Claims
- 1. A PCD element comprising a body including a matrix of crystals of a superhard material, the body having a surface, a plurality of the crystals of the matrix being exposed at the surface, wherein at least an exposed part of each of the crystals exposed at at least a portion of the surface has a rounded shape as formed.
- 2. A PCD element according to claim 1, further comprising a substrate to which the body is bonded.
- 3. A PCD element according to claim 1, wherein the matrix of crystals defines a plurality of interstices, at least some of the interstices containing a binder-catalyst material.
- 4. A PCD element according to claim 3, wherein the binder-catalyst material comprises a Group VIII material.
- 5. A PCD element according to claim 4, wherein the binder-catalyst comprises cobalt.
- 6. A PCD element according to claim 1, wherein the crystals of superhard material comprise diamond crystals.
- 7. A PCD element comprising a substrate having a front face, a table of superhard material being bonded to the front face of the substrate, the table of superhard material comprising a matrix of crystals, the table having a surface at which a plurality of the crystals are exposed, at least exposed parts of the crystals exposed at at least a portion of the surface being substantially free of microfractures.
- 8. A PCD element according to claim 7, wherein the exposed parts of the exposed crystals are of rounded form.
- 9. A PCD element according to claim 7, wherein the matrix of crystals defines a plurality of interstices, at least some of the interstices containing a binder-catalyst material.
- 10. A PCD element according to claim 9, wherein the binder-catalyst material comprises a Group VIII material.
- 11. A PCD element according to claim 10, wherein the binder-catalyst comprises cobalt.
- 12. A PCD element according to claim 7, wherein the crystals of superhard material comprise diamond crystals.
- 13. A method of manufacturing a PCD element comprising:
sintering diamond powder with a binder-catalyst material in a high pressure, high temperature press to form a body including a matrix of diamond crystals; performing a machining operation on the body to form a working surface thereon at which a plurality of diamond crystals are exposed; and treating the body to render the crystals which are exposed at at least a portion of the working surface substantially free of microfractures.
- 14. A method according to claim 13, wherein the binder-catalyst material is a Group VIII material.
- 15. A method according to claim 14, wherein the binder-catalyst material is cobalt.
- 16. A method according to claim 13, further comprising sintering the diamond powder with a substrate in the high pressure, high temperature press to bond the body to the substrate.
- 17. A method according to claim 16, wherein the substrate is a tungsten carbide substrate.
- 18. A method according to claim 13, wherein the step of treating the body includes performing a machining operation on the body in the absence of a coolant material.
- 19. A method according to claim 13, wherein the step of treating the body includes performing a machining operation on the body with a restricted coolant supply.
- 20. A method according to claim 13, wherein the step of treating the body includes performing a thermochemical treatment on the body.
- 21. A method according to claim 20, wherein the thermochemical treatment involves the treatment of the working surface of the body with at least one oxidizing compound.
- 22. A method according to claim 20, wherein the thermochemical treatment involves the treatment of the working surface of the body with at least one iron group element.
- 23. A method according to claim 13, wherein a local temperature in excess of 2000° C. is reached at at least a portion of the working surface during the step of treating the body.
- 24. A method of manufacturing a PCD element comprising:
sintering diamond powder with a binder-catalyst material in a high pressure, high temperature press to form a body including a matrix of diamond crystals; performing a machining operation on the body to form a working surface thereon at which a plurality of diamond crystals are exposed; and treating the body to render at least the exposed parts of the crystals exposed at at least a portion of the working surface of rounded form.
- 25. A method according to claim 24, wherein the binder-catalyst material is a Group VIII material.
- 26. A method according to claim 25, wherein the binder-catalyst material is cobalt.
- 27. A method according to claim 24, further comprising sintering the diamond powder with a substrate in the high pressure, high temperature press to bond the body to the substrate.
- 28. A method according to claim 27, wherein the substrate is a tungsten carbide substrate
- 29. A method according to claim 24, wherein the step of treating the body includes performing a machining operation on the body in the absence of a coolant material.
- 30. A method according to claim 24, wherein the step of treating the body includes performing a machining operation on the body with a restricted coolant supply.
- 31. A method according to claim 24, wherein the step of treating the body includes performing a thermochemical treatment on the body.
- 32. A method according to claim 31, wherein the thermochemical treatment involves the treatment of the working surface of the body with at least one oxidizing compound.
- 33. A method according to claim 31, wherein the thermochemical treatment involves the treatment of the working surface of the body with at least one iron group element.
- 34. A method according to claim 25, wherein a local temperature in excess of 2000° C. is reached at at least a portion of the working surface during the step of treating the body.
- 35. A PCD element according to claim 1, comprising a preform cutting element having a facing table and a cutting surface, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 36. A PCD element according to claim 1, comprising a preform cutting element having a facing table and a cutting surface, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 37. A PCD element according to claim 1, comprising a cutting element with a cutting surface adapted for use as a cutting insert in a machining operation.
- 38. A PCD element according to claim 1, comprising a drawing die.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application No. 60/319,157 filed Mar. 28, 2002, incorporated by reference herein for all it contains.
Provisional Applications (1)
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Number |
Date |
Country |
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60319157 |
Mar 2002 |
US |