aid；

Be dried this suspended substance with formed comprise functionalized nano-particle, diamond nano-particles and The granulate mixture of diamond grit；With

Method the most according to claim 6, be wherein dried this suspended substance include be spray-dried, One or more in lyophilization and this suspended substance of flash drying.

Method the most according to claim 6, it farther includes to suspend diamond grit In a liquid.

Method the most according to claim 6, is wherein dried this suspended substance and includes being dried this suspension Body is to form powdered product.

Method the most according to claim 9, it farther includes this powdered product and gold Hard rock abrasive grain mixes to form granulate mixture.

11. methods according to claim 10, it further includes at this granulate mixture warp Before going through HPHT condition, grind this granulate mixture.

12. methods according to claim 9, it farther includes to grind this powdered product.

13. methods according to claim 1, wherein make this granulate mixture experience HPHT Condition includes temperature and the pressure of at least 5.0GPa that this granulate mixture experiences at least 1400 DEG C Power.

14. 1 kinds of cutting elements in the earth-boring tools, this cutting element comprise by include with Under method formed polycrystalline diamond abrasive compact:

15. cutting elements according to claim 14, wherein come with one or more functional groups It is carbon-free that the surface of functionalization carbon-free nanoscale granule includes carrying out functionalization with methyl or acetylene functional groups The surface of nano-particle.

16. 1 kinds of earth-boring tools including cutting element, this cutting element comprises by including following Method formed polycrystalline diamond abrasive compact:

17. earth-boring tools according to claim 16, wherein this earth-boring tools includes revolving with boring Turn drill bit.