Diamond bonded construction with improved braze joint

Abstract

Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material.

What is claimed: 
     
         1 . A diamond bonded construction comprising:
 a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the diamond grains, wherein the interstitial regions are substantially free of a catalyst material used to initially form the body at high pressure/high temperature conditions, and wherein a population of the interstitial regions includes an infiltrant material disposed therein;   a metallic substrate attached to the body; and   a braze joint interposed between the body and the substrate, wherein the braze joint is formed from a braze material;   wherein the body includes a metallic material disposed along a substrate attachment surface and in contact with the braze joint.   
     
     
         2 . The construction as recited in  claim 1  wherein the metallic material is different from the braze joint. 
     
     
         3 . The construction as recited in  claim 1  wherein infiltrant material is different from the metallic material. 
     
     
         4 . The construction as recited in  claim 1  wherein the infiltrant material extends from a working surface opposite the substrate attachment surface a partial depth within the diamond body. 
     
     
         5 . The construction as recited in  claim 1  wherein the infiltrant material extends throughout the diamond body. 
     
     
         6 . The construction as recited in  claim 1  wherein the infiltrant material extends from a working surface positioned along a peripheral edge of the diamond body. 
     
     
         7 . The construction as recited in  claim 2  wherein the metallic material is a carbide wetting material. 
     
     
         8 . A bit for drilling subterranean earthen formations comprising a body and a number of cutting elements operatively attached to the body, wherein at least one of the cutting elements comprises the construction as recited in  claim 1 . 
     
     
         9 . A diamond bonded construction comprising:
 a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the diamond grains, wherein the interstitial regions are substantially free of a catalyst material used to initially form the body at high pressure/high temperature conditions;   a metallic substrate attached to the body; and   a braze joint interposed between the body and the substrate, wherein the braze joint comprises two or more different braze material layers;   wherein the body includes a metallic material disposed along a substrate attachment surface and in contact with the braze joint, and wherein the metallic material is different from the braze joint.   
     
     
         10 . The construction as recited in  claim 9  wherein the braze joint further comprises an intermediate metal layer interposed between the different braze material layers. 
     
     
         11 . The construction as recited in  claim 9  wherein a population of the interstitial regions in the diamond body includes an infiltrant material disposed wherein. 
     
     
         12 . The construction as recited in  claim 9  wherein the metallic material is a carbide wetting material. 
     
     
         13 . A bit for drilling subterranean earthen formations comprising a body and a number of cutting elements operatively attached to the body, wherein at least one of the cutting elements comprises the construction as recited in  claim 9 . 
     
     
         14 . A diamond bonded construction comprising:
 a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the diamond grains, wherein the interstitial regions are substantially free of a catalyst material used to initially form the body at high pressure/high temperature conditions;   a metallic substrate that is attached to the body; and   a braze joint interposed between the body and the substrate, wherein the braze joint is formed from a braze material;   wherein the body includes a first metallic material bonded to a substrate attachment surface, and wherein the construction includes a second metallic material that is interposed between the first metallic material and the braze joint.   
     
     
         15 . The construction as recited in  claim 14  wherein one or both of the first and second metallic materials is a carbide wetting material. 
     
     
         16 . A method for making a diamond bonded construction comprising the steps of:
 combining a sintered diamond body with a metallic material and subjecting the same to high pressure/high temperature conditions sufficient to form a metalized surface along a substrate attachment surface of the sintered diamond body, wherein the sintered diamond body comprises a plurality of diamond bonded grains with interstitial regions disposed between the diamond grains, the interstitial regions being substantially free of a catalyst material used to initially form the sintered diamond body, wherein the treating step takes place at high pressure/high temperature conditions, and wherein an infiltrant material is disposed within a population of the interstitial regions; and   attaching the sintered diamond body to a metallic substrate by the use of a braze joint comprising a braze materials interposed between the substrate and metalized surface of the diamond body.   
     
     
         17 . The method as recited in  claim 16  wherein the metallic material is initially provided as a carbide former, and wherein during the high pressure/high temperature conditions the carbide former reacts with the diamond to form a carbide. 
     
     
         18 . The method as recited in  claim 16  wherein the metallic material is disposed a partial depth within the diamond body extending from the substrate attachment surface. 
     
     
         19 . The method as recited in  claim 16  wherein the infiltrant material is disposed within the diamond body during high pressure/high temperature conditions. 
     
     
         20 . The method as recited in  claim 16  wherein the infiltrant material is disposed within the diamond body during the step of combining.